Transmission, installing: Installation

Installing the transmission 

Before installing the transmission it is very important that the checks and cleaning have been carried out. See Transmission, preparations before installing .

Adjust height and angle with the mobile jack and the transmission fixture.

Locate the transmission on the engine.

Ensure that the transmission goes straight in, in relation to the engine, and that the guide sleeves and guide pin for the starter motor align in the guide holes on the transmission.

Installing and tightening the screws for the transmission 

Install all 7 x M10 screws securing the transmission to the engine.

First tighten alternately and crosswise to light contact.

At the same time, check that the whole of the transmission is in contact with the engine.

Then tighten the screws crosswise.

Remove the fixture from the transmission.

Installing the torque converter screws 

Align the torque converter against the carrier plate. Do this by turning the engine with the nut for the crankshaft pulley and turning the torque converter.

Install all 6 screws loosely. Tighten the screws. Tighten until the heads are almost in contact with the carrier plate. Tighten. See Summary of tightening torques for specific components . Use a Torx socket TX50.

Lifting the engine and transmission 

Lift the engine to slightly above the horizontal position to provide better access to the rear engine mounting and engine pad.

Raise the car.

Installing the rear engine mounting 

Remove the tie strap temporarily holding the steering gear.

Install: 

• the rear engine mounting on the transmission
• the 3 x M10 screws for the engine mounting. Tighten
• the screw for the steering gear and engine pad loosely.

Check and if necessary align the bearing for the steering shaft in the boot when installing the steering gear. Also see Checking the boot for the steering shaft/firewall .

Installing the lower oil pipe on the transmission 

Use a new O-ring.

Install: 

• the oil pipe and dip stick pipe. Use both the screws. Tighten. See Summary of tightening torques for specific components
• a tie strap for the cable harness for the oil pipe
• the ground lead to the engine.

Installing the left drive shaft on the transmission and the wheel spindle 

Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission. Pull the constant velocity joint to check that the drive shaft is secure.

Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.

Install a new screw loosely in the drive shaft.

Installing the subframe on the bodywork 

Lift the subframe until it is about 150 mm from the side member.

Secure the power steering pipe at the front edge of the upper side of the subframe. Use the rubber covered clamp. Install the screw loosely. Apply a small amount of soap solution so that it glides into the clamp easily. Check the steering gear bearing in the boot at the firewall.

• ensure that the steering gear screws align in the frame
• ensure that the brake pipe passes the bracket for the exhaust pipe
• ensure that the ball joint pinion for the spring strut aligns in the control arm.

Install: 

• the new screws and the support bracket at the rear edge
• the screws for the bracket loosely.

Applies only to cars with fuel driven parking heaters: 

Align the washer with the mounting lug following the marking on the subframe.

Tighten the subframe screws. Tighten to light contact.

Remove the mobile jack.

Installing the right-hand drive shaft on the transmission, wheel spindle and control arm 

Install the cap for the drive shaft pilot bearing. Use 2 x M8 screws. Tighten.

Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.

Install a new screw loosely in the drive shaft.

Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.

Position the mobile jack lightly applied under the right side of the subframe.

Install: 

• new screws in the subframe
  NOTE:

  Lubricate the screw threads.

• the screws loosely at the rear edge of the support plate.

Tighten the subframe screws. Tighten to light contact.

Remove the mobile jack.

Install the sub-frame's four screws together with the sub-frame's brackets and engine heater, if installed.

Tighten acc. to: Tightening torque . First tighten the screws on the sub-frame's left side, then on the right.

Tighten the screws for the brackets M10.

Installing components on the engine and subframe 

Install: 

• 4 new M10 lock nuts for the steering gear and 1 M10 screw. Tighten
• 1 M10 screw for the front engine pad. Tighten.

Tighten the M10 screw for the rear engine pad.

Install the mounting for the engine stabilizer brace to the transmission. Use new screws. Tighten. See Summary of tightening torques for specific components .

Installing the collision protection system over the steering gear 

Applies only to right-hand drive cars 

Install the 2 screws. Tighten.

Installing the servo pipe in the holders 

Press the power steering pipe and the evaporator pipe into the holders on the subframe. (If there is a parking heater, also press its fuel line and the evaporator cable into place)

Install and tighten the clamps for the power steering pipe at the rear of the frame. Tighten the clamp and the clamp for the power steering line at the front edge of the top of the subframe.

Installing the front mounting for the exhaust pipe 

Install the rubber mountings for the exhaust system on the brackets on the subframe.

Installing the cross members on the body 

Install: 

• the M8 screws for the front member
• the brake pipe in the holders on the member
• the M8 screws for the rear member
• the clamp with the heated oxygen sensor (HO2S) cable on the front cross member.

Installing front suspension components 

HINT: Applies when installing front suspension components on both sides. 

Install: 

• a new M12 lock nut on the ball joint pinion. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten
• the anti-roll bar link. Use a new M10 lock nut. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten. See Summary of tightening torques for specific components . Tighten the drive shaft screw. Counterhold using a screwdriver in the brake disc vents. Tighten. See Summary of tightening torques for specific components
• the soundproofing over the drive shaft (applies to certain versions).

Installing components for the fender liner 

Install the support plate and the nuts on both sides.

Installing the cable duct 

Install: 

• the cable duct on the subframe
• any parking or additional heaters in the mounting in the subframe and the fuel line in the mountings.

Installing the front splash guard 

Install: 

• the splash guard under the engine
• the wheels. See Installing wheels .

Removing the lifting beams 

Lower the car.

Remove the lifting beams and hooks from the engine.

Installing the coolant hose 

Install the connector securing the engine coolant hose to the heater.

Remove the hose clips.

Installing the remaining screws for the transmission and starter motor 

Install: 

• the 3 x M10 screws for the transmission and engine. Tighten
• the 2 x M10 screws for the starter motor. Tighten. See Summary of tightening torques for specific components
• the bracket for the engine coolant hose and cable harness
• the bracket for the cable harness clamp and the mounting for the heated oxygen sensor (HO2S) connector at the rear edge of the transmission
• the clamp for the cable harness at the rear edge of the engine.

Installing the gear selector cable and oil pipe 

Install: 

• the ground lead and mounting on the subframe
• the oil pipe on the transmission
• the gear selector cable and bracket. Use 2 x M8 screws. Tighten.

Connect the cable to the lever. Connect the transmission connectors and the mounting for the air cleaner (ACL) housing bracket. Press the cable harness mounting into place on the control system cover.

Installing service clips 

Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.

Check that the clip is positioned in the groove as illustrated.

Installing engine compartment components 

Install: 

• the charge air pipe to the charge air cooler (CAC)
• the air cleaner (ACL) housing assembly with the intake manifold and connections
• hook the turbocharger (TC) control valve into place in the air cleaner (ACL)
• the upper engine stabilizer brace between the wheel arches. Use 4 x M10 screws. Tighten
• 1 x M12 screw for the engine stabilizer brace/engine mounting. Tighten
• the tie strap for the power steering return line in the mounting lug for the engine stabilizer brace on the right-hand side.

Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.

Also see Transmission replacement, post-checking .

Checking the boot for the steering shaft/firewall 

Check that the bearing in the boot is in position.

If it has become detached apply a little grease to the edge of the boot (around the hole). Press the bearing back down into the boot.

Check that the boot is correctly positioned against the firewall and that the snap ring is correctly positioned. Adjust if necessary.

Installing the battery lead 

Connect the battery lead.

First read Battery, disconnecting .

Finishing 

Carry out checks after working on the transmission. See Transmission replacement, post-checking .

Installing the transmission 

Before installing the transmission it is very important that the checks and cleaning have been carried out. See Transmission, preparations before installing .

Adjust height and angle with the mobile jack and the transmission fixture.

Locate the transmission on the engine.

Ensure that the transmission goes straight in, in relation to the engine, and that the guide sleeves and guide pin for the starter motor align in the guide holes on the transmission.

Installing and tightening the screws for the transmission 

Install all 7 x M10 screws securing the transmission to the engine.

First tighten alternately and crosswise to light contact.

At the same time, check that the whole of the transmission is in contact with the engine.

Then tighten the screws crosswise.

Remove the fixture from the transmission.

Installing the torque converter screws 

Align the torque converter against the carrier plate. Do this by turning the engine with the nut for the crankshaft pulley and turning the torque converter.

Install all 6 screws loosely. Tighten the screws. Tighten until the heads are almost in contact with the carrier plate. Tighten. See Summary of tightening torques for specific components . Use a Torx socket TX50.

Lifting the engine and transmission 

Lift the engine to slightly above the horizontal position to provide better access to the rear engine mounting and engine pad.

Raise the car.

Installing the rear engine mounting 

Install: 

• the rear engine mounting on the transmission
• the 3 x M10 screws for the engine mounting. Tighten.

Installing the bevel gear 

Ensure that the mating surfaces on the transmission and bevel gear are clean and not damaged.

Install the bevel gear. Use new  screws. Tighten the screws alternately to light contact. Tightening torque .

Installing the lower oil pipe on the transmission 

Use a new O-ring.

Install: 

• the oil pipe and dip stick pipe. Use both the screws. Tighten. See Summary of tightening torques for specific components
• a tie strap for the cable harness for the oil pipe
• the ground lead to the engine.

Installing the left drive shaft on the transmission and the wheel spindle 

Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission. Pull the constant velocity joint to check that the drive shaft is secure.

Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.

Install a new screw loosely in the drive shaft.

Installing the sub-frame on the bodywork 

Lift up the sub-frame until it is about 150 mm  from the side member.

Secure the power steering pipe at the front edge of the upper side of the sub-frame. Use the rubber covered clamp. Install the screw loosely. Apply a small amount of soap solution so that it glides into the clamp easily.

• ensure that the brake pipe passes the bracket for the exhaust pipe
• ensure that the ball joint pinion for the spring strut aligns in the control arm.

Install: 

• the new screws and the support bracket at the rear edge
• the screws for the bracket loosely.

Applies only to cars with fuel driven parking heaters: 

Align the washer with the mounting lug following the marking on the sub-frame.

Tighten the sub-frame screws. Tighten to light contact.

Remove the mobile jack.

Installing the right-hand drive shaft on the transmission, wheel spindle and control arm 

Install the cap for the drive shaft pilot bearing. Use 2 x M8 screws. Tighten.

Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.

Install a new screw loosely in the drive shaft.

Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.

Position the mobile jack lightly applied under the right side of the sub-frame.

Install: 

• new screws in the sub-frame.
  NOTE:

  Lubricate the screw threads.

• the screws loosely at the rear edge of the support plate.

Tighten the sub-frame screws. Tighten to light contact.

Remove the mobile jack.

Install the four subframe screws together with the subframe brackets and engine heater where appropriate.

Tighten to: Tightening torque . First tighten the screws on the left-hand side of the subframe followed by those on the right.

Tighten the bracket screws M10.

Installing components on the engine and sub-frame 

Install the 1 x M10 screw for the front engine pad. Tighten.

Loosely install the screw for the engine pad/steering gear.

Tighten the M10 screw for the rear engine pad.

Install the mounting for the engine stabilizer brace to the transmission. Use new screws. Tighten. See Summary of tightening torques for specific components .

Installing the collision protection system over the steering gear 

Applies only to right-hand drive cars 

Install the 2 screws. Tighten.

Checking the position of the tie rod in the steering gear 

Check that tie rod is in the same position as when it was removed.

Assembling the lower steering shaft 

Tighten the lower screw on the steering shaft joint mounting in the steering gear from the engine compartment. Use a new  screw. Tighten. See: Summary of tightening torques for specific components .

Installing the cross members on the body 

Install: 

• the M8 screws for the front member
• the brake pipe in the holders on the member
• the clamp with the heated oxygen sensor (HO2S) cable on the front cross member.

Installing front suspension components 

HINT: Applies when installing front suspension components on both sides. 

Install: 

• a new M12 lock nut on the ball joint pinion. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten
• the anti-roll bar link. Use a new M10 lock nut. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten. See Summary of tightening torques for specific components . Tighten the drive shaft screw. Counterhold using a screwdriver in the brake disc vents. Tighten. See Summary of tightening torques for specific components
• the soundproofing over the drive shaft (applies to certain versions).

Installing components for the fender liner 

Install the support plate and the nuts on both sides.

Installing the cable duct 

Install: 

• the cable duct on the sub-frame
• any parking or additional heaters in the mounting in the sub-frame and the fuel line in the mountings.

Installing the front splash guard 

Install: 

• the splash guard under the engine
• the wheels. See Installing wheels .

Removing the lifting beams 

Lower the car.

Remove the lifting beams and hooks from the engine.

Installing the coolant hose 

Install the connector securing the engine coolant hose to the heater.

Remove the hose clips.

Installing the remaining screws for the transmission and starter motor 

Install: 

• the 3 x M10 screws for the transmission and engine. Tighten
• the 2 x M10 screws for the starter motor. Tighten. See Summary of tightening torques for specific components
• the bracket for the engine coolant hose and cable harness
• the bracket for the cable harness clamp and the mounting for the heated oxygen sensor (HO2S) connector at the rear edge of the transmission
• the clamp for the cable harness at the rear edge of the engine.

Installing the gear selector cable and oil pipe 

Install: 

• the ground lead and mounting on the sub-frame
• the oil pipe on the transmission
• the gear selector cable and bracket. Use 2 x M8 screws. Tighten.

Connect the cable to the lever. Connect the transmission connectors and the mounting for the air cleaner (ACL) housing bracket. Press the cable harness mounting into place on the control system cover.

Installing the service clips 

Ensure that the gear selector cable is locked in position before installing the blue clip. Press the clip into place as illustrated.

Check that the clip is positioned in the groove as illustrated.

Installing engine compartment components 

Install: 

• the air cleaner (ACL) housing assembly with the intake manifold and connections
• hook the turbocharger (TC) control valve into place in the air cleaner (ACL)
• the upper engine stabilizer brace between the wheel arches. Use 4 x M10 screws. Tighten
• 1 x M12 screw for the engine stabilizer brace/engine mounting. Tighten
• the tie strap for the power steering return line in the mounting lug for the engine stabilizer brace on the right-hand side.

Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.

Also see Transmission replacement, post-checking .

Installing the battery lead 

Connect the battery lead.

First read Battery, disconnecting .

Finishing 

Carry out checks after working on the transmission. See Transmission replacement, post-checking .