Removing the gearbox, 4-cyl. diesel
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Removing the gearbox, 4-cyl. diesel
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Warning
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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 ties.
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1.
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Place the car on a lift.
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2.
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Fit wing covers to prevent paint damage and soiling of the wings.
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3.
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Remove the upper engine cover.
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4.
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Remove the plastic cover on the battery. Undo the battery connections.
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5.
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Remove the battery. Detach and move aside the maxi fuse holder and remove the battery tray.
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6.
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Release the cable tie, remove the electrical unit and move aside.
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7.
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Lock in 4th at the gearbox by removing the plastic plug and inserting
87 92 335 Lock pin
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8.
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Release the clamp which holds the selector rod in the gearbox linkage.
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9.
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Lift the gaiter. Select 3rd gear so that the selector rod comes out of the linkage, and insert
87 92 335 Lock pin
in the selector rod housing.
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11.
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Remove the locking clip at the slave cylinder and release the connection to the pressure pipe. Refit the locking clip.
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12.
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Release the connector to the reversing light switch.
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13.
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Remove the 3 top bolts to the gearbox and stay.
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14.
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Separate the gearbox linkage at the gearbox.
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15.
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Remove the nuts on the rear engine mount. Loosen the 3 bolts holding the rear engine mount using a long 10 mm socket, an extension with ball (e.g. 30 17 613) and
Extension, 500 mm, 3/8 square
82 93 102. Leave the bolts in place.
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16.
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Remove the front exhaust pipe nuts.
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17.
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Relieve the load on the engine and gearbox with
83 94 850 Lifting beam
. Place the yoke on the wheelarch so it lies against the wing edges and near the wing fixing bolts.
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18.
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Lift the car. Remove the front wheels.
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19.
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Remove the two lower engine covers and side covers in the wheelarches.
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20.
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Remove the headlamp position sensor (option) and move the sensor aside.
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21.
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Remove the front exhaust pipe with catalytic converter.
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22.
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Remove the bolt holding the front torque rod to the subframe.
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23.
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Release the clamps holding the power steering pipe.
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24.
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Remove the nuts for the power steering cooling pipe.
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25.
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Release the air filter housing from the subframe.
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26.
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Release the AC pipe from the plastic clips on the subframe.
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27.
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Pull a
83 95 212 Strap
around the radiator core and radiator bar to keep the core supported.
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28.
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Remove the bolts holding the outer ball couplings to the steering swivel member on both sides.
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29.
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On both sides release the upper ball coupling to the anti-roll bar. Hold in place with an open 17 mm wrench so that the boot does not twist. If the wrench is too wide to fit between the boot and the spring strut, grind it down.
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30.
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Remove the 4 screws holding the rear supporting plate and 2 rear screws to subframe.
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32.
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Remove the 4 remaining bolts holding the subframe.
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34.
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Lower the subframe slightly and release the steering gear.
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35.
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Release the suspension arm from the steering swivel member, lower further and roll the trolley lift away with subframe.
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36.
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Remove the gearbox oil level plug and drain plug, drain the gearbox oil. Refit the drain plug.
Tightening torque: 50 Nm (37 lbf ft)
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37.
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Remove the rear engine mount and cushion. The gearbox linkage should follow. Retain the shim.
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38.
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Remove the rear bolts to the gearbox.
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40.
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Release the two ground leads from the gearbox.
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41.
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Lower the car. Remove the bolts and nuts from the left engine cushion and remove the cushion.
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42.
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Lower the assembly so that the gearbox is clear of the structural member. Remove the gearbox fixing from the gearbox.
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43.
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Raise the car. Fit
87 92 608 Holder for single-column lift
on a single column jack. Connect the lifting tool to the gearbox, adjust the lifting tool so that its centre is in line with the gearbox centre and splitting plane.
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44.
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Remove the other bolts between the engine and gearbox. Remove and lower the gearbox.
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Warning
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Be careful that the jack does not tip over.
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45.
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Lift the gearbox off the jack and remove the lifting tool from the gearbox.
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