Manual gearbox (page 5 of 5)

Refit

1. Clean mating faces of engine and flywheel housing.
2. Lightly grease gearbox splines.
3. Position gearbox beneath vehicle and connect lifting equipment.
4. Using assistance, raise gearbox and manoeuvre into position and locate on 2 engine dowels.
5. Fit 2 lower bolts securing gearbox to engine.
6. Clean and degrease threads of 2 upper bolts securing gearbox to engine.
7. Apply Loctite 243 to threads of 2 upper bolts.
8. Models with air conditioning; Position air conditioning pipe bracket to flywheel housing.
9. Fit 2 upper bolts securing gearbox to engine and tighten to 85 Nm.
10. Tighten 2 lower bolts securing gearbox to engine to 85 Nm.
11. Raise engine and gearbox with lifting equipment and align LH torque mounting to body.
12. Fit 2 bolts securing LH torque mounting to body and tighten to 45 Nm.
13. Align gearbox to gearbox mounting bracket, fit 2 bolts and tighten to 80 Nm.
14. Tighten through bolt securing gearbox mounting to body, to 75 Nm.
15. Remove jack and disconnect lifting equipment.
16. Secure charcoal canister to mounting bracket.
17. Fit flywheel rear cover plate.
18. Fit 3 bolts securing rear engine mounting to engine and tighten to 100 Nm.
19. Connect multiplug to vehicle speed sensor.
20. Fit flywheel front cover plate and tighten 3 bolts to 9 Nm.
21. Secure starter motor cable clips to flywheel front cover.
22. Fit flywheel lower cover plate and tighten 3 bolts to 9 Nm.
23. Fit mounting bracket to flywheel housing and secure with bolts.
24. Position harness to mounting bracket and secure with clip.
25. Secure harness multiplug to mounting bracket.
26. Connect LH drive shaft to gearbox. See MANUAL GEARBOX, Repairs. LH differential oil seal.
27. Connect RH drive shaft to gearbox. See MANUAL GEARBOX, Repairs. RH differential oil seal.

28. Using tool 18G 1594 connect gear change linkage ball joint to gear change lever.
29. Using tool 18G 1594 connect gear selector linkage ball joint to gear selector lever.
30. Connect multiplug to reverse lamp switch.
31. Fit clutch slave cylinder to clutch release lever.
32. Locate clutch slave cylinder on mounting bracket and secure with locking collar.
33. Align air conditioning pipe to bracket, fit bolt and tighten to 9 Nm.
34. Position battery tray mounting bracket.
35. If fitted: Connect multiplug to dim dip resistor.
36. Fit 2 bolts securing battery tray to body and tighten to 9 Nm.
37. Tighten 2 bolts securing battery tray mounting bracket to 9 Nm.
38. Position air intake hose to battery tray mounting bracket and secure with bolt.
39. Position harness and secure with clip to body.
40. Fit battery tray to mounting bracket and tighten bolts to 9 Nm.
41. Fit starter motor. See ELECTRICAL, Repairs.
42. Fit underbelly panel. See BODY, Exterior fittings.
43. Remove stand(s) and lower vehicle.