Fitting the gearbox, 4-cyl. diesel
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Fitting the gearbox, 4-cyl. diesel
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Warning
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Cables, hoses, leads etc. are secured with hard plastic cable ties. After being tightened, the ends are cut off, leaving sharp edges at the fixing points. Be aware of the risk of injury due to these sharp ends of cable ties.
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2.
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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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Important
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Always replace the shaft seals in the gearbox. Lubricate with gearbox oil.
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3.
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Fit the gearbox with a lifting tool on the jack.
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Important
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Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.
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4.
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Insert the remainder of the gearbox. Turn the crankshaft if necessary to seat the gearbox correctly.
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5.
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Tighten all bolts except for the top one between the engine and gearbox.
Tightening torque, other bolts 70 Nm (52 lbf ft)
Tightening torque, lower bolts 40 Nm (30 lbf ft)
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6.
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Remove the lifting tool from the gearbox and lower the jack.
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7.
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Refit the gearbox bolts.
Tightening torque: 24 Nm (18 lbf ft)
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8.
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Fit the two ground leads to the gearbox.
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9.
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Fit
83 95 162 Protective collar, drive shafts
in the left-hand drive shaft seal. Ensure that the driver is clean and then insert the driver in the tool.
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Important
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Fit the driver in the gearbox until approx.20 mm are remaining and pull out the tool before the sealing surface of the shaft reaches the shaft seal.
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10.
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Insert the remainder of the shaft until the circlips engage.
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11.
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Fit the rear engine mounting. Place the engine cushion loosely in place.
Tightening torque 60 Nm + 60° (44 lbf ft + 60°)
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12.
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Lower the car and fit the left-hand engine mounting.
Tightening torque 40 Nm + 30° (30 lbf ft + 30°)
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13.
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Twist the clutch pressure pipe to the correct position and connect to the gearbox, and fit circlip. Remove the clamp pliers.
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14.
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Connect a hose to the air nipple and open until brake fluid emerges. Tighten the nipple and test the clutch. If it does not work, perform procedure
Bleed brake system
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15.
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Connect the reversing light switch connector.
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16.
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Raise the power train with the lifting yoke and fit the engine cushion nuts.
Tightening torque: 84 Nm (62 lbf ft)
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17.
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Fit the upper bolts holding the gearbox to the engine.
Tightening torque: 70 Nm (52 lbf ft)
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18.
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Add gearbox oil to the correct level. Fit the filler plug and level plug. See
Filling gearbox oil
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19.
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Raise the car and move the trolley with subframe into position. Lubricate the radiator core guide pins with vaseline. Lift the subframe carefully and guide the pins in.
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Important
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Be observant of the rubber gaiters for the inner drivers. These can knock against the centre mountings on the subframe before the subframe comes against the body.
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Guide in the ball joints.
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20.
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Fit the suspension arm in the steering swivel member, lift further and fit the steering gear.
Tightening torque: 90 Nm (66 lbf ft)
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21.
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Fit the subframe bolts and supporting plate bolts. Move the trolley lift. Tighten the bolts which hold the subframe.
Tightening torque 100 Nm + 45° (74 lbf ft + 45°)
Tightening torque, supporting plates 60 Nm (44 lbf ft).
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22.
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Remove the cable tie for the radiator and fit the power steering cooling pipe.
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23.
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Fit the air filter housing on the subframe.
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24.
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Fit the AC pipe in its plastic clips on the subframe.
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25.
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Fit the bolts holding the outer ball couplings to the steering swivel member on both sides. Tighten the nuts.
Tightening torque: 50 Nm (37 lbf ft)
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Warning
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Check that the spindle on the ball joint protrudes above the steering swivel member attachment.
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26.
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Fit the anti-roll bars. Hold in place with a thin, open-ended 17 mm wrench.
Tightening torque: 92 Nm (68 lbf ft)
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27.
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Fit the bolts which hold the torque rod to the subframe.
Tightening torque 90 Nm + 90° (66 lbf ft + 90°)
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28.
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Fit the front exhaust pipe with catalytic converter. Remember to tighten the front nuts.
Tightening torque: 25 Nm (18 lbf ft)
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29.
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Lower the car and remove the lifting beam.
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30.
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Check that the upper guide pins on the radiator core are correctly positioned. Shake the power train to prevent stresses in the engine mounts.
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31.
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Tighten the bolts to the rear engine cushion from the engine bay side, starting with the rear bolt. Then tighten the nuts.
Tightening torque, nuts 26 Nm (19 lbf ft).
Tightening torque, nuts 47 Nm (35 lbf ft).
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33.
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Remove the lock pin
87 92 335 Lock pin
from the selector rod housing, and connect the gear linkage to the selector rod.
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34.
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Select 4th gear and insert lock pin
87 92 632 Lock pin
. Tighten the clamp on the gear linkage.
Tightening torque: 22 Nm (16 lbf ft)
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35.
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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 selector lever gaiter.
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36.
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Tighten the nuts on the front exhaust pipe.
Tightening torque: 25 Nm (18 lbf ft)
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37.
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Fit the electrical unit, replace the clip. Fit the battery tray.
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38.
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Fit the maxi fuse holder and battery. Connect the battery cables. Fit the plastic cover to the battery.
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39.
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Fit the upper engine cover.
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40.
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Raise the car. Fit the two side covers in the wheelarch.
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41.
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Fit the headlamp position sensor (option).
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42.
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Fit the two lower engine covers.
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44.
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Set the clock and any radio code. Test drive the car. Check the steering wheel position during driving on straight roads. Adjust if necessary.
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