Saab 2000-06

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Remove the cover over the intake manifold.
  6.  
  7. If necessary, remove the resonator, together with hoses and mass air flow sensor.
  8.  
  9. Remove the battery.
  10.  
  11. Engage 4th gear and remove the plastic plug from the gearbox. Lock 4th gear in the gearbox by fitting a locking pin, 87 92 335.
  12.  
  13. Loosen the clamp securing the selector rod to the linkage in the gearbox from above.
  14.  
  15. Lift up the selector lever boot. Engage 3rd gear so that the selector rod disengages from the linkage and fit the locking pin, 87 92 335, in the gear lever housing.
  16.  
  17. Depress the clutch pedal about 2 inches (50mm) with a brake bracket. This prevents the brake fluid from flowing out of the reservoir.
  18.  
  19. Remove or disconnect the following: Locking clip on the slave cylinder (disconnect delivery pipe)Reverse light connectorPositive battery cable connection from transmission housing3 upper gearbox boltsConnector(s) for the oxygen sensor(s) (release from clamps)

    Locking clip on the slave cylinder (disconnect delivery pipe)
     
    Reverse light connector
     
    Positive battery cable connection from transmission housing
     
    3 upper gearbox bolts
     
    Connector(s) for the oxygen sensor(s) (release from clamps)
     

  20.  
  21. Slightly lift the engine and gearbox with lifting equipment, 83 94 850. Position the lifting device on the wheel housings so that it rests on the edges of the inner fenders.
  22.  
  23. Remove or disconnect the following: Front wheelsAny clamps on oxygen sensor cableFront exhaust system (first undo flange on turbo and then undo rear mounting)

    Front wheels
     
    Any clamps on oxygen sensor cable
     
    Front exhaust system (first undo flange on turbo and then undo rear mounting)
     

  24.  


    Click image to see an enlarged view

    Fig. Engage 4th gear with a locking pin and remove selector rod clamp-9-3



CAUTION
It is important that the exhaust system is removed in this way as the flexible bellows may other wise -be damaged. Be also careful with the oxygen sensor(s).



Air shields and belt circuit cover in right-hand wheel housing
 
End piece, suspension arm on both sides (use a puller, 89 96 696)
 
2 nuts on rear engine mount and 2 center bolts on subframe (22)
 

  1. Position complete lifting trolley (23) with front and rear holders with 83 94 801 parent fixture under the subframe. Raise the lifting trolley against the subframe.
  2.  
  3. Remove the remaining bolts (24) securing the subframe (note washers on the rear mountings).
  4.  
  5. Lower the trolley lift and push it to one side.
  6.  
  7. Remove or disconnect the following: Oil drain plug and drain oil from gearbox (screw in drain plug)Left-hand driveshaft (use removal tool for driveshafts, 89 96 654)Suspend driveshaft and insert plug, 87 92 244, in gearboxSplash plate by flywheelGround leads from gearboxBolts in engine/gearbox mating face accessible from below (except front bolt)2 left-hand engine mount bolts at bodyEngine mount from gearbox

    Oil drain plug and drain oil from gearbox (screw in drain plug)
     
    Left-hand driveshaft (use removal tool for driveshafts, 89 96 654)
     
    Suspend driveshaft and insert plug, 87 92 244, in gearbox
     
    Splash plate by flywheel
     
    Ground leads from gearbox
     
    Bolts in engine/gearbox mating face accessible from below (except front bolt)
     
    2 left-hand engine mount bolts at body
     
    Engine mount from gearbox
     

  8.  
  9. Lower the car and lower the whole drive unit slightly.
  10.  
  11. Raise the car and install a holding tool, 87 92 608, for a single column lift on a single column jack. Adjust the lifting tool so that it is centered in line with the gearbox center and mating face. Connect the lifting tool to the gearbox.
  12.  
  13. Remove the last bolt between the engine and the gearbox.
  14.  
  15. Remove the rear engine mount bracket from the gearbox.
  16.  
  17. Pull out and lower the gearbox. Lift the gearbox from the pillar jack with and engine lift and undo the lifting tool from the gearbox.
  18.  


    Click image to see an enlarged view

    Fig. Using lifting trolley to support power train for transmission removal-9-3



    Click image to see an enlarged view

    Fig. Using single column lift and jack to remove manual transmission-9-3


To install:

  1. Check that the selector lever in the car is in 3rd gear and that it is locked with the locking pin, 87 92 335, for the gear lever housing. The locking pin ring should be down in the hole.
  2.  
  3. Grease the spines of the primary shaft.
  4.  


NOTE
Check that the two locating sleeves are on the engine.

  1. Lubricate the sleeves with a thin coating of anti-corrosion oil.
  2.  
  3. If the slave cylinder is new or has been emptied of brake fluid, bleed the slave cylinder.
  4.  
  5. Install a protective collar, 83 95 162, in the right-hand shaft seal in the gearbox to protect the seal when the gearbox is mounted.
  6.  


NOTE
Always change the shaft seal in the gearbox. Lubricate with gearbox oil .

  1. Attach a holding device, 87 92 608, for a single column lift. Make sure the lifting tool center is in line with the gearbox center and mating surface.
  2.  
  3. Fit the gearbox, with lifting tool, onto a pillar jack
  4.  
  5. Push in the gearbox until about. 0.8 inch (20mm) remain, remove the protective collar from the shaft seal, then push in the gearbox completely. Turn the engine shaft, if needed, so that the gearbox can be fitted.
  6.  
  7. Install or connect the following: Rear engine mount on gearboxBottom bolts between the engine and gearbox to 50 ft. lbs. (70 Nm)Left-hand engine mount on gearbox and torque to 46 ft. lbs. (62 Nm)Lift drive unit with jack and tighten left-hand engine mount on the body to 46 ft. lbs. (62 Nm)Remove lifting tool from gearbox and remove jackGround leads to gearboxSplash plate by flywheel

    Rear engine mount on gearbox
     
    Bottom bolts between the engine and gearbox to 50 ft. lbs. (70 Nm)
     
    Left-hand engine mount on gearbox and torque to 46 ft. lbs. (62 Nm)
     
    Lift drive unit with jack and tighten left-hand engine mount on the body to 46 ft. lbs. (62 Nm)
     
    Remove lifting tool from gearbox and remove jack
     
    Ground leads to gearbox
     
    Splash plate by flywheel
     

  8.  
  9. Install a protective collar, 83 95 162, onto left-hand shaft seal.
  10.  


NOTE
Make sure the driveshaft is clean and then position it in the tool.

  1. Install the driver in the gearbox until about 0.8 inch (20mm) remains and withdraw the tool before the shaft's sealing surface reaches the shaft seal.
  2.  
  3. Insert the shaft until the locking ring snaps in place.
  4.  
  5. Carefully raise the subframe. Make sure the washers on the rear mounts are in place.
  6.  
  7. Adjust the subframe so that the screw holes correspond with the body.
  8.  
  9. Tighten the 4 corner bolts on the subframe as follows: Front: 85 ft. lbs. (115 Nm)Rear: 81 ft. lbs. (110 Nm), plus an additional 75 degrees
    1. Front: 85 ft. lbs. (115 Nm)
    2.  
    3. Rear: 81 ft. lbs. (110 Nm), plus an additional 75 degrees
    4.  

  10.  
  11. Lower the lifting trolley and move it away.
  12.  
  13. Tighten the remaining bolts on the subframe to 141 ft. lbs. (190 Nm).
  14.  
  15. Tighten the nuts on the rear engine mount to 37 ft. lbs. (50 Nm).
  16.  
  17. Position the suspension arm end piece on both sides and tighten the nuts to 55 ft. lbs. (75 Nm).
  18.  
  19. Reinstall the air shields and belt circuit cover in the right-hand wheel housing.
  20.  
  21. Install the front exhaust system and put back the clamps for the oxygen sensor cable.
  22.  
  23. Install the front wheels and tighten nuts to 81 ft. lbs. (110 Nm).
  24.  
  25. Remove the lifting equipment and tighten the upper bolts between the engine and gearbox to 50 ft. lbs. (70 Nm).
  26.  
  27. Install or connect the following: Oxygen sensor(s)Positive cable attachment on engineLead to reverse light switchClutch delivery pipe to gearbox with snap ringRemove locking pin from gear lever housing, engage 4th gear and insert locking pin again.Clamp on selector rod to 15 ft. lbs. (20 Nm)Gear lever boot

    Oxygen sensor(s)
     
    Positive cable attachment on engine
     
    Lead to reverse light switch
     
    Clutch delivery pipe to gearbox with snap ring
     
    Remove locking pin from gear lever housing, engage 4th gear and insert locking pin again.
     
    Clamp on selector rod to 15 ft. lbs. (20 Nm)
     
    Gear lever boot
     

  28.  
  29. Make an initial bleed of the clutch as follows: Take locking pin out of gearbox and put back plastic plugRemove the brake bracket from the clutch pedal.Attach a hose to the bleed nipple, open the nipple and let a little brake fluid run out.Tighten the nipple and test the clutch.Check that there are no system leaks.Fit and connect the battery.Install the engine cover or the resonator with hoses and the MAF sensor.
    1. Take locking pin out of gearbox and put back plastic plug
    2.  
    3. Remove the brake bracket from the clutch pedal.
    4.  
    5. Attach a hose to the bleed nipple, open the nipple and let a little brake fluid run out.
    6.  
    7. Tighten the nipple and test the clutch.
    8.  
    9. Check that there are no system leaks.
    10.  
    11. Fit and connect the battery.
    12.  
    13. Install the engine cover or the resonator with hoses and the MAF sensor.
    14.  

  30.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the transmission.
  4.  
  5. Remove or disconnect the following: Front grille (2001)Intake manifold coverBattery coverBattery and trayMain fuse box (2002-04)

    Front grille (2001)
     
    Intake manifold cover
     
    Battery cover
     
    Battery and tray
     
    Main fuse box (2002-04)
     

  6.  
  7. Place the vehicle in 4th gear. Remove the plastic plug from the gearbox, and lock 4th gear in position with tool 87 92 335.
  8.  
  9. Remove the clip from the selector rod.
  10.  
  11. Raise gear selector boot. Engage 3rd gear so the selector rod disengages from the linkage. Install locking pin 87 92 335 in the lever housing.
  12.  
  13. Clamp brake hose or depress brake pedal about 2 inches (50mm) with brake clamp to prevent brake fluid from overflowing reservoir.
  14.  
  15. Remove or disconnect the following: Clip from slave cylinder and disconnect delivery lineReverse light connector3 upper gearbox bolts and install locating studs in engine upper, outer guide holesOxygen sensorSelector linkage from the gearboxRear engine mount nut3 bolts from rear engine pad (loosen but do not remove)Slightly lift engine and gearbox with a lifting beam on engineBoth front wheels, wheelwell covers, and under coversHeadlamp leveling sensor brackets (if equipped); bend sensors asideFront exhaust pipeStay between the engine mount and engineRear engine mount and padBolt securing torque arm to subframe (if equipped)Steering gear boltsClips securing steering servo line to subframeA/C lines from the subframeEngine oil cooler from charge air coolerPlace strap around radiator and crossmember to retain radiatorBolts securing outer ball joints to steering swivelLoosen upper ball joint (both sides) from anti-roll barFlywheel cover plateBolts between gearbox and oil pan (B235R engines)Bolts securing the rear support plate to subframe and place a lifting trolley under subframeSubframe and front mounts for the steering servo delivery lineGearbox oilLeft driveshaftGround cables from the gearboxLeft engine padLower transmission so it clears structural memberTransmission mounting

    Clip from slave cylinder and disconnect delivery line
     
    Reverse light connector
     
    3 upper gearbox bolts and install locating studs in engine upper, outer guide holes
     
    Oxygen sensor
     
    Selector linkage from the gearbox
     
    Rear engine mount nut
     
    3 bolts from rear engine pad (loosen but do not remove)
     
    Slightly lift engine and gearbox with a lifting beam on engine
     
    Both front wheels, wheelwell covers, and under covers
     
    Headlamp leveling sensor brackets (if equipped); bend sensors aside
     
    Front exhaust pipe
     
    Stay between the engine mount and engine
     
    Rear engine mount and pad
     
    Bolt securing torque arm to subframe (if equipped)
     
    Steering gear bolts
     
    Clips securing steering servo line to subframe
     
    A/C lines from the subframe
     
    Engine oil cooler from charge air cooler
     
    Place strap around radiator and crossmember to retain radiator
     
    Bolts securing outer ball joints to steering swivel
     
    Loosen upper ball joint (both sides) from anti-roll bar
     
    Flywheel cover plate
     
    Bolts between gearbox and oil pan (B235R engines)
     
    Bolts securing the rear support plate to subframe and place a lifting trolley under subframe
     
    Subframe and front mounts for the steering servo delivery line
     
    Gearbox oil
     
    Left driveshaft
     
    Ground cables from the gearbox
     
    Left engine pad
     
    Lower transmission so it clears structural member
     
    Transmission mounting
     

  16.  
  17. Connect a lifting tool to the transmission
  18.  
  19. Remove the transmission from the vehicle
  20.  


    Click image to see an enlarged view

    Fig. Install a lifting tool to the transmission


To install:

  1. Lubricate the primary shaft splines.
  2.  
  3. Install a protective collar in the right shaft seal in the transmission.
  4.  
  5. Position the lifting trolley under the vehicle
  6.  
  7. Install or connect the following: Transmission and turn the engine shaft if needed to install the transmissionFlywheel cover plateBolts between the transmission and the oil pan and torque the bolts to 30 ft. lbs. (40 Nm)Screws between the engine and transmission and torque to 50 ft. lbs. (70 Nm). Remove the lifting trolleyTransmission bolts and torque the bolts to 18 ft. lbs. (24 Nm)Ground cables to the transmissionShaft until the circlip snaps into positionTransmission mountings and torque the bolts to 30 ft. lbs. (40 Nm)Clutch delivery line and clipsLeft engine pad. Torque the engine pad-to-transmission bolts to 62 ft. lbs. (85 Nm) and the engine pad to body bolts to 45 ft. lbs. (60 Nm)Reverse light electrical connector

    Transmission and turn the engine shaft if needed to install the transmission
     
    Flywheel cover plate
     
    Bolts between the transmission and the oil pan and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Screws between the engine and transmission and torque to 50 ft. lbs. (70 Nm). Remove the lifting trolley
     
    Transmission bolts and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Ground cables to the transmission
     
    Shaft until the circlip snaps into position
     
    Transmission mountings and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Clutch delivery line and clips
     
    Left engine pad. Torque the engine pad-to-transmission bolts to 62 ft. lbs. (85 Nm) and the engine pad to body bolts to 45 ft. lbs. (60 Nm)
     
    Reverse light electrical connector
     

  8.  
  9. Position the lifting trolley under the vehicle with the subframe properly aligned. Front ball joints and tighten the steering servo delivery linesRadiator journals to the subframeA/C lines into the brackets on the subframeScrews and rear support plate for the subframe. Move the lifting trolley aside. Torque the subframe bolts to 74 ft. lbs. (100 Nm) plus an additional 45 degreesTorque the support plate bolts to 44 ft. lbs. (60 Nm)Torque rod-to-subframe bolts and torque the bolts to 22 ft. lbs. (30 Nm)Engine oil coolerRear attaching clamps for the steering servo line to the subframeSteering gear and torque the bolts to 66 ft. lbs. (90 Nm)Outer ball joints to the steering swivel member and torque the bolts to 64 ft. lbs. 85 Nm)Anti-roll bar stay and torque the fastener to 64 ft. lbs. (85 Nm)Cover plate between the engine and transmissionRear engine pad and engine mount and torque the bolts to 50 ft. lbs. (70 Nm)Engine mount stay and torque the fastener to 16 ft. lbs. (22 Nm)Front exhaust pipe and torque the flange to the turbocharger to 19 ft. lbs. (25 Nm)Engine stay and torque the fastener to 16 ft. lbs. (22 Nm)Inner wheel well covers and remove the lifting devise from the top of the engineUpper engine bolts and torque the bolts to 50 ft. lbs. (70 Nm)Front torque arm to transmission and torque the arm to 34 ft. lbs. (47 Nm)Selector linkage to the transmission and torque the bolt to 18 ft. lbs. (24 Nm)Gear linkage to the selector rod. Place the vehicle in 4th gear and secure with a locking pin. Torque the clamp on the linakge to 16 ft. lbs. (22 Nm)Oxygen sensor connectorsBattery and tray. Connect the battery cablesBattery coverFront wheelsThrottle body coverGrille

    Front ball joints and tighten the steering servo delivery lines
     
    Radiator journals to the subframe
     
    A/C lines into the brackets on the subframe
     
    Screws and rear support plate for the subframe. Move the lifting trolley aside. Torque the subframe bolts to 74 ft. lbs. (100 Nm) plus an additional 45 degrees
     
    Torque the support plate bolts to 44 ft. lbs. (60 Nm)
     
    Torque rod-to-subframe bolts and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Engine oil cooler
     
    Rear attaching clamps for the steering servo line to the subframe
     
    Steering gear and torque the bolts to 66 ft. lbs. (90 Nm)
     
    Outer ball joints to the steering swivel member and torque the bolts to 64 ft. lbs. 85 Nm)
     
    Anti-roll bar stay and torque the fastener to 64 ft. lbs. (85 Nm)
     
    Cover plate between the engine and transmission
     
    Rear engine pad and engine mount and torque the bolts to 50 ft. lbs. (70 Nm)
     
    Engine mount stay and torque the fastener to 16 ft. lbs. (22 Nm)
     
    Front exhaust pipe and torque the flange to the turbocharger to 19 ft. lbs. (25 Nm)
     
    Engine stay and torque the fastener to 16 ft. lbs. (22 Nm)
     
    Inner wheel well covers and remove the lifting devise from the top of the engine
     
    Upper engine bolts and torque the bolts to 50 ft. lbs. (70 Nm)
     
    Front torque arm to transmission and torque the arm to 34 ft. lbs. (47 Nm)
     
    Selector linkage to the transmission and torque the bolt to 18 ft. lbs. (24 Nm)
     
    Gear linkage to the selector rod. Place the vehicle in 4th gear and secure with a locking pin. Torque the clamp on the linakge to 16 ft. lbs. (22 Nm)
     
    Oxygen sensor connectors
     
    Battery and tray. Connect the battery cables
     
    Battery cover
     
    Front wheels
     
    Throttle body cover
     
    Grille
     

  10.  
  11. Fill and bleed the clutch system.
  12.  
  13. Fill the transmission fluid to the proper level.
  14.  
  15. Start the vehicle, check for leaks and proper operation. Repair if necessary.
  16.  

5-Speed & 6-Speed



  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Upper engine cover and battery coverBattery (and cooling hose, if equipped)Cable clamp under battery trayHood switch connectorBattery trayGround cable from engine bracket and reverse light switch connection (7)Gear cables from the transmission by pulling locking sleeves back, lifting up cables from levers, and carefully moving them aside (8)Pinch off clutch hose and undo quick-release coupling from clutch slave cylinder (9)Coolant reservoir (6-speed)Upper gearbox bolts

    Upper engine cover and battery cover
     
    Battery (and cooling hose, if equipped)
     
    Cable clamp under battery tray
     
    Hood switch connector
     
    Battery tray
     
    Ground cable from engine bracket and reverse light switch connection (7)
     
    Gear cables from the transmission by pulling locking sleeves back, lifting up cables from levers, and carefully moving them aside (8)
     
    Pinch off clutch hose and undo quick-release coupling from clutch slave cylinder (9)
     
    Coolant reservoir (6-speed)
     
    Upper gearbox bolts
     

  4.  
  5. Install lift eyes, 83 96 178, to the engine and lifting beam 83 94 850 with holder 83 95 287 holder.
  6.  
  7. Remove the upper bumper shell mountings.
  8.  
  9. Suspend 2 straps in place above the radiator core so they are accessible from below. Remove or disconnect the following: Front wheelsFront spoiler shieldHose from the headlamp washers and unplug and remove connectorSecure radiator core with the strapsRadiator brackets from subframeFront part of exhaust pipe by cutting 3.43 inches (87mm) from front end of mufflerEngine torque rod from subframe (6-speed)Suspension arm from the steering swivel member on both sidesAnti-roll bar from link arm.Headlamp angle sensor connector and cable clip (if equipped)Engine torque rod from subframeSteering gear from subframe (keep nuts and washers); leave steering gear hangingClamps holding power steering pipe to subframeFront part of fender liner (bend out of way)

    Front wheels
     
    Front spoiler shield
     
    Hose from the headlamp washers and unplug and remove connector
     
    Secure radiator core with the straps
     
    Radiator brackets from subframe
     
    Front part of exhaust pipe by cutting 3.43 inches (87mm) from front end of muffler
     
    Engine torque rod from subframe (6-speed)
     
    Suspension arm from the steering swivel member on both sides
     
    Anti-roll bar from link arm.
     
    Headlamp angle sensor connector and cable clip (if equipped)
     
    Engine torque rod from subframe
     
    Steering gear from subframe (keep nuts and washers); leave steering gear hanging
     
    Clamps holding power steering pipe to subframe
     
    Front part of fender liner (bend out of way)
     

  10.  
  11. Place a trolley lift, 83 95 311, attaching fixture, 83 94 801, underneath. Position the guide pins and adjust the height with spacers to keep it level.
  12.  
  13. Remove the subframe bolts and the rear brackets.
  14.  
  15. Lower the subframe slightly.
  16.  
  17. Remove the anti-roll bar from the subframe, while protecting the steering gear boot.
  18.  
  19. Fit bolts loosely in the link arms so the anti-roll bar is kept hanging in place.
  20.  
  21. Pull out the steering arm ball joints from the steering swivel members.
  22.  
  23. Lower the subframe.
  24.  
  25. Remove or disconnect the following: Torque rod bracket (remove torque rod bolt for easier fitting)Gearbox oil (refit the oil plug)Bolts in charge air pipe bracket (move pipe away)Lower transmission bolts (leave one bolt in place loosely) (38)Ground leadABS cable from clipLeft-hand driveshaft (suspend shaft by cables)

    Torque rod bracket (remove torque rod bolt for easier fitting)
     
    Gearbox oil (refit the oil plug)
     
    Bolts in charge air pipe bracket (move pipe away)
     
    Lower transmission bolts (leave one bolt in place loosely) (38)
     
    Ground lead
     
    ABS cable from clip
     
    Left-hand driveshaft (suspend shaft by cables)
     

  26.  
  27. Lower the car. Mark the bolt positions on the left engine bracket for correct refitting, and then remove the bolts from the mount.
  28.  
  29. Lower the powertrain about 2.75 inches (70mm), with the lifting beam, to facilitate removal of the gearbox.
  30.  
  31. Raise the car. Move the power steering cooling coil aside and suspend it with a strap.
  32.  
  33. Install single-column lift holder, 87 92 608, onto a column jack. Adjust and secure the tool in the transmission. Use bolt of 8.8 grade that are about 0.8 inch (20mm) longer than the bolts that were removed.
  34.  
  35. Remove the last bolt, pull out the transmission and lower it.
  36.  
  37. Lift the transmission down from the column jack with an engine lift and chain.
  38.  
  39. Remove the lifting tool from the transmission.
  40.  


    Click image to see an enlarged view

    Fig. Disconnecting reverse light switch, removing gearbox cables, and pinching off clutch hoses-9-3 with 5-speed manual transmission 2003-04



    Click image to see an enlarged view

    Fig. Showing the location of the lower transmission bolts-9-3 with 5-speed manual transmission 2003-04


To install:

  1. Bleed the slave cylinder, if necessary.
  2.  
  3. Lubricate the primary shaft splines.
  4.  
  5. Lubricate the guide sleeves on the engine with anti-corrosion agent.
  6.  
  7. Install a protective collar, 83 95 162, in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.
  8.  


CAUTION
Always replace the shaft seals in the gearbox. Lubricate with gearbox oil.

  1. Fit the gearbox, with the lifting tool, on the column jack.
  2.  
  3. Slide in the gearbox until approx. 0.8 inch (20mm) are remaining and remove the tool.
  4.  
  5. Push in the rest of the gearbox. Turn the crankshaft if necessary to get the gearbox in place.
  6.  
  7. Tighten all bolts, except the top one between the engine and the gearbox, to 30 ft. lbs. (40 Nm) for M10 bolts, and 52 ft. lbs. (70 Nm) for M12 bolts.
  8.  
  9. Install the charge air pipe bracket.
  10.  
  11. Remove the lifting tool from the gearbox and move the jack out of the way.
  12.  
  13. Reinstall the gearbox bolts and torque to 18 ft. lbs. (24 Nm).
  14.  
  15. Undo the straps and position the power steering cooling coil. Make sure it is fitted on the correct side of the rubber seal.
  16.  
  17. Lower the car. Lift in place the powertrain with the lifting beam until it meets the engine mounting.
  18.  
  19. Install the bracket for the engine mount according to the marks made earlier. Torque the bolts to 52 ft. lbs. (70 Nm), plus an additional 45 degrees.
  20.  
  21. Remove the holder and the lifting beam.
  22.  
  23. Install or connect the following: 3 upper gearbox bolts to 52 ft. lbs. (70 Nm).Protective collar, 83 95 162, in left driveshaft seal (remove strap, ensure driveshaft is clean, lubricate it and then align it with tool).Driver in gearbox until approx.0.8 inch (20mm) are remaining and pull out tool before sealing surface of shaft reaches shaft seal; push in rest of driveshaft into gearbox until circlip clicks in.ABS cable to the clipGround cableRefill gearbox oil until level with plug hole.Filler plug to 37 ft. lbs. (50 Nm) on 5-speed, or to 7 ft. lbs. (10 Nm) on 6-speedTorque rod bracket, torque bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees

    3 upper gearbox bolts to 52 ft. lbs. (70 Nm).
     
    Protective collar, 83 95 162, in left driveshaft seal (remove strap, ensure driveshaft is clean, lubricate it and then align it with tool).
     
    Driver in gearbox until approx.0.8 inch (20mm) are remaining and pull out tool before sealing surface of shaft reaches shaft seal; push in rest of driveshaft into gearbox until circlip clicks in.
     
    ABS cable to the clip
     
    Ground cable
     
    Refill gearbox oil until level with plug hole.
     
    Filler plug to 37 ft. lbs. (50 Nm) on 5-speed, or to 7 ft. lbs. (10 Nm) on 6-speed
     
    Torque rod bracket, torque bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees
     

  24.  
  25. Position the subframe using the fixture. Also use a 3/8 inch square extension, 82 93 102, to guide the subframe. Lift until the anti-roll bar can be fitted to the subframe.
  26.  
  27. Remove the link arm nuts and fit the anti-roll bar to the subframe. Torque bolts to 13 ft. lbs. (18 Nm).
  28.  
  29. Install the suspension arm ball joints to the steering swivel member and torque bolts to 37 ft. lbs. (50 Nm).
  30.  


CAUTION
Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.

  1. Check that the guide pins fit into the reference holes, adjust the subframe until the guide pins go in easily and fit the subframe bolts and brackets. Torque as follows: Subframe bolts (except rear): 52 ft. lbs. (70 Nm), plus as an additional 90 degreesRear subframe bolts: 66 ft. lbs. (90 Nm), plus an additional 45 degrees

    Subframe bolts (except rear): 52 ft. lbs. (70 Nm), plus as an additional 90 degrees
     
    Rear subframe bolts: 66 ft. lbs. (90 Nm), plus an additional 45 degrees
     

  2.  
  3. Install the anti-roll bar link arms and torque bolts to 47 ft. lbs. (64 Nm).
  4.  
  5. Move the lift and jig away.
  6.  
  7. Fit the torque rods to the subframe and torque bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees.
  8.  
  9. Set up the engine centering tool kit, 83 96 152, and check that the engine is located correctly in relation to the subframe. Remove the centering tool.
  10.  
  11. Install or connect the following: Radiator brackets to subframe; remove straps and torque bracket bolts to 35 ft. lbs. (47 Nm)Clamps holding power steering pipe to subframeSteering gear to subframe, torquing bolts to 37 ft. lbs. (50 Nm), plus an additional 60 degreesJoint clamp on front exhaust pipe and fit it to catalytic converter; use a new gasket and new nuts, tightening to 18 ft. lbs. (25 Nm)Joint clamp where pipe was cut (place pipe ends in middle; torque joint clamp nuts to 30 ft. lbs. (40 Nm)Connector and cable clip to the headlamp angle sensor (if equipped)Coolant reservoir (6-speed)Left-hand side coverFender liner sectionConnector and hose to headlamp washerFront spoiler shieldFront wheelsBumper shell upper mountingsQuick-release coupling to clutch slave cylinder (remove hose pinch-off pliers); ensure connection is in correct positionBleed the clutchGear cables to gearboxReverse light switch connection and ground cable to engine mount; torque bolt to 13 ft. lbs. (18 Nm)Battery tray and hood switch connectorBattery (and cooling hose, if equipped)Battery coverUpper engine cover

    Radiator brackets to subframe; remove straps and torque bracket bolts to 35 ft. lbs. (47 Nm)
     
    Clamps holding power steering pipe to subframe
     
    Steering gear to subframe, torquing bolts to 37 ft. lbs. (50 Nm), plus an additional 60 degrees
     
    Joint clamp on front exhaust pipe and fit it to catalytic converter; use a new gasket and new nuts, tightening to 18 ft. lbs. (25 Nm)
     
    Joint clamp where pipe was cut (place pipe ends in middle; torque joint clamp nuts to 30 ft. lbs. (40 Nm)
     
    Connector and cable clip to the headlamp angle sensor (if equipped)
     
    Coolant reservoir (6-speed)
     
    Left-hand side cover
     
    Fender liner section
     
    Connector and hose to headlamp washer
     
    Front spoiler shield
     
    Front wheels
     
    Bumper shell upper mountings
     
    Quick-release coupling to clutch slave cylinder (remove hose pinch-off pliers); ensure connection is in correct position
     
    Bleed the clutch
     
    Gear cables to gearbox
     
    Reverse light switch connection and ground cable to engine mount; torque bolt to 13 ft. lbs. (18 Nm)
     
    Battery tray and hood switch connector
     
    Battery (and cooling hose, if equipped)
     
    Battery cover
     
    Upper engine cover
     

  12.  
  13. Check the gear positions and adjust if necessary as described below: Engage 4th gear on the gearbox.Undo the gear lever cover with rubber mat and lift up the cover.Undo the cable adjusters using a screwdriver.Secure the gear lever in its adjusted position by lifting the adjusting sleeve while pressing in the two catches. Use a pair of pliers. Let the catch engage in the adjusting position. Check that 4th gear is engaged in the gearbox.Press on the gear adjusters with a screwdriver.Lift up the adjuster sleeve to its normal position.Check the shifting positions.
    1. Engage 4th gear on the gearbox.
    2.  
    3. Undo the gear lever cover with rubber mat and lift up the cover.
    4.  
    5. Undo the cable adjusters using a screwdriver.
    6.  
    7. Secure the gear lever in its adjusted position by lifting the adjusting sleeve while pressing in the two catches. Use a pair of pliers. Let the catch engage in the adjusting position. Check that 4th gear is engaged in the gearbox.
    8.  
    9. Press on the gear adjusters with a screwdriver.
    10.  
    11. Lift up the adjuster sleeve to its normal position.
    12.  
    13. Check the shifting positions.
    14.  

  14.  
  15. Fit the gear lever cover and rubber mat.
  16.  

 
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