To Remove

IMPORTANT: Cables, hoses, leads etc.. are secured with hard plastic cable ties. After being tightened, the ends are cut off, leaving sharp edges the fixing points. Be aware of the risk of injury due to these sharp ends of cable tie.

1. Place the car on a lift.
2. Place wing protectors over the wings to prevent soiling and damage to the paintwork.





3. Remove the cover over the intake manifold or resonator with hoses and mass air flow sensor.
4. Detach the battery leads from the battery.
5. Remove the battery.





6. Engage 4th gear and remove the plastic plug from the gearbox. Lock 4th gear in the gearbox by fitting locking pin 87 92 335
7. Loosen the clamp securing the selector rod to the linkage in the gearbox from above.





8. Lift up the selector lever gaiter. Engage 3rd gear so that the selector rod disengages from the linkage and fit locking pin 87 92 335 in the gear lever housing.
9. Depress the clutch pedal about 50 mm with a brake bracket. This prevents the brake fluid from flowing out of the reservoir.





10. Remove the locking clip on the slave cylinder and disconnect the delivery pipe.





11. Unplug the connector for the reversing lights.
12. Disconnect the positive cable on the battery.
13. Remove the 3 upper gearbox bolts.





14. Unplug the connector(so) to the oxygen sensor and release them from the clamps.
15. Slightly lift the engine and gearbox with lifting beam 83 94 850. Position the beam on the wheel housings so that it is up against the wing edges.
16. Raise the car.
17. Remove the front wheels.
18. Remove any clamps on the oxygen sensor cable.





19. Remove the front exhaust system by first undoing the flange on the turbo and then undoing the rear mounting. It is important that the exhaust system is removed in this way as the flexible bellows may other wise be damaged. Be also careful with the oxygen sensor(so).
20. Remove the air shields and cover in the right-hand wheel housing.





21. Remove the end piece, suspension arm on both sides. Use puller 89 96 696.
22. Remove the two nuts on the rear engine mounting and the two centre bolts on the subframe.
23. Position complete lifting trolley with front and rear holders with parent fixture 83 94 801 under the subframe. Raise the lifting trolley against the subframe.
24. Remove the remaining bolts securing the subframe. There are washers on the rear mountings, take care of them.
25. Lower the trolley lift and push it to one side.





26. Remove the oil drain plug and drain the oil from the gearbox. Screw in the drain plug again.
Tightening torque: 50 Nm (37 ft. lbs.)





27. Pull out the left drive shaft with removing tool for drive shafts 89 96 654. Suspend the shaft with a strap 83 95 212 and fit plastic plugs 87 92 244 in the gearbox.





28. Remove the splash plate by the flywheel.
29. Disconnect the ground leads from the gearbox.
30. Undo the bolts in the engine/gearbox mating face that are accessible from below with the exception of the front one.
31. Undo the two left-hand engine mounting bolts from the body.
32. Remove the mounting from the gearbox.
33. Lower the car and lower the whole drive unit approx. 5 cm.





34. Raise the car and fit lifting tool 87 92 608 on a pillar-type jack.





35. Lifting tool 87 92 608 seen from the side.
36. Adjust the lifting tool so that it is centered in line with the gearbox centre and mating face. Connect the lifting tool to the gearbox.
37. Remove the last bolt between the engine and the gearbox.





38. Remove the rear engine mounting bracket from the gearbox. (new version in M-99)
39. Pull out and lower the gearbox.

WARNING: Take care not to tip the jack.

40. Lift the gearbox from the pillar jack with and engine lift and undo the lifting tool from the gearbox.