Gearbox (Hydraulic Clutch), Fitting

Gearbox (Hydraulic Clutch), Fitting


1. Lubricate the clutch plate's input shaft splines.






2. Install protective collar 83 95 162 in the righthand shaft seal in the gearbox to protect the seal when the gearbox is installed.






3. Connect lifting tool 87 92 608 (MKM 886). Adjust the lifting tool so that its center is in line with the center and mating face of the gearbox.

4. Install the gearbox using the lifting tool and a pillar jack.

5. Push the gearbox in until about 20 mm remains, remove seal protector tool and then push the gearbox all the way in. If necessary, turn the engine output shaft to get the gearbox into place.






6. Bolt the rear engine mounting to the gearbox.

7. Tighten the lowest bolts between engine and gearbox.
Tightening torque: 70 Nm (50 ft lbs)






8. Bolt the lefthand engine mounting bracket to the gearbox.
Tightening torque: 40 Nm (30 ft lbs)

9. Raise the power train by means of the jack and bolt the lefthand engine mounting to the body.
Tightening torque: 62 Nm (46 ft lbs)

10. Remove the lifting tool from the gearbox and pull the jack out of the way.
11. Connect the ground leads to the gearbox.
12. Install the splash guard adjacent to the flywheel.






13. Install seal protector tool in the lefthand shaft seal.
14. Make sure that the drive shaft is clean then install it in the tool.

NOTE: Install the driver in the gearbox until about 20 mm remains and withdraw the tool before the shaft's sealing surface reaches the shaft seal.

15. Push the shaft in until the retaining ring snaps into place.






16. Jack up the subframe, exercising care.
Make sure that the washers for the rear mountings are in place.

17. Adjust the subframe so that the bolt holes are in line with those in the body.

18. Tighten the four subframe corner bolts as follows:
Front: 115 Nm (85 ft lbs)
Rear: 110 Nm (81 ft lbs) + 75°

19. Lower the lifting trolley and move it away.
20. Tighten the remaining subframe retaining bolts to 190 Nm (141 ft lbs)
21. Tighten the rear engine mounting nuts to 50 Nm (37 ft lbs)
22. Install the end piece, suspension arm on both sides and tighten the nuts to 75 Nm (55 ft lbs)






23. Install the air deflectors and the cover in the righthand wheel housing.
24. Install the front exhaust pipe and put back the clamps for the oxygen sensor's lead.

25. Install the front wheels.
ightening torque: 120 Nm (90 ft lbs)
Lower the car.

26. Remove the lifting beam and tighten the other bolts between engine and gearbox.
Tightening torque: 70 Nm (50 ft lbs)

27. Connect the oxygen sensor or sensors.
28. Mount the positive cable's bracket beside the engine.






29. Connect the lead to the reversing-light switch.
30. Connect the clutch delivery pipe to the gearbox and install the locking clip.

31. Fill up the gearbox with oil of the right grade to the correct level.
Tightening torque: 50 Nm (37 ft lbs)






32. Withdraw the locking pin from the gear lever housing, engage 4th gear and put back the locking pin.

33. Tighten the clamp on the selector rod.
Tightening torque: 20 Nm (15 ft lbs)

34. Install the gear lever gaiter.
35. Withdraw the locking pin from the gearbox and put back the plastic plug.

36. Remove the brake pedal clamp from the clutch pedal and bleed the clutch. Check that there are no leaks in the system.






37. Install the battery in place and reconnect the cables.
38. Install the cover over the engine or the resonating chamber with hoses and mass air flow sensor.
39. Drive the car on test, set the clock to the right time and program the radio code, if any.