To Fit

1. Lubricate the primary shaft splines, refer to Specifications





2. Fit protective collar 83 95 162 in the right shaft seal of the gearbox to protect the seal when the gearbox is fitted.

IMPORTANT: Always replace the drive shaft seals. Lubricate with gearbox oil.

3. Raise the car.
4. Make sure that the locating studs are in place. Lubricate with thin anti-corrosion oil.





5. Connect lining tool MKM 886. (87 92 608). Adjust the lifting tool so that it is centered in line with the gearbox center and mating face.
6. Fit the gearbox with lifting tool onto a pillar jack.

IMPORTANT: Push in the gearbox until approximately 20 mm remain and remove tool 83 95 162.

7. Push in the rest of the gearbox. Turn the engine shaft, if needed, so that the gearbox can be fitted.





8. Tighten the lower screws between the engine and gearbox.
Tightening torque 70 Nm (50 ft. lbs.)
9. Remove the lifting tool from the gearbox and remove the jack.
10. Lower the car to the floor.
11. Fit the gearbox mounting.
Tightening torque 40 Nm (30 ft. lbs.)
12. Connect the ground lead to the mounting.
13. Fit tool 83 95 162 in the led shaft seal.
14. Make sure that the driver is clean and fit it into 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.

15. Push in the rest of the shaft until the circlip snaps into place.
16. Raise the unit and tighten down the left engine cushion to the gearbox.
Tightening torque 84 Nm (62 ft. lbs.)
Then fit the engine cushion screws loosely by the body.
17. Fill up with oil to the correct level. Use assembly tool 87 92 590. Tighten the level plug, drain plug and filler plug.
Tightening torque 50 Nm (37 ft. lbs.)





18. Connect the clutch delivery line to the gearbox and fit the locking clips.
19. Connect the lead to the reversing-light switch.





20. Check that the journals for the radiator assembly are correctly fixated in the radiator member
21. Raise the car and position the lifting trolley with the subframe under the car.
22. Carefully raise the subframe.

IMPORTANT: Watch out for:
^ Hoses to the engine oil cooler.
^ Rubber gaiters for the inner drivers which can bump against the middle mountings on the subframe before the subframe up against the body.

23. Tighten the front mountings (2) for the steering servo delivery line before the subframe is completely raised.
24. Guide the radiator assembly journals into the subframe.
25. Guide the AC-lines into their brackets on the subframe.
26. Adjust the subframe so that the screw holes correspond to the body. There are 2 locating studs on the lining trolley, front led and right rear, which guide the subframe into the correct position.
27. Fit the screws and the rear support plate that secure the subframe. Fit spacer washers if there are any. (up to and including chassis number W3050999)





28. Tighten the screws for the subframe.
Tightening torque 100 Nm (74 ft. lbs.)
29. Tighten the screws for the support plate.
Tightening torque 60 Nm (44 ft. lbs.)
30. Lower the lining trolley and move it away.
31. Remove the straps holding the radiator assembly.
32. Fit the engine oil cooler.
33. Tighten the 2 rear connecting clamps for the steering servo delivery line to the subframe.
34. Tighten down the air filter housing.
35. Tighten down the steering gear.
Tightening torque 90 Nm (66 ft. lbs.)





36. Tighten the outer ball joints to the steering swivel member.
Tightening torque 85 Nm (63 ft. lbs.)

WARNING: Check that the journal on the ball joint protrudes above the steering swivel member attachment

37. Fit the anti-roll bar support. Resist with an open 17 mm wrench.





38. Fit the protective cover panel between the engine and gearbox.
39. Fit the rear engine cushion, with screws, on the subframe and insert the screws.
40. Fit the rear engine cushion, engine mounting and torque arm. The linkage for the selector mechanism will follow after.
Tightening torque 70 Nm (50 ft. lbs.)
41. Fit the front exhaust pipe.
42. Fit the front cover.
43. Lower the car.
44. Remove the lifting beam, remove the locating studs and tighten the upper screws between the engine and gearbox.
Tightening torque 70 Nm (50 ft. lbs.)





45. Shake the power train unit to avoid stresses in the engine cushions. Tighten the screws for the rear engine cushion from the engine compartment side.
Tightening torque 24 Nm (18 ft. lbs.)
46. Tighten the nut for the rear engine cushion.
Tightening torque 15 Nm (33 ft. lbs.)
47. Position a jack under the gearbox and lift the power train unit until the led engine cushion is suspended freely from the body arm is in the clear.
Then lower the power train unit and tighten the screws.
Tightening torque 63 Nm (46 ft. lbs.)
Fit and tighten the two screws securing the torque arm to the subframe.
Tightening torque 30 Nm (22. ft. lbs.)
Raise the car. Loosen the screw for the front torque arm and center the rubber cushion in the arm, then tighten.
Tightening torque 47 Nm (34. ft. lbs.)
Centre and tighten the rear torque arm.
Tightening torque 47 Nm (34. ft. lbs.)
Lower the car.





48. Fit the selector linkage to the gearbox and tighten.
49. Connect selector linkage to the selector rod.
50. Adjust gear positions.
51. Connect the oxygen sensor(s).
52. Remove the pedal retainer from the clutch pedal and bleed the clutch, refer to Clutch, M/T.
Check that there are no system leaks.
53. Fit the positive lead mounting to the engine.





54. Fit the battery tray.
55. Fit the 2 cable ties on the wiring loom and the clip for the positive lead.
56. Fit and connect the battery, also fit the plastic cover.
57. Fit the front wheels.
Tightening torque 110 Nm (80 ft. lbs.)
58. Fit the cover over the engine.





59. Fit the grille
60. Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed
61. Set the correct time and radio code.