To Fit

To fit
1. Make sure the gear lever in car is in 3rd position and that it is locked with locking pin 87 92 33 for gear lever housing. The ring on the locking pin is to be down in the hole.
2. Lubricate the primary shaft splines.

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

3. If the slave cylinder is new or has been drained from brake fluid, it must be bled,Refer to Clutch M/T, Adjustment/replacement. Bleeding the slave cylinder.
4. Fit protective collar 83 95 162 in the right shaft seal in the gearbox to protect the seal while fitting the gearbox.

IMPORTANT: Always replace the shaft seal in the gearbox. Lubricate with transmission fluid.





5. Attach lining tool 87 92 608 If the setting of the lining tool has been changed after removal, it must be adjusted so that it center is aligned with the center of the gearbox and mating surface.
6. Fit the gearbox with lining tool onto a pillar jack.

WARNING: Take care not to tip the jack.

7. Push the gearbox into place until about 20 mm remains, remove protective collar 83 95 16 and push in the gearbox completely. Rotate the engine shaft if necessary in order to fit the gearbox in place.





8. Fit the rear engine mounting on the gearbox.





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 hod
Tightening torque: 62 Nm (46 ft. lbs.)
12. Remove the lining 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 into the leg 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 to 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 lining 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. Refit the air shields and belt circuit cover in the right 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 lining beam and tighten the upper bolts between the engine and gearbox.
Tightening torque: 70 Nm (50 ft. lbs.)
29. Connect the oxygen sensor(s).
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. Pull out locking pin 87 92 335 from the gear lever housing, engage 4th gear and insert locking pin 87 92 632.
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 connect a hose to the bleed nipple. Undo the nipple and allow a small amount of brake fluid to run out. Tighten the nipple and test the clutch. If it does not work, bleed the clutch. Check that the system is tight.
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 shin 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.