AEL Specifications
Transmission: | ||
code designation |
AEL
| |
Automatic transmission |
097
| |
Torque converter: | ||
code designation |
LCCA
| |
Valve block: | ||
code designation |
LAA
| |
Number of splines |
internal
|
external
|
- clutch K1 |
5
|
4
|
– clutch K2 |
5
|
5
|
- clutch K3 |
5
|
4
|
– brake B1 |
6
|
6
|
– brake B2 |
6
|
5
|
Engine |
Volume 2.3 liters
| |
Final drive ratio |
3.70
| |
Gear ratio: | ||
– 1st gear |
2.71
| |
– 2nd gear |
1.55
| |
– 3rd gear |
1.00
| |
– 4th gear |
0.68
| |
- reverse gear |
2.11
| |
automatic transmission fluid cooler |
installed in the engine radiator
|
Specifications CBU
Transmission: | ||
code designation |
CBU
| |
Automatic transmission |
097
| |
Torque converter: | ||
code designation |
LBCA
| |
Valve block: | ||
code designation |
LAC
| |
Number of splines |
internal
|
external
|
- clutch K1 |
5
|
4
|
– clutch K2 |
5
|
5
|
- clutch K3 |
5
|
4
|
– brake B1 |
6
|
6
|
– brake B2 |
6
|
7
|
Engine |
Volume 2.3 liters
| |
Final drive ratio |
3.70
| |
Gear ratio: | ||
– 1st gear |
2.71
| |
– 2nd gear |
1.55
| |
– 3rd gear |
1.00
| |
– 4th gear |
0.68
| |
- reverse gear |
2.11
| |
automatic transmission fluid cooler |
installed in the engine radiator
|
The automatic transmission fluid cooler is installed in the engine radiator
Automatic transmission cooling mechanism
- 1. Supply hose
- 2. Bolt, 10 Nm
- 3. O-ring
- 4. Nut, tightening torque 60 Nm
- 5. Washer
- 6. Gear box
- 7. Automatic transmission coolant filter
- 8. Dipstick for measuring the level of automatic transmission coolant
- 9. Radiator - with automatic transmission coolant radiator installed
- 10. Washer
- 11. Return pipe for automatic transmission coolant radiator
- 12. Washer
- 13. Bolt connection type "banjo", 40 Nm
- 14. Clamp
- 15. Washer
- 16. Bolt, 10 Nm
- 17. Bolt connection type "banjo", 30 Nm
- 18. Bolt, 10 Nm
- 19. Temperature switch, 15 Nm
- 20. Washer
- 21. Automatic transmission fluid supply pipe
- 22. Bolt connection type "banjo", 30 Nm - with hole for temperature switch
- 23. Washer
- 24. Automatic transmission radiator coolant return pipe
- 25. Bolt connection type "banjo", 40 Nm
- 26. O-ring
- 27. Supply pipeline for automatic transmission coolant radiator
- 28. Washer
Warning: Tightening torque for supply hose 1 to oil pan: 80 Nm
Warning: Always replace O-rings 3, 26.
Warning: Always replace washers 5, 10, 12, 20, 23, 28.
Warning: Automatic transmission coolant filter 7 can be replaced without removing the engine
Warning: Tightening torque for automatic transmission coolant return pipe return pipe: 40 Nm
Warning: Tightening torque for fastening the supply pipe of automatic transmission fluid 21 to the supply pipe: 40 N.m
Warning: Tightening torque for fastening the coolant return pipe 24 of the automatic transmission radiator to the return pipe: 40 Nm
Warning: Tightening torque for the supply pipe of the coolant radiator pipe 27 automatic transmission: 40 Nm
Withdrawal
1. Disconnect the negative battery cable.
2. Disconnect the speedometer connector.
3. Disconnect the temperature switch connector.
4. Remove the upper engine and transmission mounting bolts.
5. Disconnect the oxygen sensor connector.
6. Disconnect the transmission ground wire.
7. Install the engine mount.
8. Remove the lower engine shield and mounts.
9. Remove the exhaust pipe.
10. Disconnect the axles from the gearbox.
11. Remove the starter bolts.
12. Lay the starter on its side and secure with wire.
13. Remove torque converter mounting nuts (3 pieces).
14. Remove the heat shield from the multifunction switch.
15. Disconnect connectors 1, 2 and 3.
16. Remove the wire clamp from the gearbox.
17. Disconnect the automatic transmission coolant pipes.
18. Plug the hoses with plugs, item 357 853 586 B.
19. Seal the pipes with rubber caps, item 055 121 324.
Warning: Part numbers are for reference only.
20. Place a support or suitable jack under the gearbox.
21. Remove the gearbox mountings.
22. Remove the shift lever clip.
23. Disconnect the cable.
24. Remove the lower engine/transmission mounting bolts.
25. Pull the axles back.
26. Disconnect the gearbox from the engine.
27. Lower the gearbox carefully.
28. Support the torque converter so that it does not fall.
Installation
1. Installation is carried out in the reverse order of removal.
2. Check that the guide bushings are correctly installed when installing.
3. Check shift cable adjustment.
4. Adjust the cable if necessary.
Torque
Fixing the axle shafts to the drive flanges |
80 Nm
|
Bolts of fastening of the hydrotransformer |
60 Nm
|
Bolts of fastening of a transmission to the engine (4-cylinder) |
55 Nm
|
Bolts of fastening of a transmission to the engine (5-cylinder) |
see table Tightening torques (5-cylinder engines)
|
Attaching the gearbox bracket to the gearbox |
40 Nm
|
Attaching the gearbox to the body |
110 Nm
|
Automatic transmission 097 - crankcase, gears, shafts / Automatic transmission mechanism
- 1. Lid
- 2. Bolt, 30 Nm - for small drive shaft
- 3. Washer
- 4. Washer - for planet carrier
- 5. Gear box
- 6. Washer
- 7. Thrust needle bearing
- 8. Washer
- 9. O-ring
- 10. Planet carrier
- 11. Washer - for reverse gear brake (IN 1)
- 12. Inner spline ring
- 13. Outer spline ring
- 14. Pressure ring
- 15. Ring spring
- 16. One-way clutch - with B1 piston
- 17. Retaining ring - for one-way clutch
- 18. Oil deflector
- 19. Retaining ring - for mounting rim
- 20. Central gear, small
- 21. Washer
- 22. Thrust needle bearing
- 23. Central gear, large
- 24. Washer
- 25. Thrust needle bearing
- 26. Drive shaft, large
- 27. Thrust needle bearing
- 28. Needle bearing
- 29. Drive shaft, small
- 30. Thrust needle bearing
- 31. Washer
- 32. Clutch 3rd / 4th gear (K3) - with pump shaft
- 33. Washer
- 34. Thrust needle bearing
- 35. Washer
- 36. Clutch 1st - 3rd gear (K1) - with turbine shaft
- 37. Washer - for adjusting the free play of clutches K1 and K2 (if necessary, a second washer is installed)
- 38. Washer - for adjusting the free play of clutches K1 and K2 (if necessary, a second washer is installed)
- 39. Reverse clutch (K2)
- 40. Mounting bezel
- 41. Outer spline ring
- 42. Inner spline ring
- 43. Spring cap
- 44. Outer spline ring
- 45. Spring
- 46. Spring cap
- 47. Outer spline ring
- 48. Spring washer, concave
- 49. Gasket
- 50. O-ring
- 51. Automatic transmission coolant pump
- 52. Bolt, 10 Nm
Warning: Remove cover 1 with a screwdriver, install with a 40–20 sleeve.
Warning: The tongues of the washer 6 face the thrust needle bearing.
Warning: Always replace O-ring 9, installed on the planetary carrier
Warning: When installing, lightly grease the washers and needle bearing, install the washers and needle bearing on the planetary carrier, and then install the planetary rings
Warning: Before installing new inner spline rings 12, soak them in automatic transmission fluid for 15 minutes.
Warning: The flat side of the pressure ring 14 faces the rings.
Warning: The curved side of the ring spring 15 faces the one-way clutch.
Warning: After installing the retaining ring 17, install the oil deflector 18.
Warning: Oil deflector 18 is installed in the groove of the gearbox housing (near the automatic transmission fluid vent), install the reflector after installing the one-way sleeve and before installing the retaining ring of the mounting ring.
Warning: Before installing retaining ring 19, check that the one-way sleeve and oil slinger are installed.
Warning: Central gears 20, 23 are mounted on the planet carrier.
Warning: Install washer 21 with the rounded side towards the small central gear.
Warning: Washer 24 is installed with the beveled side into the large central gear.
Warning: Drive shafts 26, 29 are mounted on the planet carrier.
Warning: Thrust needle bearing 30 faces the small drive shaft. The washer can be mounted on a needle bearing.
Warning: The tongues of the washer 31 face the thrust needle bearing, the washer can be mounted on the needle bearing
Warning: The tongues of washer 33 face the thrust needle bearing.
Warning: Mounting collar 40 is installed so that the wedges of the one-way coupling fit into the groove.
Warning: Always install outer spline 41 with a thickness of 3 mm.
Warning: Before installing new inner splines 42, soak them in ATF for 15 minutes.
Warning: Remove all three spring caps 43, install after installing the first outer spline ring.
Warning: Always install an outer spline 44 with a thickness of 2 mm.
Warning: Remove all three springs 45, install after installing all outer spline rings.
Warning: Remove all three spring caps 46, install before installing the last outer spline ring.
Warning: Always replace gasket 49.
Warning: Always replace O-ring 50, installed on the automatic transmission coolant pump.
Pin arrangement
Warning: Before installing the motor, check that the pins are in place.
For some gearboxes installed on a 5-cylinder engine, it is necessary to install a deflection sleeve (item 012 301 153).
When installing a new engine, check the presence of the bushing on the crankshaft. This bushing must be installed first before installing the drive disc.
Part numbers are given for footnotes only. Please contact your dealer for the latest information.
Tightening torques (5-cylinder engines)
Position | Bolt size | Quantity | Torque (N·m) |
1
|
М12х67
|
1
|
65
|
2
|
М12х80
|
3
|
65
|
3
|
М12х90
|
1
|
65
|
4
|
М12х100
|
1
|
65
|
5
|
М12х120
|
1
|
65
|
6
|
М12х50
|
1
|
45
|
7
|
М12х38
|
1
|
45
|
8
|
М12х40
|
2
|
25
|
Positions A and B - centering sleeves |
Valve block
- 1. Oil pan
- 2. Bolt, 10 Nm
- 3. Gasket
- 4. Strut
- 5. Oil filter
- 6. Valve block
- 7. Bolt, 10 Nm
- 8. Connector connection
- 9. O-ring
- 10. Plug
- 11. O-ring
- 12. O-ring
- 13. Mechanical valve transmission rod
- 14. Carter final drive
- 15. Oil seal
- 16. Bolt, 5 Nm
- 17. Bolt, 8 Nm
- 18. Supply pipe for automatic transmission coolant radiator
- 19. Bolt, 10 Nm
Warning: The valve block can be removed without removing the transmission from the vehicle. Replace the valve block if it is dirty or damaged.
Warning: Do not start the engine or tow the vehicle if the oil pan has been removed or there is no oil in the transmission.
Warning: Before removing the oil pan 1, remove the coolant supply pipe.
Warning: Always replace gasket 3, place spacer on gasket.
Warning: Install spacer 4 on the gasket.
Warning: Install the oil filter seal 5.
Warning: Connection socket 8 is installed together with the O-ring.
Warning: Always replace O-rings 9, 11, 12.
Warning: Remove plug 10 before removing/installing the one-way clutch.
Warning: The flanged end of the mechanical valve 13 transmission rod must face the valve.
Warning: Always replace the seal 15, installed in the oil filter.
Warning: Tightening torque for the supply pipe of the coolant radiator 18 automatic transmission to the oil pan: 80 Nm
Identification
The code is embossed on a metal plate that must remain attached to the valve block.
Order of execution
1. Install the o-rings on the plug.
Warning: Before removing/installing the one-way clutch, remove the plug from the crankcase to avoid damaging the plug and O-ring.
2. Install the plug so that the rim is in the groove on the crankcase.
Mechanical valve
Installation
1. Move the gear lever to position P.
2. Install the mechanical valve all the way into the valve block. Transmitting rod A is indicated by an arrow.
3. Tighten limit screw B to 4 Nm
Warning: The lever C of the mechanical valve must be pressed against the limit screw B during installation. When tightening screw B of lever C of the mechanical valve, hold the lever by pushing it in the direction of the arrow.
Oil filter installation position
Park gear lock
- 1. Bolt, 10 Nm
- 2. Plug
- 3. O-ring
- 4. Parking brake latch
- 5. Park gear
- 6. Park gear latch pin
- 7. Return spring
- 8. Latch - for multifunction switch
- 9. Bolt, 10 Nm
- 10. Multifunction switch (F125)
- 11. O-ring
- 12. Cap
- 13. Carter final drive
- 14. O-ring
- 15. Speed sensor
- 16. Bolt, 10 N. m.
- 17. The lever of a shaft of a gear change
- 18. Bolt, 10 Nm
- 19. Sleeve
- 20. O-ring
- 21. Gearshift shaft
- 22. Lock washer
- 23. Bolt, 10 Nm
- 24. Mechanical valve lever
- 25. Bolt, 4 Nm
- 26. Locking spring
- 27. Bolt, 10 Nm
- 28. Lever
Warning: Always replace o-rings 3, 11, 14, 20.
Warning: The parking brake latch 4 is installed with the return spring, align with the parking gear.
Warning: The rounded side of the 5 park gear faces the drive gear cover.
Warning: Install the parking gear latch pin 6 with a drift.
Warning: Remove/install sleeve 19 using a mandrel.
Warning: O-ring 20 is installed in the groove of the shift shaft.
Warning: Before removing shift shaft 21, remove multi-function switch and locking spring, always install with lever.
Differential (Automatic transmission)
Warning: If you drop the speedometer drive during assembly, this may affect the accuracy of its readings in the future.
- 1. Bolt, 25 Nm
- 2. Left axle flange
- 3. Semi-axle flange seal
- 4. Bolt, 25 Nm
- 5. Automatic transmission fluid filler plug
- 6. Speedometer drive
- 7. O-ring
- 8. Final drive cover
- 9. Oil seal
- 10. Axle flange locking ring
- 11. Axle flange
- 12. O-ring
- 13. Oil seal
- 14. Needle bearing
- 15. Gear box
- 16. Gasket
- 17. Axle vent cover
- 18. Bolt, 10 Nm
- 19. Differential
- 20. Impulse ring - for electronic speedometer
Warning: Do not use household detergents. To prevent damage to the washer pump.
Warning: Always replace O-rings 7, 12.
Warning: When replacing final drive cover 8, adjust the setting of the ring gear.
Warning: Always replace the seal 9.
Warning: Remove the stuffing box 13 using the lever VW681.
Drive gear
- 1. Rubber cover
- 2. Tension bolt, 250 Nm
- 3. Spherical washer
- 4. Washer
- 5. Tapered roller bearing inner race
- 6. Tapered roller bearing outer race
- 7. Gear box
- 8. Thrust bearing
- 9. Tapered roller bearing outer race
- 10. Tapered roller bearing inner race
- 11. Drive gear
Warning: Remove the rubber cover 1 with a screwdriver, install with a 40–20 sleeve.
Warning: When removing/installing bolt 2, engage park gear.
Warning: The convex side of the spherical washer 3 faces the tension bolt.
Warning: Tapered roller bearing inner race 5: Install so that the tabs fit into the groove of the inner race of the other tapered roller bearing. After determining the required thickness of the shim, install the cage on the drive gear, after applying a layer of sealant AMV 185 10001.
Warning: Tapered roller bearing outer race 6: remove with a suitable drift, install with a thrust heel 30–20, apply a coat of sealant AMV 185 10001.
Warning: The flat side of the thrust bearing 8 faces the input shaft, install the tension bolt on the drive gear before installation.
Warning: Tapered roller bearing outer race 9: remove with a suitable drift, install with a thrust heel, apply a coat of sealant AMV 185 10001.
Pinion gear
- 1. Gear box
- 2. Drive gear - paired with a ring gear
- 3. Tapered roller bearing inner race
- 4. Tapered roller bearing outer race
- 5. Washer S3
- 6. Pinion shaft bushing
- 7. Drive gear shaft seal
- 8. Rubber cover
- 9. Hex nut
- 10. Tapered roller bearing inner race
- 11. Tapered roller bearing outer race
- 12. Bolt, 25 Nm
- 13. Pinion cover
- 14. O-ring
- 15. Spacer
- 16. Washer S4
- 17. Pinion drive
- 18. Park gear lock gear
Warning: Do not use household detergents. To prevent damage to the washer pump.
Warning: Drive gear 2 paired with ring gear are replaced together.
Warning: Tapered roller bearing outer race 4: Remove with a drift.
Warning: Pinion shaft bushing 6: Remove together with tapered roller bearing inner race.
Warning: Pinion shaft seal 7: Always replace, remove with a screwdriver.
Warning: Rubber cover 8: remove with a screwdriver.
Warning: Tapered roller bearing outer race 11: Remove with a drift.
Warning: Always replace O-ring 14.
Warning: Spacer 15: The wider contact surface faces the drive gear.
Warning: Pinion drive 17: Higher edge faces park gear latch.
Warning: Park gear lock gear 18: rounded side faces drive gear.
Differential
- 1. Differential cover
- 2. Impulse wheel
- 3. Washer S1
- 4. Tapered roller bearing outer race
- 5. Bolt, 90 Nm
- 6. Tapered roller bearing inner race
- 7. Differential box
- 8. Ring gear - paired with pinion
- 9. Tapered roller bearing inner race
- 10. Tapered roller bearing outer race
- 11. Washer S2
- 12. Gear box
- 13. Satellites
- 14. Thrust washer
- 15. Gears of semiaxes
- 16. Output shaft
- 17. Retaining ring
- 18. Axis of satellites
- 19. Axle flange nut
Warning: Before installing the tapered roller bearing inner race 9, heat it to 100°C.
Warning: When installing the pinion axle, be careful not to damage the thrust washer.
Warning: Tapered roller bearing outer race 4: Remove with a drift.
Warning: Differential box 7: adjust after replacing the ring gear.
Warning: Ring gear 8 paired with pinion are replaced together, after replacement, adjust the setting of the ring gear and pinion. To remove, remove from the differential box with a mandrel. Before installation, heat up to 100°C and install the alignment pins.
Warning: Tapered roller bearing outer race 10: Remove with a drift.
Warning: Install the output shaft 16 before installing the pinion axle.
Warning: Pinion pin 18: remove with a drift; inspect for signs of wear; replace if necessary.
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