PRE-RELEASE
To remove
| To remove |
| Important | ||
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Wiring, hoses, lines etc. are attached with hard plastic ties. After tightening, the ends are cut which leads to sharp edges remaining at the fixing point. Beware of the risk of cutting injuries from sharp ends of cable ties. |
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| 1. |
Place the car on a lift.
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| 2. |
Fit wing covers to prevent paint damage and soiling of the wings.
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| 3. |
Remove the cover over the intake manifold.
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| 4. |
Remove the plastic cover on the battery.
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| 5. |
Undo the battery connections.
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| 6. |
Remove the battery and tray.
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| 7. |
Remove the electrical unit.
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| 8. |
Select 4th gear and remove the plastic plug from the gearbox.
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| 9. |
Lock in 4th at the gearbox by inserting
87 92 335 Lock pin
.
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| 10. |
Release the clamp above which holds the selector rod in the gearbox linkage.
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| 11. |
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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| 12. |
Prevent brake fluid draining from the reservoir by pressing the clutch pedal down around 50 mm using a brake clamp, or block the brake fluid hose using
30 07 739 Hose pinch-off pliers
.
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| 13. |
Remove the locking clip at the slave cylinder and release the connection to the pressure pipe. Refit the locking clip.
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| 14. |
Detach the electrical connection to the reversing light.
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| 15. |
Remove the 3 top bolts to the gearbox and stay.
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| 16. |
Detach the electrical connection(s) to the oxygen sensor.
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| 17. |
Separate the gearbox linkage at the gearbox. Retain the shim.
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| 18. |
Remove the nuts on the rear engine mounting.
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| 19. |
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
82 93 102 Extension, 500 mm, 3/8 square
. Leave the bolts in place.
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| 20. |
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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| 21. |
Lift the car.
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| 22. |
Remove the front wheel.
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| 23. |
Remove the covers at the front and below the bumper. Remove the fixings for the headlamp position sensor (optional) and move the sensor aside.
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| 24. |
Remove the front exhaust system by first releasing the flange to the turbo and then removing the rear fixing. It is important to lower the exhaust system in this way otherwise the flexible section could be damaged. Also be careful of the oxygen sensors.
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| 25. |
Remove the stay between the engine mount and the engine.
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| 26. |
Remove the rear engine mount and cushion. The gearbox linkage should follow.
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| 27. |
Remove the bolt holding the front torque rod to the subframe.
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| 28. |
Remove the bolts holding the steering gear.
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| 29. |
Release the clamps holding the power steering pipe to the subframe.
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| 30. |
Release the air filter housing from the subframe.
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| 31. |
Release the AC pipe from the plastic clips on the subframe.
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| 32. |
Remove the engine oil cooler from the charge air cooler (2 screws).
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| 33. |
Pull a
83 95 212 Strap
around the radiator core and radiator bar to keep the core supported.
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| 34. |
Remove the bolts holding the outer ball couplings to the steering swivel member on both sides.
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| 35. |
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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| 36. |
Remove the protective plate behind the flywheel.
B235R: Remove the bolts between the gearbox and the oil sump, and the bolts to the protective plate. 
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| 37. |
Remove the 4 bolts holding the rear supporting plate and the 2 at the rear to the subframe.
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| 38. |
Place a trolley lift below the subframe. Trolley 83 94 793,
83 94 801 Parent fixture
, adjustment feet 83 95 170, base fixture 83 95 188 and mounting fixture 83 95 196.
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| 39. |
Remove the 4 remaining bolts holding the subframe.
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| 40. |
Lower the subframe and move aside. At the same time, remove the front fixings (2 x) for the power steering pipe.
Suspend the oil cooler in a bolt so that it is not in the way during the work. |
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| 41. |
Drain the gearbox oil.
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| 42. |
Release the left drive shaft using
87 92 616 Removal tool, drive shafts
. Suspend the shaft with a cable tie.
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| 43. |
Release the two ground leads from the gearbox.
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| 44. |
Lower the car to the floor.
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| 45. |
Remove the starter motor cable clamps and remove the stay.
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| 46. |
Remove the bolts and nuts from the left engine cushion and remove the cushion.
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| 47. |
Lower the assembly so that the gearbox is clear of the structural member.
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| 48. |
Remove the gearbox fixing from the gearbox.
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| 49. |
Raise the car.
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| 50. |
Fit
87 92 608 Holder for single-column lift
on a single column jack.
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| 51. |
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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| 52. |
Remove the last 2 bolts between engine and gearbox.
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| 53. |
Twist and lower the gearbox.
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Warning
| 54. |
Lift the gearbox off the jack and remove the lifting tool from the gearbox.
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