Installation Special Tool(s) | Engine support bar 303-290A | | Adapter for 303-290A 303-290-03A | | Adapter for 303-290A 303-290-13 | | Adapter for 303-290A 303-290A-15 | General Equipment Transmission jack Retaining straps Materials Name Specification High-temperature grease ESD-M1C220-A grease SA-M1C9107-A Transmission fluid WSD-M2C200-C Installation All Vehicles CAUTION:Ensure that the two guide sleeves are installed. | -
Raise and support the vehicle. For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation) / Anheben mit Wagenheber (100-02 Fahrzeug anheben, Description and Operation). | | -
Coat the input shaft splines with a thin coating of grease. | | -
Install the transaxle left-hand retaining bolt. | | -
Remove the retaining straps. | | -
Remove the transmission jack. | | -
Install the transaxle lower retaining bolts. - Install the wiring harness bracket.
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Install the rear engine mounting bracket. - Install the bolts of the rear engine mounting.
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Raise the engine / transmission assembly slightly using the special tools. | | -
Install the bolts of the rear engine mounting (rear engine mounting shown removed for clarity). | | -
NOTE: Install a new bolt on the rear engine mounting. NOTE: Do not tighten the bolt of the rear engine mounting for the moment. Install the bolt of the rear engine mounting. | | -
Raise and support the vehicle. For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation) / Anheben mit Wagenheber (100-02 Fahrzeug anheben, Description and Operation). | | -
Remove the special tools. | | -
Remove the special tools. | | -
Remove the special tool on both sides (right-hand side shown). | | -
Install the headlamp assembly on both sides. For additional information, refer to: Scheinwerfereinheit (417-01 Außenbeleuchtung, Removal and Installation). | | -
Raise and support the vehicle. For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation) / Anheben mit Wagenheber (100-02 Fahrzeug anheben, Description and Operation). | | -
Install the radiator support bracket. - Install the radiator support bracket bolts (right-hand side shown).
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Install the radiator support bracket bolts (left-hand side shown). | | -
Connect the glow plug relay electrical connector. | | -
Install the radiator lower cover. | | -
Install the clutch pedal cover. | | -
Install the left-hand halfshaft. For additional information, refer to: Linke Antriebswelle (205-04 Vorderradantriebswellen, Removal and Installation). | | -
Install the right-hand halfshaft. For additional information, refer to: Rechte Antriebswelle - 3-Türer (205-04 Vorderradantriebswellen, Removal and Installation). | | -
Install the engine roll restrictors. | | -
Install the catalytic converter bracket. | | -
NOTE: Install a new gasket and new nuts. Attach the catalytic converter to the flexible pipe. - Coat the catalytic converter studs with grease before installing.
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Remove the support sleeve or reinforcement from the flexible exhaust pipe. | | -
Hook the flexible pipe into the crossmember rubber insulators. | | -
Attach the catalytic converter clamp to the turbocharger. | | -
Install the crashbox. - Install the M10 x 16 bolt.
- Install the M10 x 25 bolts.
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Attach the intercooler outlet pipe to the intercooler. | | -
Remove the cable ties from the radiator. | | -
Install the transmission upper bolts. | | -
Attach the starter motor to the transaxle. - Install the wiring harness bracket.
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Install the ground lead on the transaxle. | | -
Attach the gearshift cables at the transaxle. - Attach the gearshift cables at the abutment.
- Attach the gearshift and selector cables at the selector mechanism.
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Adjust the selector cable. For additional information, refer to: Schaltseilzug einstellen - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MMT6) (308-00 Schaltgetriebe und Kupplung - Allgemeine Informationen, General Procedures). | | -
CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay. Attach the clutch slave cylinder pipe to the clutch slave cylinder. - Attach the clutch slave cylinder pipe to the bracket.
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Bleed the clutch system. For additional information, refer to: Kupplungssystem entlüften - Fahrzeuge ausgestattet mit MMT6/6-Gang Schaltgetriebe. | | -
Connect the reversing lamp electrical connector. | | -
Tighten the bolt of the rear engine mounting. | | -
Install the battery carrier. For additional information, refer to: Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Batterie, Befestigung und Batteriekabel, Removal and Installation). | | -
Install the air cleaner. For additional information, refer to: Luftfilter - 2.0L Duratorq-TDCi (DW) Diesel (303-12 Ansaugsystem, Removal and Installation). | | -
With the vehicle on a level surface, fill the transaxle with transmission fluid until the fluid level is just below the filler hole. | | -
Raise and support the vehicle. For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation) / Anheben mit Wagenheber (100-02 Fahrzeug anheben, Description and Operation). | | -
Install the engine undershield. | | -
Install the engine cover. | Vehicles with global closing | -
Initialise the window regulator motors. For additional information, refer to: Motor - elektrischer Fensterheber initialisieren (501-11 Fenster, Rahmen und Betätigungsmechanismen, General Procedures). | |