Intermediate shaft (Petrol)
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Intermediate shaft (Petrol)
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1.
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Disconnect the battery's negative lead.
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2.
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Place wing protectors over the wings and remove the upper engine cover.
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3.
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Remove the stay between the suspension strut towers
(RHD only)
.
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4.
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Use a ½" flexible handle to relieve the belt tensioner of tension.
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5.
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Remove the belt tensioner, using an 8 mm Allen key.
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6.
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Remove the generator's upper screw, using an 8 mm Allen key.
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8.
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Remove the right-hand wheel.
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9.
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Remove the belt circuit cover.
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10.
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Undo the nuts securing the anti-roll bar and the suspension arm's ball joint. Use
89 96 696 Puller
.
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11.
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Lower the suspension arm and fix it in position with a block of wood inserted between the suspension arm and the anti-roll bar.
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12.
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Remove the clamp and pull down the gaiter.
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13.
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Swing the wheel to the left to facilitate removal of the drive shaft.
Important
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Make sure that no dirt gets into the universal joint.
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Cover the universal joint and driver with plastic bags or the like.
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14.
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Disconnect the generator cables and the generator bracket's lower bolt.
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15.
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Move the generator aside.
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16.
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Unscrew the support bearing bracket bolts.
Important
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Place a receptacle under the gearbox to avoid spilling oil on floor.
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17.
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Pull the support bearing bracket away from the guide pins in the engine block and withdraw the intermediate shaft from the gearbox.
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2.
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Make sure that the intermediate shaft is clean and then fit the shaft in the tool.
Important
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Insert the intermediate shaft in the gearbox until about 20 mm of it remains and withdraw the tool before the shaft's sealing surface reaches the shaft seal.
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3.
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Insert the remainder of the shaft.
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4.
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First guide the support bearing bracket to the upper guide pin and then tighten the bearing bracket.
Tightening torque 24 Nm (18 lbf ft)
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5.
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Make sure that the adjusting sleeves are tapped out about 1 mm to facilitate fitting the generator on the mountings. Then fit the two generator retaining bolts and tighten the lower one.
Tightening torque 47 Nm (35 lbf ft).
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6.
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Connect the generator cables.
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7.
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Fill grease, (16) 87 92 624, in the gaiter and driver and connect the universal joint to the driver. Fit a new clamp on the gaiter and wipe away excess grease. It is important that the clamp is fitted as illustrated.
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8.
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Remove the wooden block, swing the suspension arm back and connect it to the steering swivel member. Fit the bolt and tighten it.
Tightening torque 75 Nm (55 lbf ft).
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9.
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Secure the anti-roll bar.
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10.
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Lower the car to the floor.
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11.
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Tighten the generator's upper bolt.
Tightening torque 47 Nm (35 lbf ft).
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12.
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Fit the belt tensioner.
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14.
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Fit the stay between the suspension strut towers and press the protective caps in place
(RHD only)
.
Tightening torque 24 Nm (18 lbf ft)
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15.
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Press the cover over the intake manifold into place.
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16.
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Connect the negative lead to the battery.
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17.
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Fill the gearbox with oil to the correct level.
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18.
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Raise the car and fit the cover over the belt circuit.
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19.
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Fit the wheel.
Tightening torque 110 Nm (81 lbf ft)
Important
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The wheel should hang freely when the wheel bolts are tightened.
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20.
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Lower the car to the floor.
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21.
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Set the clock and any radio code.
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