To fit
To fit |
1. |
Lubricate the primary shaft splines, see
List of lubricants and sealing compounds
.
|
2. |
If the slave cylinder is new or empty of brake fluid, it must be bled, see
Bleeding the slave cylinder
.
|
3. |
Fit
83 95 162 Protective collar, drive shafts
in the right-hand shaft seal in the gearbox to protect the seal when the gearbox is refitted.
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4. |
Lift the car.
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5. |
Connect lifting tool
87 92 608 Holder for single-column lift
.
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6. |
Adjust the lifting tool so that its centre is in line with the gearbox centre and splitting plane.
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7. |
Fit the gearbox using the lifting tool on a column jack.
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8. |
Insert the remainder of the gearbox. Turn the crankshaft if necessary to seat the gearbox correctly.
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9. |
B235R:
Fit the protective plate behind the flywheel. Fit the bolts between the gearbox and oil sump, and the bolts to the protective plate.
Tightening torque Gearbox - oil sump 40 Nm (30 lbf ft) |
10. |
Tighten the lowest bolts between the engine and gearbox.
Tightening torque 70 Nm (50 lbf ft) |
11. |
Remove the lifting tool from the gearbox and lower the jack.
Refit the gearbox bolts. Tightening torque: 24 Nm (18 lbf ft) |
12. |
Fit the ground leads to the mounting and gearbox.
|
13. |
Fit
83 95 162 Protective collar, drive shafts
to the left-hand shaft seal.
|
14. |
Ensure that the driver is clean and then insert the driver in the tool.
|
15. |
Insert the remainder of the shaft until the circlips engage.
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16. |
Lower the car to the floor.
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17. |
Fit the gearbox mounting.
Tightening torque: 40 Nm (30 lbf ft) |
18. |
Connecting the coupling pipe to the gearbox and fit the circlips, checking that the pipe fixing to the body is tight.
|
19. |
Lift the unit.
|
20. |
Tighten the left-hand engine cushion to the body and gearbox, first inserting all bolts and nuts.
Tightening torque Engine cushion - gearbox 85 Nm (62 lbf ft) Engine cushion - body 60 Nm (45 lbf ft) |
22. |
Fit the clip to the starter motor cable.
|
23. |
Add oil to the gearbox to the correct level. Use mounting tool
87 92 590 Tool, oil level plug
. Tighten level plug, drain plug and filling plug.
Tightening torque: 50 Nm (37 lbf ft) |
24. |
Connect the line to the reversing light switch.
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25. |
Check that the radiator core guide pins are correctly fastened to the radiator bar.
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26. |
Suspend the oil cooler.
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27. |
Raise the car and move the trolley lift with subframe below the car.
|
28. |
Carefully raise the subframe.
|
29. |
Tighten the power steering pipe front fixings (2 x) before the subframe is fully raised.
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30. |
Guide the radiator core guide pins into the subframe.
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31. |
Guide the A/C pipe into its holder on the subframe.
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32. |
Adjust the subframe so that the screw hole lines up with the body. On the trolley lift are 2 guide pins, front left and rear right, which guide the subframe into position.
|
33. |
Mount the screws and rear supporting plate which holds the subframe.
|
34. |
Remove the trolley lift.
|
35. |
Tighten the bolts to the subframe.
Tightening torque 100 Nm + 45° (74 lbf ft + 45°) |
36. |
Tighten the supporting plate bolts.
Tightening torque 60 Nm (44 lbf ft) |
37. |
Fit and tighten the bolts which hold the torque rod to the subframe.
Tightening torque 90 Nm + 90° (66 lbf ft + 90°) |
38. |
Remove the cable tie supporting the radiator core.
|
39. |
Refit the oil cooler.
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40. |
Tighten the 2 rear fixing clamps connecting the power steering pipe to the subframe, tighten the nuts which fasten the oil cooling coil.
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41. |
Tighten the air filter housing.
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42. |
Tighten the steering gear.
Tightening torque 90 Nm (66 lbf ft) |
43. |
Tighten the outer ball joints on the steering swivel member.
Tightening torque: 50 Nm (37 lbf ft)
|
44. |
Fit the anti-roll bar stay. Hold in place with a thin, open-ended 17 mm wrench or a hold the hex plug with a socket.
Tightening torque: 84 Nm (62 lbf ft) Tightening torque, nut with steel lock 95 Nm (66 lbf ft)
|
45. |
Fit the protective plate between the engine and gearbox (not B235R).
|
46. |
Fit the rear engine cushion with bolts to the subframe, and insert the front two bolts.
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47. |
Fit the rear engine mounting, the linkage to the gear change follows.
Tightening torque: 70 Nm (50 lbf ft) |
48. |
Fit and tighten the stay between the engine mount and engine.
Tightening torque: 22 Nm (16 lbf ft) |
49. |
Fit the front exhaust pipe, by:
|
• |
Tightening the flange to the turbo.
Tightening torque: 25 Nm (18 lbf ft) |
• |
Fit and tighten the stay to the engine.
Tightening torque: 22 Nm (16 lbf ft) |
• |
Fit the circlip for the rubber mounting.
|
• |
See also
Front exhaust system with catalytic converter, 4-cyl. B205E
or
Front exhaust system with catalytic converter, B235E/R
.
|
50. |
Fit the headlamp position sensor (option). Fit the shields and brake circuit splash guard.
|
51. |
Lower the car and remove the lifting beam.
|
53. |
Tighten the nut to the rear engine cushion.
Tightening torque: 45 Nm (33 lbf ft) |
54. |
Lift the car.
|
55. |
Tighten the bolt to the front torque rod at the gearbox, centre the rubber cushion in the stay and tighten.
Tightening torque: 47 Nm (34 lbf ft) |
56. |
Lower the car to the floor.
|
57. |
Remove the brake clamp from the clutch pedal. Connect a hose to the breather nipple, loosen this and allow some brake fluid to escape. Tighten the nipple and check the clutch; if it does not work, bleed as described in
Bleeding the brake system
.
Check the system for leaks. |
58. |
Fit the shim and gearbox linkage to the gearbox and tighten. Use
74 96 268 Thread locking adhesive
on the bolt.
Tightening torque: 20 Nm (15 lbf ft) |
59. |
Remove the lock pin
87 92 335 Lock pin
from the selector rod housing, and connect the gear linkage to the selector rod.
|
60. |
Select 4th gear and insert
87 92 632 Lock pin
. Tighten the clamp on the gear linkage.
Tightening torque: 22 Nm (16 lbf ft) |
61. |
Remove the lock pins, check the gear positions and that the ignition key can be removed. Insert the plastic plug in the gearbox. Fit the gaiter.
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62. |
Connect the oxygen sensors.
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63. |
Fit the electrical unit.
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64. |
Fit the battery tray and connect the battery, attach the plastic cover.
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65. |
Fit the front wheels which must be freely suspended. See
Wheels
Tightening torque: 110 Nm (80 lbf ft) |
66. |
Fit the cap over the throttle body.
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67. |
Test drive the car. Check the steering wheel position during driving on straight roads. Adjust if necessary.
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68. |
Set the clock and radio code.
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