To fit, gearbox, V6 diesel


1.Lubricate the primary shaft splines, see Summary of lubricants and sealants .
2.If the slave cylinder is new or without brake fluid it must be bled, see Bleeding of slave cylinder.

3.Insert 83 95 162 Protective sleeve, drive shafts into the right-hand shaft seal in the gearbox to protect the seal when the gearbox is fitted.

Important

Always replace the drive shaft seals. Lubricate with gearbox oil, see


4.Raise the car.
5.Make sure that the locating studs are in place. Lubricate with thin anti-corrosion oil.
6.Connect 87 92 608 Holder for single-column lift. Adjust the jack so that it is directly under the centre of the gearbox by the mating face.
7.Fit the gearbox with lifting tool onto a pillar jack.

Important

Push in the gearbox until approx. 20 mm remain and remove tool 83 95 162.
8.Push in the rest of the gearbox. Turn the engine shaft, if needed, so that the gearbox can be fitted.

9.Fit and tighten the lower bolts securing the gearbox to the engine.

Tightening torque 40 Nm (30 lbf ft)
10.Remove the lifting tool from the gearbox and remove the jack.

Replace and tighten the gearbox bolts.

Tightening torque 24 Nm (18 lbf ft)
11.Fit the upper bolts to the gearbox that can be accessed from beneath.

Tightening torque 70 Nm (52 lbf ft)
12.Fit the bracket for the torque arm on the transmission.

Tightening torque 41 Nm (30 lbf ft)
13.Fit the ground cables to the mounting and the gearbox.

14.Fit and connect the starter motor and fit the cable duct.

15.Fit the rear engine bracket and gear linkage. Connect the linkage to the gearbox. Tighten the bolt.

Tightening torque, engine bracket, 60 Nm (44 lbf ft)

gear linkage, 20 Nm (15 lbf ft)
16.Insert 83 95 162 Protective sleeve, drive shafts into the left-hand shaft seal.
17.Make sure that the driver is clean and fit it into the tool.

Important

Fit the driver in the gearbox until about 20 mm remains and withdraw the tool before the shaft's sealing surface reaches the shaft seal.


18.Push in the rest of the shaft until the circlip snaps into place.

19.Lower the car to the floor.
20.Fit the upper gearbox bolts.

Tightening torque 70 Nm (52 lbf ft)
21.Plug in the reversing-light switch.
22.Fit the gearbox mounting.

Tightening torque 40 Nm (30 lbf ft)
23.Connect the clutch delivery line to the gearbox.
24.Remove the pinch-off pliers. Connect a plastic hose to the bleed nipple and open the nipple until brake fluid runs out the hose. Tighten the nipple and test the clutch. If the clutch does not work perform Bleeding the clutch hydraulic system in the car. Check integrity.

25.Fit the nut to the cable duct.
26.Raise the power train with the lifting beam.
27.Fit the left-hand engine pad to the body and gearbox. Thread all the bolts and the nut. Tighten the nut.

Tightening torque 77 Nm (57 lbf ft)
28.Lower the power train taking the weight off the lifting beam.

29.Fill the gearbox with oil to the correct level. Tighten the level plug, drain plug and filler plug.

Tightening torque 50 Nm (37 lbf ft)
30.Check that the journals for the radiator assembly are correctly fixated in the radiator member.
31.Raise the car and fit the rear engine pad, loosely tightening the nut.

32.Roll the lifting trolley with subframe under the car.

33.Carefully raise the subframe. Make sure that the centre mountings on the subframe do not foul the rubber gaiters for the inboard drive cups before the subframe is in contact with the body. Guide the ball joints into the steering swivel member. Observe the position of the anti-roll bar links.
34.Fit the bolts for the steering gear before the subframe is fully raised.

Tightening torque 90 Nm (66 lbf ft)
35.Fit the steering servo deliver pipe into the clips.
36.Guide the radiator assembly dowels into the subframe. Grease with petroleum jelly to facilitate fitting.
37.Guide the AC-lines into their brackets on the subframe.

38.Fit the coolant pipe to the power steering.
39.Adjust the subframe so that the bolt holes are aligned with the body. On the lifting trolley there are 2 journals, front left and rear right, which guide the subframe into the correct position.
40.Fit the bolts securing the subframe and rear side plates. Tighten sufficiently so that the subframe is not dislodged when the lifting trolley and fixture are removed.

Note

Do not mix up the centre bolts on the subframe with the other bolts (different sizes and designs).
41.Roll the lifting trolley out the way.
42.Tighten the subframe bolts.

Tightening torque 100 Nm + 45° (74 lbf ft + 45°)
43.Tighten the bolts for the support plate.

Tightening torque 63 Nm (46 lbf ft)
44.Fit and tighten the bolts securing the torque arm to the subframe.

Tightening torque 90 Nm + 90° (66 lbf ft + 90°)
45.Remove the strap suspending the radiator and fit the bracket for the charge air cooler pipe.
46.Fit the air baffle to the radiator.
47.Connect the hose to the battery cooler.
48.Fit the air cleaner.
49.Tighten the outer ball joints to the steering swivel member.

Tightening torque 50 Nm (37 lbf ft)

 Warning

Check that the journal on the ball joint protrudes above the steering swivel member attachment.

50.Fit the anti-roll bar stay. Take the strain with a thin open ended 17 mm spanner.

Tightening torque 85 Nm (64 lbf ft)

Note

To avoid the gaiter being pressed in, a thin spanner should be used for support.
51.Fit the centre section of the exhaust pipe.

52.Lower the car and remove the lifting beam and holder.

53.Tighten the bolts for the rear engine pad from the engine bay side, starting with the rear bolt.

Tightening torque 24 Nm (18 lbf ft)
54.Take the weight off the left-hand engine pad by lifting the gearbox with a jack. Then lower the jack and tighten the bolts.

Tightening torque 40 Nm (30 lbf ft)
55.Tighten the nut for the rear engine pad. Rock the engine to avoid tension in the engine pad.

Tightening torque 45 Nm (33 lbf ft)
56.Fit the front catalytic converter and loosely tighten the nuts.

57.Raise the car and fit the lower bolts on exhaust pipe and the bolts for the catalytic converter.
58.Undo the bolt securing the front torque rod to the gearbox. Centre the rubber pad in the rod and tighten the bolt.

Tightening torque 47 Nm (34 lbf ft)
59.Lower the car to the floor.
60.Remove the locking pin 87 92 335 from the gear lever housing.
61.Engage 4th gear and insert locking pin 87 92 632. Tighten the clamp on the gear linkage.

Tightening torque 22 Nm (16 lbf ft)
62.Remove the locking pins, check the gear positions and that the ignition key can be removed. Fit the plastic plug in the gearbox.
63.Fit the gear lever boot.
64.Fit the hose to the intake manifold.
65.Tighten the nuts securing the front exhaust pipe to the turbocharger.

Tightening torque 25 Nm (18 lbf ft)
66.Fit the pipe between the turbocharger and charge air cooler as well as the clip for the positive cable on the pipe.
67.Fit the electrical distribution unit.
68.Fit the battery tray.
69.Fit the MAXI fuse board.

70.Fit and connect the battery, also fit the plastic cover.

71.Fit the upper engine cover.
72.Fit the intake manifold and the turbocharger heat shield.
73.Raise the car and fit the side covers in the wheel housings.
74.Fit the level sensor for the xenon headlamps (option)

75.Fit the rear and front lower engine covers.
76.Fit the front wheels. The wheels must hang freely when tightened. Refer to Wheels .

Tightening torque 110 Nm (80 lbf ft)
77.Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
78.Set the clock and enter the radio code (if applicable).