- before disconnecting the steering shaft from the steering mechanism, be sure to block the steering wheel and wheels 8 with a special device in the position of movement in a straight line, and they must remain locked during the entire time of work;
- if the alignment of the contact plate was not done correctly, the steering wheel must be removed for re-alignment.
Only experienced workers who have undergone special training are allowed to perform this operation.
Removing
Place the car on a two post lift.
Remove the battery cover.
Disconnect the wires from the battery terminals, starting with the negative terminal.
Remove the engine undertray.
Drain the gearbox oil.
Remove:
- front wheels;
- upper engine covers;
- battery;
- battery shelf;
- injection computer with bracket;
- mass air flow sensor;
- air intake pipe.
Remove the wire harness holders.
Disconnect select and shift cables from transmission.
Disconnect both cables from the levers on the gearbox.
Squeeze the tip of the rope at points (A), pull the lock towards (IN) and lift the rope at the point (WITH).
Loosen the hub nut using the tool (Rou. 604-01).
Remove the tie rod end ball joint using the tool (Tav. 476) and ball joint of the anti-roll bar.
Remove the ball joint of the suspension arm.
Disconnect the drive shaft from the steering knuckle.
Remove the drive shaft.
Secure the engine cooling radiator/condenser assembly to the top cross member with twine.
Remove the side reinforcements.
Remove the radiator cross member.
Remove the catalytic converter bracket from the clutch housing.
Loosen the mounting bolts and remove the starter.
Remove the top tie rod.
Remove the lower jet link.
Remove the steering shaft yoke.
Remove the subframe corner bracket.
Remove the front suspension subframe.
Disconnect the wiring harness from the reversing light switch and the wiring harness from the TDC sensor.
Use a syringe to remove the brake fluid from the reservoir to the fitting of the pipeline of the clutch master cylinder.
Disconnect the clutch slave cylinder by removing the retainer.
Install engine mount (Mot. 1453).
Remove the silent block of the gearbox support and the pendulum support of the gearbox.
Remove the upper bolts securing the gearbox to the engine block.
Place a hydraulic jack under the gearbox.
Remove the lower bolts securing the gearbox to the engine block.
Remove the transmission studs.
Remove the gearbox.
Installation
Attention! Do not apply grease to the input shaft of the gearbox, so as not to damage the clutch slave cylinder and splines of the input shaft of the gearbox.
Note. To prevent fluid leakage, be sure to replace the clutch slave cylinder when replacing the clutch cover.
Note. Make sure that the locating bushings are present and correctly positioned to center the engine and gearbox relative to each other.
Installation is made in an order, the return to removal.
When installing, be sure to tighten the bolt of the terminal connection of the steering shaft universal joint yoke.
Torque tighten:
- wheel bolts (110 Nm);
- hub nut (280 Nm);
- nut of fastening of a finger of a spherical support of the suspension arm (62 Nm);
- nut of fastening of a finger of a ball joint of a tip of steering draft (37 Nm);
- anti-roll bar ball joint nut (44 Nm);
- side panel bolts (2 Nm);
- bolts of fastening of a transmission and a starter to the engine (44 Nm);
- bolts for fastening jet thrust to the engine (180 Nm);
- tie rod to subframe bolts (105 Nm);
- box pendulum support bolts (62 Nm);
- nut for fastening the pendulum support to the pillow (180 Nm);
- bolts of the terminal connection of the fork and the cardan joint of the steering shaft (21 Nm);
- front radiator cross member bolts (105 Nm);
- rear radiator cross member bolts (210 Nm);
- cross member mounting bolts (62 Nm);
- rear subframe bolts (140 Nm);
- connecting rod bolts to subframe (105 Nm);
- gearbox drain plug (25 Nm);
- gearbox filler plug (3 Nm).
Pour oil into the gearbox.
Attention! Be sure to bleed the clutch hydraulics by doing the following:
- add brake fluid to the reservoir;
- bleed the hydraulic clutch;
- add brake fluid to the correct level.
Attach the wires to the battery terminals, starting with the positive terminal.