Install the manual transmission
CAUTION:
Materials harmful to health.
Contact with fluids harmful to health!
Contact with fluids harmful to health!
- Note and follow safety instructions on containers.
- Conduct all work in appropriate personal protective equipment only.
NOTE:
RISK OF DAMAGE
Damage to the engine block.
Serious damage to the engine block and transmission due to damaged and corroded screws.
Damage to the engine block.
Serious damage to the engine block and transmission due to damaged and corroded screws.
- It is imperative that protruding threads of the transmission bolts are checked for corrosion and damage prior to removal.
- It is imperative that all rust is removed from corroded threads and that they are cleaned prior to removal.
- Replace rusted and damaged bolts.
NOTE:
RISK OF DAMAGE
Improper screw length can cause component damage.
The use of screws of improper length can lead to component damage.
Improper screw length can cause component damage.
The use of screws of improper length can lead to component damage.
- Note the correct screw length.
- Install screws that correspond to the original length.
- Incorrect: Do not use screw (1) (starter threaded connection) for the lower threaded connection of the transmission.
- Correct: Use only screw (2) (M8x40) for the lower threaded connection of the transmission and flange-mount the transmission.
- Replace the bolts (arrows).
Parts: Screws
- Tighten screws (arrows).TIGHTENING TORQUE SPECIFICATIONS
Transmission to engine M8 Tightening torque 19 Nm M12 Tightening torque 66 Nm - Replaces crews (1).
Parts: Screws
- Tighten down screws (1).TIGHTENING TORQUE SPECIFICATIONS
Transmission mounting M10 Replace screws. Joining torque 40 Nm Angle of rotation 90° - Replace screws (1).
Parts: Screws
- Tighten down screws (1).TIGHTENING TORQUE SPECIFICATIONS
Transmission to engine M8 Tightening torque 19 Nm M12 Tightening torque 66 Nm - Install clutch slave cylinder.
- Replace screws (1).
Parts: Screws
- Tighten down screws (1).TIGHTENING TORQUE SPECIFICATIONS
Clutch slave cylinder to transmission housing M8 Tightening torque 19 Nm Connect and lock the gear sensor plug connection (2).
Clamp the cable (1) to the transmission with the holder.
- Replace the screw (1).
Parts: Screw
- Tighten the ground strap to the transmission using the screw (1).
- Clip the clip onto the stop/holder (2).
- Attach the selector lever cables (3) onto the ball joints.
Install battery carrier
- Insert and install battery carrier (5).
- Hand-tighten the bolt (4).
- Hand-tighten the bolts (3).
- Tighten down screw (4).TIGHTENING TORQUE SPECIFICATIONS
Battery carrier to engine mount Hexagon screw M8x30 Tightening torque 19 Nm - Tighten down screws (3).TIGHTENING TORQUE SPECIFICATIONS
Battery carrier to engine mount Hexagon screw M8x30 Tightening torque 19 Nm - Attach coolant line (2) on battery carrier (5).
- Attach cable clip (1) on battery carrier (5).
Install E-box
Precondition
Battery ground lead is disconnected.
NOTE: RISK OF DAMAGE
Improper routing of cables and wiring harnesses.
Trapped, crushed or damaged cables may cause short circuits and malfunctions.- Route all cables without abrasions, do not trap and crush.
- Feed in the E-Box (1) into the guide (2) in the arrow direction and install.
- Ensure that the E-Box (1) is positioned correctly on the cowl (2).
- Tighten down screw (1).TIGHTENING TORQUE SPECIFICATIONS
E-box to battery tray M8x16 15 Nm - Feed the holder (1) into the E-Box (2) in the arrow direction and install.
- Make sure the holder (1) engages audibly.
- Feed in and install the wiring harness section (2) of the engine in the arrow direction.
- Ensure that the locking mechanisms (1) engage audibly.
- Feed in and install the wiring harness section (2) of the Valvetronic servomotor in the arrow direction.
- Ensure that the locking mechanisms (1) engage audibly.
- Feed in the wiring harness section (3) for the injectors and ignition coils in the arrow direction and install.
- Make sure the locking mechanism (2) engages audibly.
- Insert and install the positive battery cable (1).
- Connect all connectors (1) and lock.
- Ensure that the connectors (1) engage audibly.
- Connect and lock all connectors (1) in the arrow direction.
- Ensure that the connectors (1) engage audibly.
- Connect connectors (1) and lock.
- Make sure the connector (1) engages audibly.
- Feed the connector (1) into the E-Box (2) in the arrow direction and install.
- Feed the cover (2) into the guides (3) in the arrow direction and install.
- Ensure that the cover (2) engages audibly into the guides (3).
- Tighten down screw (1).TIGHTENING TORQUE SPECIFICATIONS
Cover panel to E-box RF5x26.5 Tightening torque 2.5 Nm - Insert and install the positive battery cable (2) on the holder (3).
- Insert and install the battery positive terminal (1).
- Tighten the battery positive terminal (1).TIGHTENING TORQUE SPECIFICATIONS
Positive battery terminal to battery Nut M6 Tightening torque 5 Nm - Loosening the luggage strap (3).
- Remove special tools 0 490 133 (00 2 030)
and 0 495 827 (23 4 150)
.
Follow-up work
- Refer to INSTALLING THE LEFT RADIAL SHAFT SEAL ON THE DIFFERENTIAL (GS6-58BG) .
- Refer to INSTALLING THE RIGHT RADIAL SHAFT SEAL ON THE DIFFERENTIAL (GS6-58BG) .
- Refer to INSTALLING THE LEFT OUTPUT SHAFT AT THE TRANSMISSION END .
- Refer to INSTALLING RIGHT OUTPUT SHAFT AT TRANSMISSION END .
- Refer to INSTALLING STARTER MOTOR .
- Refer to INSTALLING AND SECURING COMPLETE FRONT AXLE .
- Refer to SECURING MOUNTED PARTS ON THE FRONT AXLE SUPPORT .
- Refer to CONNECTING PURGE AIR LINE
- Refer to CONNECTING CONNECTOR ON STEERING GEAR .
- Refer to FASTENING THE RUBBER MOUNT ON THE FRONT AXLE SUPPORT .
- Refer to SECURING THE ANTI-ROLL BAR ON THE LEFT AND RIGHT ON THE ANTI-ROLL BAR LINK .
- Refer to FASTENING THE CABLE FOR THE RIDE HEIGHT SENSOR .
- Refer to INSTALLING WHEEL ARCH COVER AT FRONT LEFT AND RIGHT .
- Refer to IF INSTALLED: INSTALLING UNDERBODY PROTECTION AT REAR .
- Refer to INSTALL THE FRONT LEFT AND RIGHT WHEELS
- Refer to REMOVING THE MOUNTING FOR THE COOLANT RADIATOR ON THE LEFT AND RIGHT .
- Refer to SECURING THE STEERING SHAFT AT THE BOTTOM ON THE STEERING GEAR .
- Refer to TAKING ENGINE OUT OF INSTALLATION ORIENTATION .
- Refer to INSTALLING THE BATTERY .
- Refer to INSTALLING THE BATTERY COVER
- Refer to TOPPING UP THE OIL LEVEL IN THE MANUAL TRANSMISSION .
- Refer to INSTALLING SECOND UPPER BULKHEAD .
- Refer to INSTALLING THE RIGHT WINDSHIELD PANEL COVER .
- Refer to INSTALLING THE LEFT WINDSHIELD PANEL COVER .
- Refer to INSTALLING THE REAR HOOD SEAL .
- Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
- Refer to INSTALLING INTAKE SILENCER HOUSING
- Refer to INSTALLING INTAKE PORT .
- Refer to INSTALLING ACOUSTIC COVER .