Removal and installation of gearbox C58: 1 - engine protection cover (left side), 2 - engine protection cover (right side), 3 - spring, 4 - oxygen sensor connector, 5 - gasket, 6 - bracket, 7 - front engine mount with bracket, 8 - ground wire, 9 - clutch slave cylinder with hydraulic drive pipe, 10 - right drive shaft, 11 - starter, 12 - battery holder, 13 - battery, 14 - battery support, 15 - control cables, 16 - holder, 17 - cotter pin, 18 - washer, 19 - air filter with hose, 20 - rear engine mount bracket, 21 - engine wiring clamp, 22 - left engine mount bracket, 23 - reversing light switch connector, 24 - left drive shaft, 25 - lock nut cap, 26 - cotter pin, 27 - tie rod end, 28 - plug, 29 - plug, 30 - front towing eye, 31 - plug, 32 - bracket of the exhaust pipe Ne1, 33 - exhaust gas temperature sensor, 34 - beam of the central support of the engine mount, 35 - air conditioning pipe, 36 - exhaust pipe, 37 - gasket, 38, 39 - retaining ring
Note:
- Installation is carried out in the reverse order of removal.
- Check the front wheel alignment and road test.
1. Remove the battery and air filter with hose.
2. Remove the clutch slave cylinder and pipe.
- a) Loosen the tube bracket mounting bolt. Tightening torque 12 Nm.
- b) Unscrew the two bolts and remove the clutch slave cylinder. Tightening torque 12 Nm.
3. Remove the engine wiring clamp.
4. Disconnect the reversing light switch connector.
5. Loosen the bolt and disconnect the ground wire.
6. Disconnect the control cables.
- a) Remove the cotter pins and washers.
- b) Remove the holders from the cables.
- c) Disconnect the control cables.
7. Loosen the upper starter mounting bolt. Tightening torque 39 Nm.
8. Unscrew the three upper gearbox mounting bolts. Tightening torque 64 Nm.
9. Loosen the four bolts and remove the left engine mount bracket. Tightening torques:
- Bolt A 87 Nm
- Bolt B 52 Nm
10. Raise the engine.
11. Remove the front wheels.
12. Remove the engine protection cover.
13. Drain the gearbox oil. Transmission oil:
- API oil class: GL-4 or GL-5
- Recommended viscosity: SAE 7SW-90
- Filling capacity: 1.9 l
14. Remove the drive shafts.
15. Remove the exhaust pipe.
- a) Disconnect the oxygen sensor connector.
- b) Unscrew the two bolts, remove the exhaust gas temperature sensor, sensor and gasket.
- c) Unscrew the two bolts, remove the springs and gasket from the exhaust manifold. Tightening torque 62 Nm.
- d) Unscrew the two bolts, nuts and remove the gasket. Tightening torque 43 Nm.
- d) Disconnect the intake pipe from bracket No.1 and remove it.
16. Remove the engine mount center support beam.
- a) Loosen the bolt and disconnect the air conditioner pipe.
- b) Loosen the two bolts and remove the front towing eye.
- c) Remove the two plugs and plug I. Unscrew the 7 bolts and remove the engine mount central support beam. Tightening torques:
- Bolt A 35 Nm
- Bolt B 72 Nm
17. Remove the starter.
- a) Disconnect the connector and wire from the starter.
- b) Unscrew the lower starter mounting bolt. Tightening torque 39 Nm.
- c) Remove the starter.
18. Place a jack under the gearbox.
19. Unscrew the two bolts and remove the front engine mount with the bracket. Tightening torque 64 Nm.
20. Loosen the four bolts and remove the rear engine mount bracket. Tightening torques:
- Bolt A 87 Nm
- Bolt B 64 Nm
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21. Remove the bracket and unscrew the lower gearbox mounting bolt.
- a) Unscrew the five bolts and remove the bracket. Tightening torque 43 Nm.
Note:
- when installing the bracket, temporarily tighten the mounting bolt No.1.
- tighten the bolts according to the numbers (see picture).
- b) Loosen the lower gearbox mounting bolt. Tightening torque 46 Nm.
22. Lower the left side of the engine and remove the gearbox.
Note:
- when installing, align the splines of the primary shaft and the driven clutch disc and install the gearbox on the engine.
- temporarily tighten the gearbox mounting bolts.