Complete transmission, 4 cyl. diesel
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Complete transmission, 4 cyl. diesel
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1.
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Place drapes over the wings and front to keep the paintwork clean and to protect it from damage.
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2.
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Remove the upper engine cover.
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3.
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Remove the battery cover and the battery.
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4.
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Remove the MAXI fuse board and remove the battery tray.
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5.
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Undo the main fuse box and move it aside. Use
83 95 212 Strap
. Undo the cable clip from the main fuse box mounting.
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6.
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Undo the transmission connector and remove the cable clip.
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7.
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Remove the breather hose from the transmission.
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8.
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Remove the selector lever cable from the selector lever.
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9.
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Remove the locking clip and carefully bend in the selector cable locking tabs with a suitable screwdriver. Remove the cable from the mounting.
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10.
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Remove the cable clamp from the starter motor cable.
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11.
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Remove the vacuum tank together with the mounting bracket.
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12.
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Remove the left-hand heat shield over the exhaust manifold.
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14.
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Clean around the dipstick tube where it enters the transmission. Remove the dipstick tube and plug the hole.
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15.
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Remove the nuts from the exhaust pipe.
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17.
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Undo the two bolts which hold the rear engine pad. Do not remove the bolts. The third bolt is removed from underneath.
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18.
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Position
83 94 850 Lifting beam
in place on the engine. Relieve the weight of the engine and transmission.
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20.
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Raise the vehicle and remove the front wheels.
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21.
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Remove the lower engine cover, the spoiler shield and both side covers.
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22.
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Remove the front exhaust system.
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23.
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Remove the rear engine bracket and the engine pad.
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24.
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Remove the two clamps securing the power steering delivery pipe to the subframe.
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25.
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At the same time free the AC pipes from the plastic clips on the subframe.
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26.
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Detach the power steering cooling pipe. Hang up the pipe with a cable tie or something similar.
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27.
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Remove the air cleaner casing from the subframe.
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28.
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Fit a
83 95 212 Strap
around the radiator core and the radiator crossmember.
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29.
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Remove the bolts securing the outer ball joints to the steering swivel member on both sides.
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30.
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Undo the upper anti-roll bar ball joint. Hold with a 17 mm spanner so that the boot does not twist. If the spanner is too wide to fit between the boot and the suspension strut, it must be ground narrower.
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31.
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Undo the nut on the coolant pipe holder and remove the front bolt on the torque arm.
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32.
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Remove the rear support plates.
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34.
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Place the lifting trolley with lifting table and holder under the subframe. Lift up the lifting table, be careful to position it correctly. Push aside the battery cooling pipe sufficiently to avoid the trolley guide pin.
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35.
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Remove the last 4 bolts securing the subframe. Lower the subframe slightly and detach the steering gear.
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36.
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Detach the suspension arms from the steering swivel member, lower the subframe and remove the lifting trolley.
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37.
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Remove the starter motor heat shield.
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38.
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Detach the starter motor electrical connections and remove the starter motor.
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39.
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Undo the 3 bolts securing the torque converter to the drive plate. Rotate the engine in the normal rotational direction using the drive belt pulley.
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40.
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Remove the remaining bolts holding the transmission except for one which must remain to hold the transmission in place. Remove the rubber plug and press the torque converter towards the transmission and fit
87 92 574 Holder
to keep the torque converter in place while the transmission is removed. The torque converter may need to be rotated slightly in order to fit the holder.
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41.
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Disconnect the ground leads.
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42.
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Remove the torque arm together with the bracket.
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43.
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Drain the transmission fluid, fit the drain plug with a new sealing washer.
Tightening torque 40 Nm (30 lbf ft)
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44.
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Disconnect the oil cooler inlet and outlet hoses. Plug the inlet and outlet passages on the transmission and also plug the hoses. Use plug no. (10) 91 32 929 and seal no. (10) 91 32 937.
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47.
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Lower the vehicle and remove the left-hand engine pad.
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48.
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Lower the unit about 70 mm measured at the transmission mounting bracket. Remove the mounting bracket from the transmission.
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49.
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Raise the vehicle, fit
87 92 608 Holder for pillar jack
on a pillar jack. Adjust and secure the holder to the transmission as shown in the illustration. Use a bolt that is approx. 20 mm longer than that removed and a nut and bolt for the rear lifting eye.
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50.
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Remove the remaining bolts securing the transmission to the engine.
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51.
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Pull out and lower the transmission casing.
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Important
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The pillar-type jack may tip over. Exercise care.
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52.
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Lift down the gearbox from the pillar jack using an engine hoist and
87 92 442 Lifting cable
while removing the lifting tool from the transmission.
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When fitting a new transmission, transfer the holder for the torque converter from the new transmission to the old one.
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1.
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Turn the torque converter so that the bolt holes line up with the holes in the drive plate. Fit
87 92 574 Holder
to keep the torque converter in place while fitting.
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5.
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Secure the tool to the transmission as described for removal.
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Important
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The pillar-type jack may tip over. Exercise care.
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7.
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Place the transmission in position.
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Important
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Push the transmission into place until approx. 20 mm remains and then remove tool 83 95 162.
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8.
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Remove the
87 92 574 Holder
that is keeping the torque converter in place and press the converter against the drive plate. Fit the plug.
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9.
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Tighten the bottom bolts between the engine and the transmission.
Tightening torque, M12, 70 Nm (51 lbf ft)
Tightening torque, M10, 40 Nm (30 lbf ft)
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10.
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Remove the lifting tool from the transmission and move aside the jack. Refit the transmission bolts.
Tightening torque 24 Nm (18 lbf ft)
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11.
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Lower the car and fit the engine pad mounting on the gearbox.
Tightening torque 60 Nm + 60° (44 lbf ft + 60°)
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12.
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Raise the power train. Do not lift higher than necessary as this could make fitting to the subframe more difficult. Fit the bolts securing the engine pad to the body.
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Note
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One of the rear bolts is shorter in order not to screw into the bottom of the hole. Ensure that the bolt holes are as close as possible to the centre of the engine pad holes without tensioning the engine pad.
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Tightening torque, bolt with loose washer 63 Nm (46 lbf ft)
Tightening torque, bolt with captive washer 40 Nm + 30° (30 lbf ft + 30°)
Tightening torque, nut 84 Nm (62 lbf ft)
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13.
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Lower the engine assembly so that it is almost hanging free in the lifting beam.
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15.
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Make sure that the drive shaft is clean and then align it with the tool.
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Important
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Insert all but 20 mm of the drive shaft in the transmission and then withdraw the tool before the shaft's sealing surface reaches the shaft seal.
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16.
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Push in the rest of the shaft until the circlip clicks in. Fit the ABS cable and brake pipe into the clips.
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17.
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Raise the car and apply
74 96 268 Thread locking adhesive
to the bolts that secure the torque converter to the drive plate.
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Note
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Use the original bolts and their washers. If excessively long bolts are fitted, the torque converter will be damaged.
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18.
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Fit the 3 bolts without tightening them. Rotate the engine in the normal rotational direction using the drive belt pulley.
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19.
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Tighten them when they are all fitted in place.
Tightening torque 60 Nm (44 lbf ft)
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20.
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Fit the lower starter motor bolt and the starter motor bracket. Screw on the heat shield nut loosely.
Tightening torque 20 Nm (15 lbf ft)
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21.
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Re-connect the starter motor connections.
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22.
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Fit the starter motor heat shield and tighten the nut.
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23.
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Fit the oil cooler hoses. The hoses should be horizontal so that they do not chafe against the subframe. Use new seals greased with petroleum jelly.
Tightening torque 27 Nm (20 lbf ft)
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24.
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Fit the bracket for the torque arm on the transmission.
Tightening torque 47 Nm (35 lbf ft)
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25.
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Connect the ground cable to the bracket and to the transmission.
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26.
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Place the subframe on the lifting trolley, lubricate the rubber bushes for the radiator core studs with vaseline and raise the subframe slightly.
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27.
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Lift up the subframe, whilst guiding it into place with the help of the pins on the holder. Fit and tighten the steering gearbox bolts before the subframe is fully lifted. At the same time guide in:
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The radiator core's studs
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The power steering pipe
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Outer ball joints
Tightening torque, steering gearbox 90 Nm (66 lbf ft)
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28.
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Fit the bolts to the subframe and fit the rear support plates. Adjust the subframe so that the guide pins on the holder are aligned with the holes in the body before tightening the bolts. Remove the lifting trolley before tightening the bolts.
Tightening torque, subframe bolts 100 Nm + 45° (74 lbf ft + 45°)
Tightening torque, support plate bolts 60 Nm (44 lbf ft)
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Note
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The centre bolts on the subframe must not be mixed up with the other bolts. The centre bolts have smaller washers and 20 mm heads.
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Note
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Make sure that the transmission's oil cooler hoses do not rest against the subframe.
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29.
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Fit the bolts securing the outer ball joint to the steering swivel member. Tighten the nut.
Tightening torque 50 Nm (37 lbf ft)
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Important
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Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.
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30.
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Tighten the anti-roll bar link. If the spanner is too wide to fit between the boot and the suspension strut, it must be ground narrower.
Tightening torque 92 Nm (68 lbf ft)
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31.
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Assemble the air filter housing nuts to the subframe. Remove the strap round the radiator core. Attach the power steering cooling pipe.
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32.
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Fit the battery cooling pipe nut.
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33.
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Fit the rear engine pad and position the bolts. Lower the vehicle and tighten the pad bolts from above.
Tightening torque 24 Nm (18 lbf ft)
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34.
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Check that the upper radiator core locating pins are correctly positioned with respect to the core and the radiator crossmember.
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35.
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Lift the vehicle and fit the engine bracket to the transmission.
Tightening torque 60 Nm + 60°(44 lbf ft +60°)
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36.
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Tighten the torque arm on the subframe.
Tightening torque 90 Nm + 90°(66 lbf ft +90°)
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37.
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Fit the coolant pipe nut to the torque arm.
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38.
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Fit the front exhaust system. Lubricate studs with
90 513 210 Universal paste
. Put on the front nuts and tighten the rear ones.
Tightening torque 25 Nm (18 lbf ft)
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39.
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Raise the car, lower the engine, and remove the lifting beam.
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40.
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Tighten the exhaust pipe nuts.
Tightening torque 24 Nm (18 lbf ft)
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41.
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Shake the unit to ensure there is no tension in the engine pads. Tighten the rear engine pad nuts.
Tightening torque 47 Nm (35 lbf ft)
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42.
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Fit the bolts securing the transmission to the engine and tighten them.
Tightening torque 70 Nm (52 lbf ft)
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43.
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Fit the exhaust manifold heat shield.
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44.
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Remove the bolts holding the starter motor wiring harness.
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45.
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Fit the vacuum tank together with the hose.
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46.
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Fit the upper engine cover.
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47.
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Fit the transmission's breather hose.
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48.
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Fit the selector cable to the bracket on the transmission. Fit the clamp and attach the cable to the selector lever.
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50.
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Clean and fit the dipstick tube. Lubricate the O-ring with acid free vaseline.
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51.
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Fit the transmission wiring harness clip and connect the connector.
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52.
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Fit the main fuse box.
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53.
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Refit the battery tray, Maxi fuse board, battery, and battery cover.
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54.
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Raise the car. Slacken the bolt securing the front torque arm and centre the rubber pad in the arm. Tighten the bolt.
Tightening torque 50 Nm + 120° (37 lbf ft + 120°)
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55.
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Fit the spoiler shield, the drive belt system cover, the left-hand side cover and the lower engine cover.
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58.
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If the transmission has been changed and the oil is contaminated
87 91 824 Flushing equipment
must be connected before starting the vehicle.
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59.
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Test drive the car with varying engine loads and rpm and delete any diagnostic trouble codes. Also check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
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