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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 drained 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.

Important

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


4. Lift the car.

5. Connect lifting tool 87 92 608 Holder for single-column lift .


6. Adjust the lifting tool so that its centre is in line with the gearbox centre and mating face.

7. Fit the gearbox using the lifting tool on a column jack.

Important

Insert the gearbox until around 20 mm remains, and remove tool 83 95 162.


8. Insert the remainder of the gearbox. Turn the crankshaft if necessary to seat the gearbox correctly.

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.

Important

Fit the driver in the gearbox until around 20 mm remains, and twist off the tool before the shaft sealing surface reaches the shaft seal.


15. Insert the remainder of the shaft until the circlips engage.

16. Lower the car to the floor.

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 mounting to the body is tight.

19. Lift the unit.

Note

Do not raise higher than necessary or it is more difficult to refit the subframe.


20. Tighten the left-hand engine pad to the body and gearbox, first inserting all bolts and nuts.

Tightening torques

Nut, up to and including Vehicle Identification Number 73514907:

84 Nm (62 lbf ft)

Nut, from and including Vehicle Identification Number 73514908:

74 Nm (55 lbf ft)

Engine pad - body 60 Nm (45 lbf ft)


21. Fit the stay (certain models) on the gearbox and the engine pad. Tighten the other upper bolts on the gearbox.

Tightening torque, gearbox 70 Nm (50 lbf ft)

Tightening torque, stay to engine pad 63 Nm (46 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.

25. Check that the radiator core guide pins are correctly fastened to the radiator bar.

26. Suspend the oil cooler.


27. Raise the car and move the trolley lift with subframe below the car.

28. Carefully raise the subframe.

Important

Check:

- Hoses to oil cooler.

- Rubber boots for inner drivers which can contact the centre mountings on the subframe before the subframe contacts the body.

- Guide in the front ball joints.


29. Tighten the power steering pipe front mountings (2 x) before the subframe is fully raised.

30. Guide the radiator core guide pins into the subframe.

31. Guide the A/C pipes into their holders on the subframe.

32. Adjust the subframe so that the screw holes line up with the body. On the trolley lift are 2 guide pins, front left and rear right, which guide the subframe into position.

33. Fit the bolts 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.

40. Tighten the 2 rear mounting clamps connecting the power steering pipe to the subframe, tighten the nut which fastens the oil cooling coil.

41. Tighten the air filter housing.

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)


Warning

Check that the pin on the ball joint protrudes above the steering swivel member mounting.


44. Fit the anti-roll bar stays. 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)

Note

To avoid pressing the boot in, use a thin wrench as counterhold.


45. Fit the protective plate between the engine and gearbox (not B235R).


46. Fit the rear engine pad with bolts to the subframe, and insert the front two bolts.

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 circlips 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.

52. Shake the power train to prevent stresses in the engine pads. Tighten the bolts to the rear engine pad from the engine bay side, starting with the rear bolt.


Tightening torque: 24 Nm (18 lbf ft)

53. Tighten the nut to the rear engine pad.

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 pad in the stay and tighten.

Tightening torque up to VIN 73514478: 47 Nm (35 lbf ft)

Tightening torque from VIN 73514479: 38 Nm (28 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.

62. Connect the oxygen sensors.

63. Fit the electrical centre.


64. Fit the battery tray and connect the battery, attach the plastic cover.

65. Fit the front wheels .

66. Fit the cap over the throttle body.

67. Test drive the car. Check the steering wheel position during driving on straight roads. Adjust if necessary.

68. Set the clock and radio code.