Figure 6.1. Checking the transmission oil level - 1.6 liter models
2. Carefully inspect the surfaces of the gearbox and clutch housing connection, seals. Also check the reverse gear selection switch.
Checking the transmission oil level - 1.6L models.
3. Place the car on a flat horizontal surface, apply the handbrake, turn off the ignition. Do not start the engine or move the car when checking the oil level.
4. Unscrew the filler/level plug at the front of the gearbox (photo).
2.4. Unscrewing the filler plug/level - 1.6 liter models
5. Check with your finger that the oil is level with the base of the plug hole. Add oil if necessary.
6. If the gearbox oil has been overfilled to the point that it starts to leak after the filler/level plug is unscrewed, drain the excess into a container. Once the oil stops leaking, screw the filler/level plug back in.
7. After topping up, clean the filler plug, apply sealant to the threads and tighten the plug to the tightening torque specified in the Specification.
Checking the transmission oil level - 1.8 liter models (including Turbo) and 2.0 liters
8. Place the car on a horizontal surface, apply the handbrake, turn off the ignition.
9. Unscrew and disconnect the speedometer drive gear assembly from the rear of the transmission.
10. Wipe the pinion assembly, especially the teeth, and insert the assembly back into the gearbox to use as a feeler gauge. Make sure the pinion sleeve is seated on the gearbox housing surface (Figure 6.2). Remove the gear assembly, the oil level should be within the limits marked on the gear teeth.
Figure 6.2. Checking the transmission oil level - 1.8 models (including Turbo) and 2.0 liters
11. If necessary, add oil to the required level (photo). If the level is too high, suck out the excess with a syringe or something similar.
2.11. Topping up transmission oil - model 1.8 (including Turbo) and 2.0 liters
12. After setting the level, check the seal on the speedometer drive gear bushing, then install the gear assembly. Tighten the screw to the tightening torque specified in the Specifications.
Transmission Oil Change - All Models
13. For best performance, warm up the engine/transmission assembly to normal operating temperature.
14. Place the car on a level surface, apply the handbrake, turn off the ignition.
15. Open the hood, remove the filler/level plug (1.6 liter models) or assembly of the speedometer drive gear (all other models) as described above. Place a suitable container under the gearbox.
16. On 1.6 liter models, use a 13 mm drain plug wrench to loosen the drain plug underneath the left drive shaft (photo).
2.16. Unscrewing the drain plug - 1.6 liter models
17. On 1.8 ligra models (including Turbo) and 2.0 liter models, unscrew the drain plug on the clutch housing, under the right drive shaft (photo).
2.17. Location of drain plug - model 1.8 (including Turbo) and 2.0 liters
18. Drain the oil into a container.
19. When all the oil has drained, clean the drain plug, including the magnetic insert (where is available). On 1.6 litre models, apply thread sealant and tighten the plug. On all other models, check the condition of the gasket, replace if distorted or damaged, then apply thread sealant and install the plug. Tighten the drain plug to the tightening torque specified in Specifications.
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20. Fill the gearbox with transmission oil and check the level as described above.