Gearbox in block with driving axle (1.8 l diesel) — installation

Special tool

	Engine Support Beam 303-290A (21-140A)
	Adapter for 303-290A (21-140) 303-290-01 (21-140-01)
	Adapter for 303-290A (21-140) 303-290-02 (21-140-02)
	Adapter for 303-290A (21-140) 303-290-03A (21-140-03A)
	Adapter for 303-290A (21-140) 303-290-06 (21-140-06)

General equipment:

• Gearbox jack
• Fixing clamp

Installation

All cars

1. General Note: Use only new self-locking nuts.

2. Move the gearbox to the required position using the gearbox jack and secure the gearbox using wooden blocks and a locking clamp.



3. Move the engine and gearbox assembly forward and insert a 350 mm long wooden block between the engine and the subframe.



4. Screw in the lower flange bolts.




5. Screw in the lower flange bolts.



6. Lower the vehicle.

7. Install the rear engine mount bracket.



8. Raise the engine and gearbox assembly using special tool 303-290A.

9. Install the rear engine mount.



10. Disconnect the special tools.




11. Install the upper flange bolts.



12. Connect the coolant line to the gearbox.

• Install the retainer onto the transmission wiring harness connector.

13.

WARNING: Brake fluid leakage. Avoid contact with skin and eyes. If brake fluid comes into contact with skin or eyes, rinse the affected area immediately with water.

CAUTION: If brake fluid comes into contact with paintwork, immediately wash the affected areas with water.

Connect the high pressure line to the clutch slave cylinder.

• Insert the pressure pipe into the bracket.
• Install the clamp.

14. Raise the vehicle. Refer to Section 100-02 for additional information.

Cars manufactured up to 10.2001.

15.

NOTE: The shift cable is marked white.

NOTE: The gear selector cable is marked black.

Connect the gear shift cables to the bracket.

• 1. Release the support bracket by turning it counterclockwise and connect the gear shift cable.
• 2. Release the support bracket by turning it counterclockwise and connect the gear selector cable.

16.

NOTE: The shift/selector levers are in neutral when they are in the vertical position.

Move the gear shift/selector levers to neutral position.



17. Connect the gear shift cables to the gear shift lever.

• 1. Connect the gear shift cable to the gear shift lever.
• 2. Connect the gear selector cable to the gear shift lever.

Cars manufactured since 10.2001.

18.

NOTE: The shift cable is marked white.

NOTE: The gear selector cable is marked black.

Connect the gear shift cables to the bracket.

• 1. Release the support bracket by turning it counterclockwise and connect the gear shift cable.
• 2. Release the support bracket by turning it counterclockwise and connect the gear selector cable.

All cars

19. Install the engine roll limiter.



20. Install the catalytic converter with the flexible exhaust pipe. Refer to Section 309-00 for additional information.



21.

CAUTION: The inner hinge should not be deflected at an angle exceeding 18 degrees. The outer hinge should not be deflected at an angle exceeding 45 degrees.

NOTE: Use new nuts and a new intermediate bearing cap.

Install the right axle shaft together with the intermediate shaft.



22.

CAUTION: The inner hinge should not be deflected at an angle exceeding 18 degrees, and the outer hinge should not be deflected at an angle exceeding 45 degrees.

NOTE: Install a new snap ring.

Install the left half shaft (shown with the subframe removed).



23. Install the starter.



24.

CAUTION: Do not damage the case.

Connect both lower control arms and the left stabilizer bar link to the vehicle (left side shown).

• Install a heat shield.

25. Install the tie rod end onto the left steering knuckle.

• Secure the tie rod end nut with a cotter pin.

26. Install the drive belt cover.

• Install the engine guard (nine bolts) (if equipped).

27. Install the left front wheel.



28. Lower the vehicle.

29. Connect the catalytic converter to the exhaust manifold.



30. Install the blower fan.

• Insert the blower fan and secure the clamps on both sides.

31. Connect the bracket for the power steering high pressure line.



32. Connect the plug connectors.

• Vehicle Speed Sensor (VSS)
• Gearbox Wiring Harness
• Reverse light switch

33. Secure the wiring harness and connect the fan motor plug connector.



34. Install the crankcase ventilation oil separator.



35. Connect the plug connector and connect the glow plug wires.

• 1. Generator connector
• 2. High pressure fuel pump connector
• 3. Glow plug wire

36. Install the air intake pipe.



37. Install the air filter housing.

• 1. Install the hose clamps.
• 2. Connect the plug connector.
• 3. Connect the vacuum hose.

38. Install the intercooler.



39. Install the intake air temperature (IAT) sensor connector.



40. Connect the intercooler air duct.



41. Tighten the suspension strut nuts on both sides.



42. Install the battery shelf.

• 1. Connect the wiring harness.
• 2. Tighten the bolts.
• 3. Connect the plug connector and secure it.

43. Bleed the clutch hydraulic system. Refer to Section 308-00 for additional information.

44. Adjust the shift cables. Refer to Section 308-00 for additional information.

45. Install the battery. For additional information, refer to Section 414-01.

46. Standard finishing operations.

• Check the fluid levels and adjust them if necessary.
• Check the vacuum hose and electrical wiring and secure them with clamps.