Contents: For vehicles with DPF ⬇ Continued for all vehicles ⬇ For vehicles without DPF ⬇ Continued for all vehicles ⬇ For vehicles with DPF ⬇ Continued for all vehicles ⬇ Installation ⬇ Tightening torques ⬇ Checking the transmission oil level ⬇
Before disconnecting the battery in vehicles with a car radio equipped with an anti-theft jamming code, you must know this code. The wire connecting the battery terminal to the ground (body) of the vehicle should be disconnected with the ignition off. Remove the upper engine cover. Remove the complete air filter with the air hose. Remove the battery and battery holder.
Remove the gearshift cable drive with the gearshift lever by unscrewing nut "1." Remove the cable drive (Bowden) for the preselective gearshift control device with the shift guide lever "4" by disconnecting the retaining ring "3" of the shift guide lever.
For vehicles with DPF
Remove the boost air pipe (leading from the turbocharger to the charge air cooler).
Continued for all vehicles
Having removed the flexible roller counter support (bowden cables) "arrows", put it aside and tie it. After removing the pipe and hose line "A" from the holder "C" on the gearbox, remove the holder. After removing the clutch release drive slave cylinder "B", put it aside and secure it with wire without opening the system.
Important: Do not depress the clutch pedal.
Unlock and disconnect the "arrow 1" connector from the starter and the "arrow 2" connector from the "F4" reversing light switch. Using a lever motion, remove the protective cap and unscrew the "arrow 3" wire from the starter.
Disconnect the "arrow" connector from the speedometer sensor "G22" (if installed).
Remove the engine cover holder "arrow" (one of the two assembly hooks of the fastening suspension device should be installed in this hole).
Install the engine mount.
Important: When installing the suspension device, ensure that the hoses and wires near the eyes are not damaged.
Using the lead screw (spindle), apply slight pre-stress to the engine-gearbox assembly. Remove the upper bolts connecting the gearbox to the engine. Remove the upper starter mounting screws. After removing the left front wheel, lift the car.
Remove the lower engine cover. Unscrew the protective sheet of the "arrow" (if installed) for the inner protective cuff of the right cardan shaft.
After unscrewing the starter holder "arrow", put it aside along with the wires.
Remove the starter. Remove the wheel arch (fender) liner of the left front wheel. Turn the steering wheel all the way to the left and remove the cardan shafts from the flange shafts. The right cardan shaft should be secured as high as possible, eg. using a rope. At the same time, do not damage the protective paint coating of the cardan shaft.
For vehicles without DPF
Remove the front section of the exhaust pipe with the catalytic converter.
Continued for all vehicles
Unscrew screws "1" of the left head of the ball joint.
Important: After installation, it is necessary to check the geometry (kinematics) car.
Unscrew the stabilizer connecting rod "2" from the stabilizer "arrow". Rotate the stabilizer connecting rod upward. Fold the wheel bearing housing cover outward. In this case, the cardan shaft should be guided into the wheel well and attached, for example. with a rope to the shock absorber. Drain the coolant.
After removing clamp "3" as far as it will go, disconnect the hose with the drain cock from the radiator (fasten the hose, for example. wire so that it does not interfere during further removal of the gearbox). Disconnect the plug connector "2".
After removing the "arrow" screws, remove the fan holder in a downward direction.
Important: Also, for vehicles with air conditioning, the screw must be removed (at the top of the fan holder), air conditioner pipeline pipe holding holder.
Unscrew the rocking support -arrows 1 and 2-.
Unscrew the bolt connecting the engine and gearbox under the right flange shaft.
Important: When installing the rocker arm bolts, place the screws "1" in the slots so that the gearbox and suspension mount beam are as far apart as possible.
Take off (if installed) small protective sheet "A" for the flywheel behind the right shaft with the "arrow" flange.
For vehicles with DPF
Remove the exhaust pipe bracket "1". Disconnect the exhaust pipe at the double clamp. Free (center) axle suspension mounting beam.
Continued for all vehicles
Remove the engine mount "arrow" mounting screws from the engine mount bracket.
Remove the "arrow" mounting screws from the gearbox bearing.
Lower the engine-gearbox unit through the lead screw to such an extent as to open access to the bolts securing the gearbox bracket "A" from the wheel arch of the left wheel.
Remove the gearbox bracket "arrow" mounting screws as follows. Remove gearbox bracket "A" from the gearbox.
Important: When lowering the engine-gearbox unit, ensure that the gearbox does not touch the suspension mounting beam.
Install the gearbox mounting fixture into the engine and gearbox removal and installation device. Assemble the engine and gearbox removal and installation device with the gearbox mounting device, the alignment board for the "02R" gearbox and the mounting elements as follows. Place the alignment board on the gearbox mounting fixture (the alignment board is installed in only one single position). Adjust the position of the gearbox mounting device arms according to the holes in the alignment board. Screw in the fastening elements "A" and "C" according to the marks on the alignment board, screw in the journals in the manner indicated on the alignment board.
Place the device for removing and installing the engine and gearbox under the vehicle, the arrow - symbol B - on the alignment board points in the direction of vehicle movement. With the alignment board aligned parallel to the gearbox, secure the locking clamps. Remove the lower mounting bolts connecting the engine and gearbox. Having pressed the gearbox away from the engine, move it towards the suspension mounting beam.
Rotate the gearbox using the lead screws back and down towards the suspension mounting beam. Then carefully lower the gearbox. During lowering, change the position of the gearbox using a lead screws of the gearbox silting device.
Important: Ensure that during removal the gearbox "1" does not rest on the longitudinal beam "2" "arrows". When lowering, route coolant hoses around the gearbox.
Installation
Before starting installation, unscrew the oil level check plug and, if necessary, add transmission oil. The gearbox is installed in the reverse order of actions. Ensure that the unit is installed in the vehicle without pre-tensioning. Before installing the gearbox, press the clutch release lever against the gearbox housing and secure it with a mounting bolt or an M8 x 35 bolt.
The bolt should be removed again after installing the gearbox and clutch slave cylinder. The hole is subsequently closed with the 3rd screw for fastening the flexible roller counter support (bowden cables). When replacing the gearbox, the original speed sensor should be used if possible, see. drawing (if it is installed), gear shift lever and preselector lever. After cleaning the splines on the drive shaft, lightly lubricate them with grease -G 000 100-. The clutch disc should move freely on the drive shaft. When replacing the gearbox, ensure that the metal gasket is installed correctly (intermediate sheet) between the engine and the gearbox.
Check the presence of centering bushings on the gearbox mounting flange to the engine for centering the gearbox; if necessary, invest them. Install the engine mount. Assemble the exhaust system in such a way that it is free of internal stress. Screw on the axle suspension mounting beam. Check the transmission oil level. Install the starter and wires. Install the left front wheel. Install the lower engine cover. Adjust the gear shift mechanism. Install the supplied air filter with air hose. Install the battery and battery holder. After disconnecting and then reconnecting the wire connecting the battery terminal to the ground (body) of the vehicle, some additional work must be performed. - Check the geometry (kinematics) car.
Tightening torques
Three-cylinder engine vehicles without a DPF filter
| Pos. | Screw | Pcs. | Nm | |
| 1 | M12 x 50 | 2 | 80 | |
| 21) | M12 x 150 | 1 | 80 | |
| 31) | M12 x 150 | 1 | 80 | |
| 41) | M10 x 58 | 1 | 40 | |
| 5 | M10 x 50 | 1 | 40 | |
| 6 | M12 x 55 | 1 | 80 | |
| 72) | M6 x 8 | 1 | 10 |
- 1) M8 headless grub screw.
- 2) Attaching the flywheel protective sheet.
- A: Centering bushings
Three-cylinder engine vehicles with DPF filter
| Pos. | Screw | Pcs. | Nm |
| 1 | M12 x 50 | 1 | 80 |
| 21) | M12 x 55 | 1 | 80 |
| 31) | M12 x 150 | 2 | 80 |
| 41) | M10 x 50 | 1 | 40 |
| 5 | M10 x 50 | 1 | 40 |
| 6 | M12 x 60 | 1 | 80 |
| 72) | M8 | 1 | 10 |
- 1) M8 headless grub screw.
- 2) Attaching the flywheel protective sheet.
- A: Centering bushings
Vehicles with a four-cylinder engine without a DPF filter
| Pos. | Screw | Pcs. | Nm |
| 1 | M12 x 50 | 2 | 80 |
| 21) | M12 x 150 | 2 | 80 |
| 3 | M10 x 50 | 3 | 40 |
| 4 | M12 x 55 | 1 | 80 |
| 52) | M6 x 8 | 1 | 10 |
- 1) M8 headless grub screw.
- 2) Attaching the flywheel protective sheet.
- A: Centering bushings
Four-cylinder engine vehicles with DPF filter
| Pos. | Screw | Pcs. | Nm |
| 1 | M12 x 50 | 1 | 80 |
| 21) | M12 x 55 | 1 | 80 |
| 31) | M12 x 150 | 2 | 80 |
| 41) | M10 x 50 | 1 | 40 |
| 5 | M10 x 50 | 2 | 40 |
| 6 | M12 x 60 | 1 | 80 |
| 72) | M6 x 8 | 1 | 10 |
- 1) M8 headless grub screw.
- 2) Attaching the flywheel protective sheet.
- A: Centering bushings Swing support
Important: The "1" bolts of the rocker support must be placed in the slots in such a way that the gearbox and the suspension mounting beam are as far apart as possible.
- 1 - 30 Nm + 90° (1/4 turn) - replace
- 2 - 40 Nm + 90° (1/4 turn) - replace
| Details | Tightening torque |
| Gearbox bracket gearbox 1) M10 | 40 Nm + 90° |
| Gearbox bearing mounting screws 1)M10 | 40 Nm + 90° |
| Propeller shaft protective cap - engine | 35 Nm |
Checking the transmission oil level
Remove the lower engine cover. Unscrew the threaded plug of the transmission oil level check hole "arrow". If the transmission is filled with the correct amount of oil, the oil level reaches the lower edge of the filler hole. After screwing in the threaded oil filler plug "arrow", tighten it with the appropriate tightening torque.
When refilling, the following instructions should be observed. Unscrew the threaded plug "arrow" of the oil filler hole. Pour transmission oil up to the lower edge of the oil filler hole. Screw in the "arrow" screw plug. Start the engine, engage gear, and crank the transmission for about 2 minutes. Stop the engine, unscrew the "arrow" screw plug, and add transmission fluid up to the bottom edge of the oil filler hole. After screwing in the threaded oil filler plug "arrow", tighten it with the appropriate tightening torque. Install the lower end of the engine.