Removal and installation
Removal
Attention. When removing a manual transmission from a vehicle, always replace the concentric slave cylinder (CSC). To remove the manual transmission, the CSC insert is moved to its original position. Dust on the sliding components of the clutch plate can damage the CSC seal and cause clutch fluid to leak.
1. Disconnect the cable from the negative terminal of the battery.
2. Disconnect the saloon hose. See above.
3. Remove the air cleaner housing and air duct (inlet). See chapter «Mechanical part of the engine».
4. Remove the battery.
5. Disconnect the connectors (A) and then remove the bracket (1).
6. Drain the clutch fluid and disconnect the clutch tube from the concentric slave cylinder (CSC). See above.
Attention. Do not press the clutch pedal during removal.
7. Disconnect the connectors from the position switches.
8. Disconnect the ground cable.
9. Remove the electrical wiring from the gearbox.
10. Disconnect the gear selector cable and shift cable from the transmission assembly. See above.
11. Remove the starter. See chapter «Electrical equipment».
12. Remove the engine protection from the bottom.
13. Drain the transmission oil. See above.
14. Disconnect the front exhaust pipe. See chapter «Accelerator fuel system and exhaust system».
15. Remove the front drive shafts. See chapter «Front axle and suspension».
Note. After removing the front drive shafts, install suitable plugs into the differential seals.
16. Remove the rear engine mount brackets and rear torque rod. See chapter «Mechanical part of the engine».
17. Remove the suspension beam and suspension beam strut. See chapter «Front axle and suspension».
18. Support the transmission assembly and then the engine assembly with suitable jacks.
Attention. When installing a suitable jack, but touch the switches.
19. Unscrew the transmission assembly mounting bolts.
20. Unscrew the nut securing the through bolt of the engine mount. See chapter «Mechanical part of the engine».
21. Remove the manual transmission assembly from the vehicle.
Attention:
- When removing the gearbox, secure it with a jack.
- The gearbox assembly must not touch the electrical wiring and clutch tube.
22. Remove the concentric slave cylinder (CSC). See above.
Installation
Installation is carried out in the reverse order of removal, taking into account the following:
- Tighten the transmission assembly mounting bolts to the required torque. The figure shows a view from the engine side.
Attaching the manual transmission to the engine.
Mounting the engine to the manual gearbox.
Bolt designation | A | IN |
Quantity | 3 | 6 |
Bolt length, mm | 60 | 50 |
Tightening torque Nm (kg-m) | 62 0 (6 3) |
Attention:
- The gearbox assembly must not touch the electrical wiring and clutch tube.
- When installing the transmission assembly, do not touch the drive shaft to the clutch housing.
- Concentric Slave Cylinder Installation Operations (CSC) see above.
- See above for connecting the gearshift cable and gear selection cable.
- Bleed the air from the clutch hydraulic drive. See above.
- After installation, check the oil level for leaks. See above.