Complete gearbox, Z19 DT/DTH
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Complete gearbox, Z19 DT/DTH
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1.
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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.
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2.
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Remove the upper engine cover and insulation.
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3.
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Remove the battery cover.
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4.
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Disconnect the battery terminals and remove the battery. Undo the cable clamp under the battery tray.
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5.
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Remove the glow plug relay and fuse holder from the battery tray.
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6.
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Disconnect the bonnet switch.
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7.
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Remove the battery tray.
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8.
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Unplug the connector for the reversing light switch.
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9.
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Remove the gear cables from the gearbox by pulling the locking sleeves back.
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10.
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Lift up the cables from the levers.
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12.
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Remove the upper bolts from the gearbox.
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13.
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Remove the upper bolt closest to the cylinder block from the starter motor.
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15.
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Undo the upper bumper shell mountings.
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16.
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Suspend two
83 95 212 Strap
in place above the radiator core so they are accessible from below.
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18.
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Remove the front wheels.
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20.
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Secure the radiator core with the straps.
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21.
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Remove the front section of the exhaust pipe.
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22.
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Remove the engine torque rod from the subframe.
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23.
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Remove the bolt and nut holding the suspension arm to the steering swivel member on both sides.
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25.
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Detach the anti-roll bar from the link arm.
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26.
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Unplug the connector and detach the cable clip of the headlamp angle sensor (option)
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27.
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Remove the steering wheel shaft from the steering gear.
Warning
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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.
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28.
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Remove the electrical connections from the EHPS unit and undo the cable tie.
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29.
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Remove the front cover on the left-hand side. Detach the front section of the wing liner and bend it aside slightly.
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31.
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Remove the subframe bolts and the rear brackets.
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32.
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Lower the subframe slightly.
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33.
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Pull out the steering arm ball joints from the steering swivel members.
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35.
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Remove the front catalytic converter bracket.
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36.
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Remove the torque rod brackets from the gearbox.
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37.
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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)
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38.
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Remove the engine oil filter cab to enable access to the gearbox bolts.
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39.
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Remove the lower bolts from the gearbox. Use
87 92 723 Access tool
. Allow one slackened bolt to remain in place.
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40.
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Remove the ground lead and starter motor bolts.
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43.
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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.
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44.
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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.
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45.
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Fit
87 92 608 Holder
onto a column jack. Adjust and fasten the tool in the gearbox as illustrated. Use the M12 holes for the torque rods.
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46.
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Remove the last bolt, pull out the transmission and lower it.
Important
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The jack can tip over. Be careful.
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47.
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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.
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2.
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Lubricate the primary shaft splines, see List of lubricants and sealants.
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3.
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Lubricate the guide sleeves on the engine with anti-corrosion agent.
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4.
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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
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Always replace the shaft seals in the gearbox. Lubricate with gearbox oil.
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5.
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Fit the gearbox with the lifting tool on the column jack.
Important
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Make sure the gear cables are positioned correctly when lifting the gearbox.
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Important
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Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.
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6.
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Push in the rest of the gearbox. Turn the crankshaft if necessary to get the gearbox in place.
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7.
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Tighten all bolts except the topmost between the engine and gearbox in the sequence illustrated.
Tightening torque, M10 bolts 40 Nm (30 lbf ft)
Tightening torque, M12 bolts 60 Nm (44 lbf ft)
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8.
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Thread the starter motor bolts.
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9.
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Remove the lifting tool from the gearbox and move away the jack.
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10.
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Lower the car to the floor.
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11.
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Lift the powertrain into place with the lifting beam until it meets the engine mounting.
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12.
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Fit the bracket for the engine mounting according to the marks made earlier.
Tightening torque 70 Nm +45° (52 lbf ft +45°)
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13.
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Remove the lifting beam.
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14.
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Fit the upper bolt to the starter motor.
Tightening torque 24 Nm (18 lbf ft)
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15.
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Fit the upper bolts for the gearbox and the wiring harness bracket.
Tightening torque 60 Nm (44 lbf ft)
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17.
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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
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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.
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18.
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Push in the rest of the drive shaft into the gearbox until the circlip clicks in.
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19.
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Attach the ABS cable to the clip.
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20.
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Tighten the lower bolt on the starter motor.
Tightening torque 24 Nm (18 lbf ft)
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21.
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Fit the ground cable.
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22.
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Fit the oil filter cap.
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23.
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Fit the bracket for the front catalytic converter.
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24.
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Fit the torque rod brackets on the gearbox.
Tightening torque 80 Nm (59 lbf ft)
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25.
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Position the subframe using the fixture.
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26.
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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.
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27.
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Guide the radiator assembly into the brackets.
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28.
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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°)
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29.
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Fit the anti-roll bar link arms.
Tightening torque 64 Nm (47 lbf ft)
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30.
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Fit the track rod ends.
Tightening torque 32 Nm (24 lbf ft)
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31.
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Connect the connector and the cable clip to the headlamp angle sensor (optional).
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32.
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Move away the trolley lift and jig.
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33.
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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)
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35.
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Remove the straps.
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36.
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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)
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37.
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Plug the connector into EHPS and secure the wiring in the clip.
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40.
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Fit the front cover and the front section of the wing liner.
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41.
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Plug in the connector. Fit the front spoiler shield. Fit the lower engine cover.
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43.
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Lower the car and fit the bumper shell upper mountings.
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44.
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Check that the upper radiator guides engage their brackets.
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45.
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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.
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47.
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Attach the gear cables to the gearbox.
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49.
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Plug in the reversing light switch.
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50.
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Remove the oil filler plug and fill with 2.2 l of oil. See List of lubricants and sealants. Fit the plug.
Tightening torque 45 Nm (33 lbf ft)
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51.
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Fit the battery tray and the bonnet switch connector.
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52.
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Fit the cable clamp under the battery tray.
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53.
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Fit the glow plug relay and fuse holder.
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55.
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Fit the battery cover.
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56.
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Fit the insulation and upper engine cover.
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57.
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Remove the wing covers.
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59.
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Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
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