PRE-RELEASE
To remove
| To remove |
| Important | ||
|
Cables, hoses, leads etc. are secured with hard plastic cable ties. After being tightened, the ends are cut off, leaving sharp edges at the fixing points. Be aware of the risk of injury due to these sharp ends of cable tie. |
||
| 1. |
Place the car on a lift.
|
|
| 2. |
Place wing protectors over the wings to prevent soiling and damage to the paintwork.
|
|
| 3. |
Remove the cover over the intake manifold.
|
|
| 4. |
Remove the plastic cover from the battery.
|
|
| 5. |
Detach the battery leads from the battery.
|
|
| 6. |
Remove the battery from the battery tray.
|
|
| 7. |
Remove the main fuse box.
|
|
| 8. |
Engage 4th gear and remove the plastic plug from the gearbox.
|
|
| 9. |
Lock 4th gear in the gearbox by inserting
87 92 335 Locking pin
.
|
|
| 10. |
Remove the clip from above that secures the selector rod in the linkage on the gearbox.
|
|
| 11. |
Lift up the gaiter. Engage 3rd gear so that the selector rod disengages from the linkage and fit
87 92 335 Locking pin
in the selector lever housing.
|
|
| 12. |
To avoid brake fluid running out of the brake fluid reservoir, depress the clutch pedal approximately 50 mm using a brake cramp. Alternatively, the brake fluid hose can be clamped using
30 07 739 Hose pinch-off pliers
.
|
|
| 13. |
Remove the clip by the slave cylinder and disconnect the connection for the delivery line. Refit the clip.
|
|
| 14. |
Unplug the connector for the reversing lights.
|
|
| 15. |
Remove the 3 upper bolts securing the gearbox and stay.
|
|
| 16. |
Unplug the electric connection/s for the oxygen sensor.
|
|
| 17. |
Disconnect the selector linkage by the gearbox.
|
|
| 18. |
Remove the nut from the rear engine mounting.
|
|
| 19. |
Loosen the 3 bolts that secure the rear engine cushion, use a long 10 mm socket, an extension piece with ball (e.g. 30 17 613) and
82 93 102 Extension, 500 mm, 3/8 square
. Leave the bolts in place.
|
|
| 20. |
Slightly lift the engine and gearbox with
83 94 850 Lifting beam
. Position the beam so that it rests on the edges of the wings near the wing retaining bolts.
|
|
| 21. |
Raise the car.
|
|
| 22. |
Remove the front wheels.
|
|
| 23. |
Dismantle the covers in front of and under the bumper. Remove the headlamp levelling sensor brackets (option) and bend aside the sensors.
|
|
| 24. |
Remove the front exhaust system by first parting the flange from the turbocharger and then removing the rear mounting. It is important that the exhaust system is removed in this manner to avoid damaging the flexible section. Also, be careful with the oxygen sensors.
|
|
| 25. |
Dismantle the stay between the engine mounting and engine.
|
|
| 26. |
Remove the rear engine mounting and engine pad. The gearbox linkage will follow along.
|
|
| 27. |
Dismantle the bolt that secures the torque arm to the subframe.
|
|
| 28. |
Remove the bolts that secure the steering gear.
|
|
| 29. |
Remove the clips that secure the steering servo delivery line to the subframe.
|
|
| 30. |
Remove the air filter housing from the subframe.
|
|
| 31. |
Remove the AC-lines from the plastic clips on the subframe.
|
|
| 32. |
Remove the engine oil cooler from the charge air cooler (2 bolts).
|
|
| 33. |
Place a
83 95 212 Strap
around the radiator and radiator crossmember to suspend the radiator.
|
|
| 34. |
Remove the bolts that secure the outer ball joints to the steering swivel member on both sides.
|
|
| 35. |
Slacken the upper ball joint, on both sides, for the anti-roll bar. Take the strain with a 17 mm spanner making sure that the gaiter does not rotate. If the spanner is too wide to go in between the gaiter and MacPherson strut it must be filed down.
|
|
| 36. |
Remove the protective cover plate behind the flywheel.
B235R: Remove the bolts between the gearbox and engine oil sump as well as the bolts to the protective cover. 
|
|
| 37. |
Remove the 4 bolts that secure the rear support plate and the 2 bolts on the subframe.
|
|
| 38. |
Position the lifting trolley under the subframe. Trolley 83 94 793,
83 94 801 Parent fixture
, adjusting feet 83 95 170, basic fixture 83 95 188 and assembly fixture 83 95 196.
|
|
| 39. |
Remove the remaining 4 bolts that secure the subframe.
|
|
| 40. |
Lower the subframe and move it aside. At the same time, remove the front mountings (2) for the steering servo delivery line.
Hang up the engine oil cooler on a bolt so that the cooler is not in the way during the rest of the work. |
|
| 41. |
Drain the gearbox oil.
|
|
| 42. |
Disconnect the left-hand drive shaft using
87 92 616 Removal tool, drive shafts
. Suspend the drive shaft with a strap.
|
|
| 43. |
Remove both ground cables from the gearbox.
|
|
| 44. |
Lower the car to the floor.
|
|
| 45. |
Remove the starter motor cable clamp and remove the stay.
|
|
| 46. |
Remove the bolts and nuts from the left engine pad and lift off the pad.
|
|
| 47. |
Lower the unit so that the gearbox goes clear from the structural member.
|
|
| 48. |
Remove the gearbox mounting from the gearbox.
|
|
| 49. |
Raise the car.
|
|
| 50. |
Fit
87 92 608 Holder for single-column lift
to a single-column jack.
|
|
| 51. |
Connect the lifting tool to the gearbox, adjust the lifting tool so its centre is aligned with the centre of the gearbox and mounting face.
|
|
| 52. |
Remove the last 2 bolts between the engine and gearbox.
|
|
| 53. |
Pull out and lower the gearbox.
|
|||||||||
Warning
| 54. |
Lift the gearbox from the jack and remove the lifting tool from the gearbox.
|
|
