Installing
Installing
Installing the transmission
Install the transmission
Use the mobile jack and gearbox fixture to adjust the height and angle. Locate the gearbox on the engine.
Fit the 7 screws. Tighten crosswise hand-tight. Then tighten crosswise. Torque 50 Nm .
Note! When tightening the screws, check carefully that the guide bushings locate correctly in their guide holes. Check that the torque converter cover is in contact with the engine before tightening.
Remove the fixture and the mobile jack from the gearbox.
Installing the torque converter screws
Note! Use new screws, Torx TX50.
Align the torque converter with the carrier plate by turning the engine with the crankshaft pulley nut and turning the torque converter (accessible through the hole in the cover.)
Fit all 6 screws hand tight. Tightened the screws sufficiently so the heads lie against the carrier plate. Now tightened with 35 Nm . Socket Torx TX 50 (earlier models TX40 must be changed to TX50).
Note! Remove the socket wrench from the crankshaft.
Raise the engine and transmission
Unscrew the lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook to the previously noted measurement between lifting bar and the spark plug cap. See item Removing Transmission, Removal.
Ensure that the dip stick pipe is free of the fan and that that no hoses or cables are crimped.
Installing the rear engine mounting on the gearbox
Install the mounting on the gearbox (3 screws). Tighten the two rear screws. Torque: 50 Nm . Remove the front screw.
Install the cover. Use the screw for the mounting.
Press up the cover against the mounting. Tighten the screw. Torque: 50 Nm .
Installing the engine pad
Align the engine pad's guide pin in the cover. Use new nut. Fit the nut lightly.
Install the screw for the steering gear engine pad
Do not tighten the screw.
Remove the support hook 999 5045 COMPRESSION HOOK 999 5045 Compression Hook.
Install:
- The heated oxygen sensor's cable with clamps in the cover
- The connector and cable to the speed sensor.
- Ground lead on the gearbox
Right-hand drive cars only
Remove the tape from the drive shaft and let the shaft rest on the oil pipe.
Raise the frame approximately 100 mm from the body.
Aligned the steering gear on the right-hand side and the collision protection system on the sub-frame. Fit the screws for the anti-roll bar's left-hand bearing with cap and tighten both bearing caps.
Torque: 50 Nm .
Installing the sub-frame
Note! Use new screws (4 x M14). Lubricate the screw threads. Make sure that the screws for the steering gear locate in the frame.
Begin on the left-hand side. Raise the sub-frame with the mobile jack.
Fit the screws for the frame and support bracket. First tighten the frame's screws with 105 Nm + 120° , and then the screws for the frame's bracket with 50 Nm . Use a protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Move the jack to the right-hand side and repeat the procedure.
Remove:
- Lifting hook, lifting bar and fender edge support.
- The lifting fork from the engine.
Tighten nut for the rear engine pad.
Torque: 50 Nm .
Install:
- The 5 steering gear nuts. Use new nuts. Torque: 50 Nm.
- The nut for the collision protection system/sub-frame (A). (Only right-hand drive vehicles.) Torque: 50 Nm
- the screw for the front engine mounting - sub-frame.
Tighten the screws for the front and rear engine pads. Torque: 50 Nm.
Install:
- Torque stay mounting's bracket on the gearbox.
Note! Use new screws.
Torque: Late design M10, 35 Nm + 40° . Early design M8, 18 Nm + 90° . Use protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
- The screws for the brackets for the oil pipe. Torque: 25 Nm .
Tighten the clamp for the exhaust pipe.
Jiggle the pipes during tightening.
Installing the right drive shaft
Note! Ensure that the seal ring in the transmission and the boot on the drive shaft are not damaged.
Install the bearing cap. Torque: 25 Nm .
Installing the collision protection system over the steering gear (right-hand drive cars only)
(2 screws.) Tighten with torque: 80 Nm .
Installing the left drive shaft
Ensure that the ABS sensor pulse wheel on the drive shaft is free of dirt.
Press in the drive shaft firmly so that the snap ring engages in its groove in the [1][2]differential gear. Check by pulling carefully on the drive shaft constant velocity joint.
Note! Ensure that the seal ring in the transmission and the boot on the drive shaft are not damaged.
Apply metallic adhesive 1161370-0 on the drive shaft splines for the hub as illustrated.
Fold out and turn the spring strut and locate the drive shaft in the hub.
Use holder 999 5563 SUPPORT 999 5563 Support to press the control arm down.
Fit the drive shaft nut manually.
Early design (M20): Use a new oiled nut.
Late design (M22): The old nut can be used again. Oil the nut.
Remove the holder.
Note! Take care not to damage the drive shaft boot.
Fit to both sides:
- Control arm/ball joint for the wheel spindle. Remove the bush 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket from the ball joint. Make sure the slot in the ball joint stud aligns with the screw hole in the wheel spindle. Use new lock nuts on the screws.Torque: 50 Nm .
- The linkage to the anti-roll bar. Use new lock nuts. Torque: 50 Nm.
Tightening, left drive shaft nut
Use a counterhold 999 5461 COUNTERHOLD 999 5461 Counterhold (4 wheel studs) or 999 5540 COUNTERHOLD 999 5540 Counterhold (5 wheel studs) and protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Tighten with 120 Nm + 60°.
Remove the counterhold.
Lock nut, early design (M20): Knock down the nut's locking flange in the slot on the drive shaft.
Lock nut, late design (M22): The nut is self-locking.
Install:
- The bracket for the brake line/ABS cable (both sides)
- the ABS sensor in the stub axle. Clean the sensor with a soft brush.
Note! Ensure that the sensor seat is absolutely clean.
Tighten the sensor. Torque 10 Nm .
- The plastic nuts (both sides) and Torx screws for the wheel arch liner (left-hand side, early design).
Install:
- The cable conduit on the sub-frame.
- The carbon filter container. Clamp the hoses to the sub-frame with tie straps. Hook the hoses into place in the sub-frame.
- Casing under the engine (Early design).
Install:
- The front cover. Press it into position at the front. Press it forward and upward at the rear so that cover guide is seated in its slot. Install the screws
- The wheel. Lubricate the hub's guide for the rim using rust inhibitor 1161030-0. Fit the screws by hand. Now tighten crosswise. Torque: 110 Nm .
Note! Also see Tightening the wheel studs Service and Repair.
Fit the screws between the gearbox-engine and gearbox-starter motor.
Note! The cooler hose bracket (Early design).
Gearbox-engine (3), torque: 50 Nm
Gearbox-starter motor (2), torque: 40 Nm
Install:
- Cable conduit on the gearbox (Late design)
- Heated oxygen sensor connector in the bracket (Late design)
- Dipstick pipe with new O-ring. Torque: 25 Nm .
Install:
- Clamp/clamps for the cable harness/ground lead
- Connector to the gearbox (Note seal)
- Oil cooler hoses
- Air vent hose from the gearbox to the clamp/holder (early design)
- The hoses to the regulator valve. (Cars with EGR only).
Adjust the gear cable and install on the gearbox. See Adjusting the gear cable Adjusting the Gear Cable.