PREVENTION According to the identification plate be convinced that the new transmission of the same type, as old.

For the KP installation it is necessary to execute:

a) preparatory operations:

Fig. 5.33. Installation of a support under the transmission

— install the transmission on a support 999 5979 in assembly situation and fix by arms (see fig. 5.33);

— apply a small amount of jellied lubricant 1161246-2 on vents of a main shaft;

— apply lubricant 1161035-9 on vents (the right half shaft) on the transmission;

— move up the transmission to the engine so that the shaft entered vents of the conducted clutch plate and establish the right half shaft on vents;

b) attach the transmission to the engine:

Fig. 5.35. Bolts of fastening of KP to the engine (two bolts are not shown)

— put and tighten four fixing bolts (fig. 5.35) the moment of an inhaling of 50 N · m;

— remove a support 999 5972;

c) connect a transmission support to a body:

Fig. 5.24. Bolts of fastening of the left mudguard (are shown by shooters)

— mount a transmission support by means of three bolts (fig. 5.24);

— adjust position of the engine by means of the lifting device and establish a bolt in a support on a body;

— put three bolts and tighten the moment 45 N · m;

— lower the engine so that the lifting beam ceased to hold it;

NOTE You watch to damaging a tube of hydraulic system of coupling.

— wrap a bolt from a body, tighten the moment 98 N · m;

— exempt the engine from the lifting device;

Fig. 5.20. Bolts of fastening of KP (are specified by shooters)

d) establish bolts of fastening of the transmission from above and tighten their moment 50 N · m (fig. 5.20);

Fig. 5.19. Bolts of fastening of a starter (are shown by shooters)

e) establish a starter on the place and put three fixing bolts (fig. 5.19) and tighten their moment 50 N · m;

— lift the car;

— remove protection from a trekhshipovik and take out a cap from a transmission opening;

— turn a steering wheel against the stop to the right;

— carefully establish the left half shaft in differential (see fig. 5.33);

— turn a steering wheel against the stop to the left and install the lower bolt in the shock-absorber/fastener of a rotary fist;

— establish protective covers;

— put three bolts and tighten the moment 25 N · m;

g) attach a rotary fist to the shock-absorber:

— put the top bolt;

— tighten both bolts the moment of 90 N · m;

— install the pipeline of the brake system in an arm and record a bracket;

— fix an ABS system wire in arms;

— clear the socket and connect a backing lamp switch wire;

Fig. 5.25. A bolt of fastening of a mass wire to KP (it is shown by an arrow)

— connect a wire of connection with "mass" of the transmission (see fig. 5.25), having carefully cleared contact surfaces;

— fix a wire by the moment of 40 N · m;

h) install the right half shaft and a flexible shaft of a speedometer on the transmission;

— fill an opening under the fixing pins with sealant 1161058-1;

If the opening from the transmission is from below (the space basis between teeths) between two vents, then the corresponding opening has to be in a half shaft from above (top) and vice versa;

— establish two new lock pins in a half shaft;

— establish a new sealing ring on a flexible shaft of a speedometer and fix it;

Fig. 5.31. Detachment of the right half shaft: 1 — a mandrel

— with a force press a flexible shaft in the case and put a lock ring (see fig. 5.31);

— establish wheels;

i) establish a gear shifting bar;

— grease details of hinged connections with jellied Volvo 1161241-3 lubricant;

— check rubber elements;

Fig. 5.28. Fastening of a bar of gear shifting to KP: 1 — a bar; 2 — a bolt; 3 — a nut

— establish a bar of gear shifting on the place and insert a bolt (fig. 5.28) tighten a bolt the moment of 16 N · m;

j) establish the central longitudinal beam:

Fig. 5.27. Details of fastening of support of the engine and the central longitudinal beam (are shown by shooters)

— mount support on arms of the engine (fig. 5.27);

— put bolts in support and acquire them;

— put four bolts of fastening of a longitudinal beam to a body: in front — long bolts; behind — short bolts;

— tighten bolts the moments: four bolts of fastening of a beam of 69 N · m; two bolts of support of the engine of 52 N · m;

— at first tighten a back bolt, and then forward;

Fig. 5.26. Bolts of fastening of the heat-insulating screen (are shown by shooters)

— install the heat-insulating screen, and at first put a bolt And (fig. 5.26); then other two bolts, moment of an inhaling of 10 N · m;

k) fill in oil in the transmission:

— substitute a stopper of a jellied (control) opening;

— fill the transmission with oil 3345534-6 to the lower edge of a jellied opening;

— put a new sealing ring on a stopper of a jellied (control) opening;

— put and tighten a stopper of a filling (control) opening, the moment of 22 N · m;

l) establish engine mudguards:

— wrap three bolts of fastening of the left mudguard and tighten their moment 17 N · m (fig. 5.24);

Fig. 5.23. Removal of a forward mudguard of the engine

— establish a forward mudguard, fix it by bolts and screws the moment of 10 N · m (fig. 5.23);

— install the sensor of a flywheel and fix it by two screws, tighten screws the moment of 20 N · m;

Fig. 5.14. Fastening of the working cylinder of coupling: 1 — the union; 2 — bolts

m) install the working cylinder of coupling on the transmission (fig. 5.14):

— press the piston as it is possible more deeply in the cylinder;

— remove a collar from the coupling cylinder;

— insert a rod into a clutch release fork lever;

— put two bolts of fastening of the cylinder;

— tighten bolts the moment of 30 N · m;

— establish a tube with the Banzho union, tighten the union the moment of 25 N · m;

Fig. 5.18. Screws of fastening of the air filter (are shown by shooters)

o) install the air filter by rotary motion (fig. 5.18) and tighten their moment 10 N · m;

— check installation of an air inlet;

Fig. 5.13. Fastening of an inlet hose of the air filter: 1 and 3 — places of fastening of a hose of ventilation of a case of the engine; 2 and 6 — collars; 4 — the socket of the air sensor; 5 — a hose of the air pump; 7 — a hose of the air filter

— establish an inlet air hose (fig. 5.13).

PREVENTION You watch that the cam of a butterfly valve was not hooked for a collar.

— connect a hose and record two collars;

Establish a hose of preliminary heating.

o) establish:

— negative wire of the rechargeable battery; engine cover moment of an inhaling of 11 N · m;

p) start the engine and check coupling work.