Transmission, Installing
Transmission, installing
Special tools:
951 2050 Bevel Protractor 951 2050 Bevel Protractor
Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.
Installation
Note! For tightening torques, see Tightening Torque
Installing the transmission
Before installing the transmission it is very important that the checks and cleaning have been carried out. See Transmission, preparations before installing Transmission, Preparations Before Installing.
Adjust height and angle with the mobile jack and the transmission fixture.
Locate the transmission on the engine.
Ensure that the transmission goes straight in, in relation to the engine, and that the guide sleeves and guide pin for the starter motor align in the guide holes on the transmission.
Installing and tightening the screws for the transmission
Install all 7 x M10 screws securing the transmission to the engine.
First tighten alternately and crosswise to light contact.
At the same time, check that the whole of the transmission is in contact with the engine.
Then tighten the screws crosswise.
Remove the fixture from the transmission.
Installing the torque converter screws
Note! Use new screws.
Align the torque converter against the carrier plate. Do this by turning the engine with the nut for the crankshaft pulley and turning the torque converter.
Install all 6 screws loosely. Tighten the screws. Tighten until the heads are almost in contact with the carrier plate. Tighten. See Tightening Torque Use a TORX socket TX50.
Note! Remove the socket wrench from the crankshaft.
Lifting the engine and transmission
Lift the engine to slightly above the horizontal position to provide better access to the rear engine mounting and engine pad.
Note! Check that the connection on the hose for the heater is not trapped between the engine and firewall when the engine is lifted.
Raise the car.
Installing the rear engine mounting
Remove the tie strap temporarily holding the steering gear.
Install:
- the rear engine mounting on the transmission
- the 3 x M10 screws for the engine mounting. Tighten
- the screw for the steering gear and engine pad loosely.
Check and if necessary align the bearing for the steering shaft in the boot when installing the steering gear. Also see Checking the boot for the steering shaft/firewall.
Installing the lower oil pipe on the transmission
Use a new O-ring.
Install:
- the oil pipe and dip stick pipe. Use both the screws. Tighten. See Tightening Torque
- a tie strap for the cable harness for the oil pipe
- the ground lead to the engine.
Installing the left drive shaft on the transmission and the wheel spindle
Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission. Pull the constant velocity joint to check that the drive shaft is secure.
Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.
Install a new screw loosely in the drive shaft.
Installing the subframe on the bodywork
Note! Use new screws. Lubricate the screw threads.
Lift the subframe until it is about 150 mm from the side member.
Secure the power steering pipe at the front edge of the upper side of the subframe. Use the rubber covered clamp. Install the screw loosely. Apply a small amount of soap solution so that it glides into the clamp easily. Check the steering gear bearing in the boot at the firewall.
Note! Ensure the following when lifting the subframe:
- ensure that the steering gear screws align in the frame
- ensure that the brake pipe passes the bracket for the exhaust pipe
- ensure that the ball joint pinion for the spring strut aligns in the control arm.
Install:
- the new screws and the support bracket at the rear edge
- the screws for the bracket loosely.
Applies only to cars with fuel driven parking heaters:
Align the washer with the mounting lug following the marking on the subframe.
Tighten the subframe screws. Tighten to light contact.
Remove the mobile jack.
Installing the right-hand drive shaft on the transmission, wheel spindle and control arm
Install the cap for the drive shaft pilot bearing. Use 2 x M8 screws. Tighten.
Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.
Install a new screw loosely in the drive shaft.
Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.
Position the mobile jack lightly applied under the right side of the subframe.
Install:
- new screws in the subframe
Note! Lubricate the screw threads.
- the screws loosely at the rear edge of the support plate.
Tighten the subframe screws. Tighten to light contact.
Remove the mobile jack.
Install the sub-frame's four screws together with the sub-frame's brackets and engine heater, if installed.
Tighten acc. to: Tightening torque Tightening Torque. First tighten the screws on the sub-frame's left side, then on the right.
Tighten the screws for the brackets M10.
Installing components on the engine and subframe
Install:
- 4 new M10 lock nuts for the steering gear and 1 M10 screw. Tighten
- 1 M10 screw for the front engine pad. Tighten.
Tighten the M10 screw for the rear engine pad.
Install the mounting for the engine stabilizer brace to the transmission. Use new screws. Tighten. See Tightening Torque
Installing the collision protection system over the steering gear
Applies only to right-hand drive cars
Install the 2 screws. Tighten.
Installing the servo pipe in the holders
Press the power steering pipe and the evaporator pipe into the holders on the subframe. (If there is a parking heater, also press its fuel line and the evaporator cable into place)
Install and tighten the clamps for the power steering pipe at the rear of the frame. Tighten the clamp and the clamp for the power steering line at the front edge of the top of the subframe.
Installing the front mounting for the exhaust pipe
Install the rubber mountings for the exhaust system on the brackets on the subframe.
Installing the cross members on the body
Install:
- the M8 screws for the front member
- the brake pipe in the holders on the member
- the M8 screws for the rear member
- the clamp with the heated oxygen sensor (HO2S) cable on the front cross member.
Installing front suspension components
Hint: Applies when installing front suspension components on both sides.
Install:
- a new M12 lock nut on the ball joint pinion. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten
- the anti-roll bar link. Use a new M10 lock nut. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten. See Tightening torque [1][2]Specifications. Tighten the drive shaft screw. Counterhold using a screwdriver in the brake disc vents. Tighten. See
- the soundproofing over the drive shaft (applies to certain versions).
Installing components for the fender liner
Install the support plate and the nuts on both sides.
Installing the cable duct
Install:
- the cable duct on the subframe
- any parking or additional heaters in the mounting in the subframe and the fuel line in the mountings.
Installing the front splash guard
Install:
- the splash guard under the engine
- the wheels. See Installing wheels Service and Repair.
Removing the lifting beams
Lower the car.
Remove the lifting beams and hooks from the engine.
Installing the coolant hose
Install the connector securing the engine coolant hose to the heater.
Remove the hose clips.
Installing the remaining screws for the transmission and starter motor
Install:
- the 3 x M10 screws for the transmission and engine. Tighten
- the 2 x M10 screws for the starter motor. Tighten. See Tightening torque [1][2]Specifications
- the bracket for the engine coolant hose and cable harness
- the bracket for the cable harness clamp and the mounting for the heated oxygen sensor (HO2S) connector at the rear edge of the transmission
- the clamp for the cable harness at the rear edge of the engine.
Installing the gear selector cable and oil pipe
Install:
- the ground lead and mounting on the subframe
- the oil pipe on the transmission
- the gear selector cable and bracket. Use 2 x M8 screws. Tighten.
Connect the cable to the lever. Connect the transmission connectors and the mounting for the air cleaner (ACL) housing bracket. Press the cable harness mounting into place on the control system cover.
Note! Check that the transmission bleed hose/valve is not trapped. There is a risk of overpressure in the transmission.
Installing service clips
Note! The automatic transmission has a gear selector cable while the manual transmission has two gear selector cables.
Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.
Check that the clip is positioned in the groove as illustrated.
Installing engine compartment components
Install:
- the charge air pipe to the charge air cooler (CAC)
- the air cleaner (ACL) housing assembly with the intake manifold and connections
- hook the turbocharger (TC) control valve into place in the air cleaner (ACL)
- the upper engine stabilizer brace between the wheel arches. Use 4 x M10 screws. Tighten
- 1 x M12 screw for the engine stabilizer brace/engine mounting. Tighten
- the tie strap for the power steering return line in the mounting lug for the engine stabilizer brace on the right-hand side.
Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.
Also see Transmission replacement, post-checking Transmission Replacement, Post-Checking.
Checking the boot for the steering shaft/firewall
Check that the bearing in the boot is in position.
If it has become detached apply a little grease to the edge of the boot (around the hole). Press the bearing back down into the boot.
Check that the boot is correctly positioned against the firewall and that the snap ring is correctly positioned. Adjust if necessary.
Note! It is essential that the above checks are carried out. Otherwise there may be noise from the transmission/engine and road noise in the passenger compartment.
Installing the battery lead
Connect the battery lead.
First read Battery, disconnecting Battery Disconnecting.
Finishing
Carry out checks after working on the transmission. See Transmission replacement, post-checking Transmission Replacement, Post-Checking.