To Fit
To FitWhen fitting a new gearbox, transfer the holder for the torque converter and the plugs form the new gearbox to the old one and the gear shift cable lever to the new gearbox.
1. Turn the torque converter so the holes are aligned with the holes on the driver plate and turn the engine so the oval hole in the driver plate is opposite the starter motor opening.
Fit 87 92 574 Holder to secure the torque converter in place while fitting. Lubricate the torque converter locating pin with grease.
2. Make sure the two guide sleeves are on the engine and apply grease to the sleeves.
3. Lubricate and fit new drive shaft seals (does not apply to new gearboxes). Use 87 92 657 Fitting drift, drive shaft seals for the left and 32 025 025 Fitting drift, drive shaft seals for the right-hand drive shaft seal.
4. Fit 83 95 162 Protective collar, drive shafts in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.
5. Fit 87 92 608 Holder for single-column lift onto a column jack.
6. Secure the tool to the transmission as for removal.
Important: The jack can tip over. Be careful.
7. Fit the gearbox to the engine. Remove 87 92 574 Holder just before the gearbox is in place. Tighten the lower bolts between the engine and the gearbox. Fit the upper bolt loosely at the same time to the wiring harness metal bracket.
Tightening torque 60 Nm (44 ft. lbs.)
8. Fit 83 95 162 Protective collar, drive shafts into the sealing ring. Lubricate the sealing ring.
9. Make sure that the drive shaft is clean and then align it with the tool.
Important: Fit the drive shaft 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.
10. Push in the rest of the shaft until the circlip clicks in.
11. Press the torque converter against the driver plate. Fit the plug.
12. Apply Thread locking adhesive, Loctite 242 to the bolts holding the torque converter to the driver plate.
Note: Use the original bolts with associated washers. Using bolts that are too long will harm the torque converter.
13. Turn the engine clockwise with the belt pulley and tighten the bolts one at the time starting at the oval hole in the driver plate.
Tightening torque 60 Nm (44 ft. lbs.)
14. Remove the lifting tool from the transmission and move away the jack. Fit the bolt into the transmission.
Tightening torque 22 Nm (16 ft. lbs.)
15. Lower the car to the floor.
16. Lift up the unit and fit the bolts to the engine bracket according to the marks made earlier.
Tightening torque 53 Nm (39 ft. lbs.)
17. Remove the lifting beam and the holder.
18. Connect the air exhaust hose.
19. Fasten the cable to the cable retainer by pulling back the locking sleeve.
20. Fit the gear cable to the selector lever arm.
21. Fit the cable to the rear mounting.
22. Fit the upper bolts between the engine and the gearbox.
Tightening torque 60 Nm (44 ft. lbs.)
23. Put the wiring harness in place and fit the cable duct to the gearbox.
24. Connect and secure the control module connector.
25. Fit the coolant pipe with a new O-ring to the thermostat housing. Lubricate with Vaseline. Do not tighten the screw until the screw for the attaching lug has been fitted.
26. Fit the turbo delivery hose.
27. Raise the car.
28. Remove the oil cooler hose seals (does not apply to new gearboxes). Use 83 90 270 Sliding hammer, 87 92 319 Adapter, 3/8" - M10 and 87 92 756 Puller, oil pipe seal, automatic transmission.
Important: Ensure that the surfaces in the gearbox gasket opening are not damaged.
29. Fit new seals lubricated with Vaseline for the oil cooler hoses (does not apply to gearbox). Use 87 92 814 Fitting, oil pipe seal, automatic transmission.
30. Lubricate the pipes with Vaseline, non-acidic and attach the oil cooler hoses. The pipes press holes into the seals during fitting.
31. Fit the screws to the coolant pipe attaching lugs.
32. Fit the battery ground cable and the wiring harness clamp to the metal bracket.
33. Fit the starter motor.
Tightening torque 47 Nm (35 ft. lbs.)
34. Fit the electrical connections to the starter motor.
35. Fit the secondary air pump with mounting.
36. Fit the air connections and electrical connections plus the coolant hose to the secondary air pump.
37. Fit the rear torque rod bracket to the gearbox.
Tightening torque 80 Nm (69 ft. lbs.)
38. Fit the front torque rod bracket to the gearbox.
Tightening torque 80 Nm (69 ft. lbs.)
39. Roll the trolley lift with subframe under the car.
40. Lift the frame. Position the suspension arm ball joints in the steering swivel member and the radiator guide pins. Make sure the upper radiator guides are against their brackets.
Important: Press up the pin carefully.
The groove in the pin must be visible in the screw hole in the spindle housing.
If the rubber gaiter is pressed down, it will not seal properly to the swivel pin.
41. Fit the anti-roll bar to the subframe.
42. Lift in place the subframe. Steer the guide pins in the fixture to the holes in the body.
43. Fit the subframe. bolts and rear brackets. Lift the subframe. against the body so that the bushes do not rotate when the bolts are tightened.
Tightening torque, subframe: 75 Nm +135° (55 ft. lbs. + 135°)
Tightening torque, rear bracket bolts: 90 Nm +45° (60 ft. lbs. + 45°)
44. Remove the trolley lift.
45. Fit the power steering pipe to the subframe plastic clips.
46. Fit the steering gear with bolts, washers and nuts.
Tightening torque 50 Nm +60° (37 ft. lbs. +60°)
47. Fit the engine torque rod to the subframe.
Tightening torque, front nut 60 Nm +90° (44 ft. lbs. +90°)
Tightening torque, rear bolt 80 Nm (59 ft. lbs.)
48. Fit the suspension arms to the steering swing member. Use new nuts.
Tightening torque 50 Nm (38 ft. lbs.)
Important: Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.
49. Fit the connector and cable clip to the headlamp angle sensor. (Option)
50. Remove the straps.
51. Set up 83 96 145 centering tool, subframe - engine and 83 96 152 centering tool, power train with 32 025 059 Support, without the long supports. Check that the engine is correct in relation to the subframe. Remove the centering tool.
52. Fit the rear catalytic converter. Lubricate the threads with 90 513 210 Universal paste.
Tightening torque, exhaust flanges 30 Nm (22 ft. lbs.)
Tightening torque, exhaust clamp 40 Nm (30 ft. lbs.)
53. Fit the front wing liner section on both sides of the car.
54. Fit the spoiler shield. CV: Fit Chassis reinforcement, front subframe, CV.
55. Fit the wheels. See Wheels.
56. Lower the car to the floor.
57. Fit the upper bumper shell mountings.
58. Tighten the screw on the thermostat housing.
59. Test pressurize the cooling system, see Cooling system, test pressurizing.
60. Fill with three liters of gearbox oil, refer to List of lubricants and sealing compounds. If a new or reconditioned gearbox is being fitted, more oil may be needed as the gearbox can be empty.
61. Fit the filler plug.
Tightening torque 45 Nm (33 ft. lbs.).
62. Fit the lower heat shield from the catalytic converter.
63. Fit the upper heat shield over the catalytic converter.
64. Fit the expansion tank.
65. Fit the battery tray.
66. Fit the cable duct, bonnet switch electrical connection and the electrical center to the battery tray.
67. Fit the battery.
68. Fit and connect the battery cables.
69. Fit the battery cover.
70. Fit the hose to the mass air flow sensor and the air filter cover.
71. Fit the vacuum hoses.
72. Fit the hose to the secondary air pump.
73. Fit the mass air flow sensor connector.
74. Fit the upper engine cover.
75. Fill with coolant, see Bleeding and topping up the cooling system.
76. If the gearbox has been changed, perform Checking and adjustment, selector lever cable.
77. Check the transmission fluid level. See Check/adjust fluid level, B284
78. If the gearbox has been changed, perform After changing a control module.
79. Carry out Measures after disconnecting the battery.
80. Remove the wing covers.
81. After gearbox replacement, carry out Adaptation, resetting.
82. Test drive the car with varying engine loads and rpm and delete eventual trouble codes. Also check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.