- Mating surfaces of the engine and manual transmission;
- Primary shaft seals for manual transmission;
- Filler cap;
- Drain plug.
Before the control check, it is necessary to warm up the manual transmission oil thoroughly during a short (up to 30 km) trip.
36. Drive the car onto a ramp or inspection pit, or jack it up and place it on supports in a strictly horizontal position. If an oil leak is detected, first eliminate its cause, and then adjust the oil level in the manual transmission.
Note: Checking and adjusting the level should only be done if oil leaks from the manual transmission are detected. In other cases, there is no need to do this.
37. Carefully wipe the surface of the gearbox housing around the inspection plug. If necessary, remove the protective cover of the engine compartment. On models equipped with 1.4/1.6/1.8 l petrol engines and a Z17DTL diesel engine with an F13/F17+ manual transmission, the inspection hole is located on the left rear of the gearbox (behind the primary shaft) (see accompanying illustration 4.37a). The location of the inspection and drain holes on the manual transmission of the Z17DTH engine with the F23 manual transmission is shown in the accompanying illustration 4.37b.
38. To check, unscrew the plug of the inspection hole and measure the oil level in the manual transmission crankcase using a wire bent at 90° - the oil level should not fall below the edge of the inspection hole by more than 16 mm (minimum acceptable level).
39. If necessary, the level is adjusted using a special syringe through the hole for installing the reverse light switch sensor, or through a special filler hole (F23 manual transmission) - unscrew the sensor/plug (see accompanying illustration). Oil should be poured until its level reaches the lower edge of the inspection hole.
Note: Transmission oil has a high viscosity - it takes time for it to be evenly distributed throughout the entire volume of the gearbox housing. Make adjustments in several stages, do not pour too much oil at once, check its level periodically.
If oil begins to leak out of the edge of the inspection hole, allow the excess to drain off.
40. After completing the adjustment, tighten the inspection hole plug back to approximately 4 Nm and tighten it with a wrench approximately 1/8 to 3/8 of a turn (45°-135°). Then screw in the reverse light switch sensor, having first replaced the sealing gasket, and tighten it to 20 Nm. For the F23 transmission, the tightening torque for both the inspection and filler hole plugs is 35 Nm.
Caution: Accessing the plug on the F23 transmission may require removing the battery and its installation tray (see Chapter 5).
41. On diesel engines 1.3 and 1.9 l with manual transmission M32 control of transmission oil level is not provided. Control hole (see accompanying illustration) is designed to monitor the oil level when filling the gearbox and its plug should not be unscrewed, as this will lead to oil spillage on the manual transmission. If a leak is detected, it is necessary to eliminate its cause and replace the transmission oil (see Chapter 6).
42. After completing the work, remove traces of oil from the gearbox, remove the tool from under the car and lower the latter to the ground if it was jacked up or lifted. During the first trips, check the gearbox for leaks.
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