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Gearbox assembly, Z19

Gearbox assembly, Z19

To remove


1. Take the key out of the ignition and turn the wheels straight ahead. Protect the paintwork on the wings and front from damage and dirt.

2. Remove the upper engine cover.


3. Remove the battery cover.

4. Disconnect the battery terminals and remove the battery. Undo the cable clamp under the battery tray.

5. Remove the glow plug relay and fuse holder from the battery tray.


6. Disconnect the bonnet switch.

7. Remove the battery tray.

8. Unplug the connector for the reversing light switch.


9. Remove the gear cables from the gearbox by pulling the locking sleeves back.

10. Lift up the cables from the levers.

11. Fit 30 07 739 Hose pinch-off pliers to the clutch hose and undo the quick-release coupling from the clutch slave cylinder.


12. Remove the upper bolts from the gearbox.


13. Remove the upper bolt closest to the cylinder block from the starter motor.


14. Fit 83 94 850 Lifting beam . Z19 DT: Use 32 025 037 Hook, 83 96 178 Lifting eyes, B207 and 83 95 287 Holder . Place an M12 nut between. Z19DTH: On engines without lifting eye on the camshaft housing, first disconnect the pressure sensor and fit 32 025 020 Lifting eye. Take the strain off the engine and gearbox.


15. Undo the upper bumper shell mountings.


16. Suspend two 83 95 212 Strap in place above the radiator core so they are accessible from below.

17. Raise the car.

18. Remove the front wheels.

19. Remove the lower engine cover and the front spoiler shield and unplug the connector.


20. Secure the radiator core with the straps.


21. Remove the front section of the exhaust pipe.


22. Remove the engine torque rod from the subframe.

23. Remove the bolt and nut holding the suspension arm to the steering swivel member on both sides.

24. Remove the track rod end from the steering swivel member. Use 87 91 287 Puller, 150 mm .


25. Detach the anti-roll bar from the link arm.

26. Unplug the connector and detach the cable clip of the headlamp angle sensor (option)

27. Remove the steering wheel shaft from the steering gear.

Warning

In order to avoid the contact roller for the airbag twisting and breaking the steering wheel must be secured via the steering column lock or by taping it to the panel.



28. Remove the electrical connections from the EHPS unit and undo the cable tie.


29. Remove the front cover on the left-hand side. Detach the front section of the wing liner and bend it aside slightly.


30. Place 83 95 311 Trolley lift , 83 94 801 Parent fixture , 83 95 188 Basic fixture , 83 95 170 Adapter (4 pcs) and 83 96 137 Centring tool, subframe - body under the vehicle. Position the locating pins and adjust the height of the adapters for even pressure.


31. Remove the subframe bolts and the rear brackets.

32. Lower the subframe slightly.

33. Pull out the steering arm ball joints from the steering swivel members.

34. Lower the subframe.

35. Remove the front catalytic converter bracket.


36. Remove the torque rod brackets from the gearbox.

37. Place a receptacle under the car, remove the drain plug. Drain the gearbox oil. Refit the drain plug.

Tightening torque 50 Nm (37 lbf ft)

38. Remove the engine oil filter cab to enable access to the gearbox bolts.


39. Remove the lower bolts from the gearbox. Use 87 92 723 Access tool . Allow one slackened bolt to remain in place.

40. Remove the ground lead and starter motor bolts.

41. Detach the ABS cable from the clip using a screwdriver and undo the left-hand drive shaft using 87 92 616 Removal tool, drive shafts .


42. Suspend the shaft with a 83 95 212 Strap .

43. Lower the car, mark the positions of the bolts on the left-hand engine bracket with a marker pen for correct refitting and then remove the bolts from the mounting.


44. Lower the drive unit approx. 70 mm from the lifting beam to facilitate the removal of the gearbox. Measure the distance at the left-hand engine mounting.

45. Fit 87 92 608 Holder onto a column jack. Adjust and secure the tool in the transmission as illustrated. Use bolts of 8.8 grade that are about 20 mm longer than the bolts that were removed.


46. Remove the last bolt, pull out the transmission and lower it.


Important

The jack can tip over. Be careful.


47. Lift the transmission down from the column jack with an engine lift and 87 92 442 Lifting cable while undoing the lifting tool from the transmission.

48. Plug the holes for the drive shafts with 87 92 665 Protective plug, drive shaft hole if the gearbox is to be transported any distance.


To fit


1. If necessary, perform the procedure Bleeding the slave cylinder .

2. Lubricate the primary shaft splines, see Summary of lubricants and sealants .

3. Lubricate the guide sleeves on the engine with anti-corrosion agent.

4. Fit 83 95 162 Protective collar, drive shafts in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.

Important

Always replace the shaft seals in the gearbox. Lubricate with gearbox oil.


5. Fit the gearbox with the lifting tool on the column jack.

Important

Make sure the gear cables are positioned correctly when lifting the gearbox.


Important

Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.


6. Push in the rest of the gearbox. Turn the crankshaft if necessary to get the gearbox in place.

7. Tighten all bolts except the top one between the engine and the gearbox.

Tightening torque, M10 bolts 40 Nm (30 lbf ft)

Tightening torque, M12 bolts 60 Nm (44 lbf ft)


8. Thread the starter motor bolts.

9. Remove the lifting tool from the gearbox and move away the jack.

10. Refit the gearbox bolts.

Tightening torque 24 Nm (18 lbf ft)

11. Lower the car. Lift in place the power train with the lifting beam until it meets the engine mounting.

12. Fit the bracket for the engine mounting according to the marks made earlier.

Tightening torque 70 Nm +45° (52 lbf ft +45°)


13. Remove the lifting beam.

14. Fit the upper bolt to the starter motor.

Tightening torque 24 Nm (18 lbf ft)


15. Fit the upper bolts for the gearbox and the wiring harness bracket.

Tightening torque 60 Nm (44 lbf ft)


16. Raise the car.

17. Fit 83 95 162 Protective collar, drive shafts in the left drive shaft seal. Remove the strap. Make sure that the drive shaft is clean, lubricate it and then align it with the tool.

Important

Fit the driver in the gearbox until approx.20 mm are remaining and pull out the tool before the sealing surface of the shaft reaches the shaft seal.



18. Push in the rest of the drive shaft into the gearbox until the circlip clicks in.

19. Attach the ABS cable to the clip.

20. Tighten the lower bolt on the starter motor.

Tightening torque 24 Nm (18 lbf ft)


21. Fit the ground cable.

22. Fit the oil filter cap.

23. Fit the bracket for the front catalytic converter.


24. Fit the torque rod brackets on the gearbox.

Tightening torque 80 Nm (59 lbf ft)

25. Position the subframe using the fixture.

26. Fit the suspension arm ball joints to the steering swivel member.

Tightening torque 50 Nm (37 lbf ft)

Press up the pin carefully.

The groove in the pin should be visible in the bolt hole in the swivel member.

If the rubber gaiter is pressed down, it will not seal properly against the swivel pin.


27. Guide the radiator assembly into the brackets.

28. Check that the guide pins fit into the reference holes, adjust the subframe until the guide pins go in easily and fit the subframe bolts and brackets.

Tightening torque, subframe: 75 Nm +135° (55 lbf ft +135°)

Tightening torque, rear bracket bolts: 90 Nm +45° (66 lbf ft +45°)


29. Fit the anti-roll bar link arms.

Tightening torque 64 Nm (47 lbf ft)

30. Fit the track rod ends.

Tightening torque 32 Nm (24 lbf ft)

31. Connect the connector and the cable clip to the headlamp angle sensor (optional).


32. Move away the trolley lift and jig.

33. Fit the torque rods to the subframe.

Tightening torque, front 60 Nm +90° (52 lbf ft +90°)

Tightening torque, rear 80 Nm (59 lbf ft)


34. Assemble 83 96 145 Centring fixture, subframe - engine with 83 96 368 Additional kit for centring fixture . Check that the engine is positioned correctly relative to the subframe. Remove the centring tool.

35. Remove the straps.


36. Fit the steering shaft joint to the steering gear. Clean the threads. Apply 74 96 292 Threadlock to the threads.

Tightening torque 30 Nm (22 lbf ft)


37. Plug the connector into EHPS and secure the wiring in the clip.


38. Fit the front pipe. Grease the threads with 30 20 971 Screw-thread paste .

Tightening torque: 25 Nm (18 lbf ft)


39. Fit the bracket to the oil sump.

Tightening torque 19 Nm (14 lbf ft)

40. Fit the front cover and the front section of the wing liner.


41. Plug in the connector. Fit the front spoiler shield. Fit the lower engine cover.


42. Fit the front wheels .

43. Lower the car and fit the bumper shell upper mountings.


44. Check that the upper radiator guides engage their brackets.

45. Fit the quick-release coupling to the clutch slave cylinder. Remove the hose pinch-off pliers. Make sure the connection is secured in the correct position.


46. Bleed the clutch. See Bleeding the clutch hydraulic system in the car .

47. Attach the gear cables to the gearbox.


48. Check the gear positions and adjust if necessary as described under Adjusting gear cables, 6-speed .

49. Plug in the reversing light switch.

50. Remove the oil filler plug and fill with 2.4 l of oil. See Summary of lubricants and sealants . Fit the plug.

Tightening torque 45 Nm (33 lbf ft)

51. Fit the battery tray and the bonnet switch connector.


52. Fit the cable clamp under the battery tray.

53. Fit the glow plug relay and fuse holder.

54. Fit the battery.

55. Fit the battery cover.

56. Fit the upper engine cover.

57. Remove the wing covers.

58. Carry out Measures after disconnecting the battery .

59. Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.