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Bearing housing cover gasket, to removal and fitting

Bearing housing cover gasket, to removal and fitting

To remove


1. Place drapes over the wings to keep the paintwork clean and protect it from damage.

2. Remove the upper engine cover and the battery cover.


3. Disconnect the battery terminals and remove the battery.

4. Undo the cable clamp under the battery tray.

5. Unplug the bonnet switch connector.

6. Remove the battery tray.


7. Undo the ground cable from the engine mounting

8. Remove the clutch cables from the gearbox

Undo the gear selector cables (1) from the gear cover (2)

2x Remove from the support


9. To remove the gear change unit (5)

4x Unscrew bolts (6)

Remove the gearchange unit

10. Remove the reversing light switch

Remove the wiring loom connector (4)

Unscrew the reversing light switch (3)

11. Fit 83 94 850 Lifting beam .

12. Remove the front engine mount

Undo bolt (2) from the front suspension frame


13. Remove the rear engine mount

Undo the bolt (1) from the front suspension frame

14. Remove the LH front wheel

5x Unscrew bolts

15. If fitted: Remove the front sensor for headlight adjustment

16. Remove the LH engine mount

3x Unscrew bolts (3)

Important: Check that the engine and engine components are not resting against the front suspension frame or subframe. Cables and hoses must not be stretched.

17. Lower the engine/gearbox

Lower using lifting beam 83 94 850 Lifting beam , until the bearing housing is not up against the front suspension frame or subframe whilst removing

18. To remove the bearing housing cover

Put an oil tray underneath as oil will run out

9x Unscrew bolts

Note: If necessary: Free the bearing housing cover with light taps of a rubber hammer. Collect any oil that runs out

Remove the gasket.


19. Screw in a guide pin

Screw in 87 92 962 Guide pins gearcase 2x F17 (1)

Note: These are used to guide the bearing housing so as to avoid damage to the central clutch sealing ring.

20. To remove the bearing housing from the gearbox

Put an oil tray underneath as oil will run out

4x Remove bolts (arrowed)

21. Remove the bearing housing

Carefully lift away the bearing housing

Note the magnet (2) and spacer (1) of the reverse gear shaft

Note: Remove if necessary


22. Remove the gasket.

23. Check for damage and wear on all components

24. Remove all traces of sealant and clean the mating surfaces.

To fit



25. To fit the bearing housing

Fix a new gasket in place onto the gearcase sealing surface using grease.

Carefully assemble the bearing housing to the gearcase

Directions: Note the magnet (2) and spacer (1) of the reverse gear shaft


26. Tighten the bearing housing

4x Screw tight using new bolts (arrowed) (22Nm)

Remove 87 92 962 Guide pins gearcase 2x F17 (1)


27. Fit the bearing housing cover

Assemble using a new gasket on the gearcase

4x Tighten the bolts - M7 (15 Nm)

5x Tighten the bolts - M8 (20 Nm)

28. Where appropriate: Fit the front sensor for headlight adjustment

29. Fit the LH engine mount

Raise into position using 83 94 850 lifting beam

3x Fit the mounting bolts (3) for the LH engine mount but do not tighten yet

Note: The engine mount must remain loose until the engine/gearbox has been adjusted

Important: Do not adjust the support bearing

30. Put in place KM-6313 ( 83 96 145 Centring jig, subframe - engine ) with 83 96 368 Supplementary set for centring jig (1) in the front subframe

Note: In order to ensure that the drive train is correctly adjusted when the engine mount bolts have been loosened, the drive train must be positioned relative to the front subframe.

Insert 83 96 376 Adapter set sleeves x4 .

The pins (3, 6) must be located in the guide holes in the front subframe

2x Tighten the adjustment rail bolts (arrowed)

The rear support bearing (4) must locate in the guide pin on the rear engine mount holder without any free-play

The front support bearing (5) must locate in the guide pin on the front engine mount without any free-play


31. Lower the engine/gearbox with 83 94 850 Lifting beam

Note: The engine mount guide bearing and holder must locate in the support bearing (3, 4)


32. Fit the LH engine mount

Tighten the three LH engine mount bolts (1) (55 Nm)


33. Fit the front engine mount

Tighten bolt (2) with a new nut on the front suspension frame ( 80 Nm)

34. Fit the rear engine mount

Tighten the bolt (1) on the engine mount holder (80 Nm)

35. Remove 83 96 145 Centring jig, subframe - engine (1)

Screw back the support bearing (2, 3)

2x Undo the adjustment rail bolts (arrowed)


36. Fit the gearchange unit (2)

Assemble with a new gasket

4x Tighten the bolts (1) (15 Nm)


37. Assemble the gear selector cables to the gearbox

2x Fit into the support (4)

Attach the gear selector cables (3) to the gear cover

38. Adjust the oil level in the gearbox

see service procedure Gearbox oil level, checking and correcting F17 .

39. Check that all gears run smoothly

when the car is stationary

with the engine running and with the clutch disengaged.

40. Fit the reversing light switch (1)

Assemble with a new sealing ring

Tighten the reversing light switch (20 Nm)

Replace the wiring loom connector (2)


41. Attach the ground cable to the engine mounting. Tightening torque 18 Nm (13 lbf ft)

42. Fit the battery tray and the bonnet switch connector.

43. Fit the battery.

44. Fit the battery cover and upper engine cover.

45. Remove the wing covers.

46. Fit the wheel. See Wheels

47. Carry out Measures after disconnecting the battery .