To Fit

1. Check that the selector lever in the car is in 3rd gear and that it is locked with locking pin 87 92 335 for the gear lever housing. The locking pin ring should be down in the hole.

2. Grease the spines of the primary shaft.

IMPORTANT: Check that the two locating sleeves are on the engine. Lubricate the sleeves with a thin coating of anti-corrosion oil.

3. Bleed the slave cylinder.





4. Fit protective collar 83 95 162 in the right shaft seal in the gearbox to protect the seal when the gearbox is mounted.

IMPORTANT: Always change the shaft seal in the gearbox. Lubricate with gearbox oil.





5. Connect lifting tool 87 92 608 If the lifting tool position is altered after removing, then the lifting tool must be adjusted so that its centre is in line with the gearbox centre and mating face.
6. Fit the gearbox with lifting tool onto a pillar jack.

WARNING: Take care not to tip the jack.

7. Push in the gearbox until approx. 20 mm remains, remove protective collar 83 95 162. and then push in the gearbox completely. Turn the engine shaft, if needed, so that the gearbox can be fitted.





8. Fit the rear engine mounting on the gearbox. (new version in M-99)





9. Tighten the bottom bolts between the engine and gearbox.
Tightening torque 70 Nm (50 ft. lbs.).
10. Fit the left-hand engine mounting on the gearbox.
Tightening torque 40 Nm (46 ft. lbs.)
11. Lift up the drive unit with a jack and tighten the left-hand engine mounting on the body.
Tightening torque: 62 Nm (46 ft. lbs.)
12. Remove the lifting tool from the gearbox and remove the jack.
13. Fit the ground leads to the gearbox.
14. Put back the splash plate by the flywheel.





15. Fit protective collar 83 95 162 in the left shaft seal.
16. Make sure the drive shaft is clean and then position it in the tool.

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

17. Insert the shaft until the locking ring snaps in place.
18. Carefully raise the subframe. Make sure the washers on the rear mountings are in place.
19. Adjust the subframe so that the screw holes correspond with the body.
20. Tighten the four corner bolts on the subframe.
Tightening torques
front 115 Nm (85 ft. lbs.)
rear 110 Nm (81 ft. lbs.)+75.
21. Lower the lifting trolley and move it away.
22. Tighten the remaining bolts on the subframe.
Tightening torque: 190 Nm (141 ft. lbs.).





23. Tighten the nuts on the rear engine mounting.
Tightening torque: 50 Nm (37 ft. lbs.)
24. Position the suspension arm end piece on both sides and tighten the nuts.
Tightening torque: 75 Nm (55 ft. lbs.)





25. Put back the air shields and the cover in the right-hand wheel housing.
26. Fit the front exhaust system and put back the clamps for the oxygen sensor cable.
27. Fit the front wheels.
Tightening torque 110 Nm (81 ft. lbs.).
Lower the car to the floor.





28. Remove the lifting beam and tighten the upper bolts between the engine and gearbox.
Tightening torque: 70 Nm (50 ft. lbs.)
29. Connect the oxygen sensor(so).
30. Fit the positive cable mounting on the engine.





31. Connect the lead to the reversing-light switch.
32. Connect the clutch deliver pipe to the gearbox and fir the locking clip.





33. Remove the locking pin from the gear-lever housing, engage 4th gear and insert the locking pin again.
34. Tighten the clamp on the selector rod.
Tightening torque: 20 Nm (15 ft. lbs.)
35. Put back the gear lever gaiter.





36. Take the locking pin out of the gearbox and put back the plastic plug.
37. Remove the brake bracket from the clutch pedal and bleed the clutch. Check that there are no system leaks.





38. Fit and connect the battery.
39. Put back the cover over the engine or the resonator with hoses and the mass air flow sensor.
40. Test drive the car and shift gears. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed as well as set the correct time on the clock and program any eventual radio code.