Removal and Installation

To Remove





1. Place drapes over the wings to keep the paintwork clean and protect it from damage.
2. Remove the grille.





3. Remove the cover from the intake manifold.
4. Remove the battery cover, battery and battery tray.
5. Unplug the 16-pin and 1O-pin connectors. The connectors are mounted in a holder.





6. Remove the breather hose from the gearbox.
The hose is positioned differently depending on engine variant.
7. Remove the gear selector arm from the gearbox. The selector lever must be in position
8. Remove the clamp and press out the shifting cable, using a suitable screwdriver.
9. V6: Detach the cable channel from the engine and gearcase.
10. Remove the three upper bolts on the gearbox.
11. Clean the area round the dipstick tube where it enters the gearbox.
12. Remove the dipstick tube and plug the hole.





13. Unplug the oxygen sensor connectors.
14. Remove the nut for the rear engine mounting.
15. Undo the three bolts securing the rear engine cushion, leaving the bolts in place.





16. V6: Fit lifting lugs, one on the rear cylinder head and one on the front cylinder head (undo the existing bolt first).
17. Put the Lifting beam 83 93 850 in position and relieve the weight on the engine and gearbox.

IMPORTANT: Place suitable protective pads or the like under the feet of the lifting beam to avoid damaging the paintwork.

18. Raise the car.
19. Remove the front wheels.





20. Remove covers.
21. Remove the front exhaust system. Be careful with the oxygen sensors.
22. 4 cyl: Remove the rear engine mounting and engine pad.





23. Remove the screws securing the steering gear.
24. Remove the two rear clamps securing the power steering delivery pipe to the subframe. Remove the AC pipes from the plastic clips on the subframe at the same time.
25. Remove the air cleaner casing from the subframe.
26. 4-cyl: Detach the engine oil cooler from the charge air cooler.
27. Fit a strap part number 83 95 212, round the radiator core and radiator crossmember.





28. Remove the bolts securing the outer ball joints to the steering knuckle housing on both sides.
29. Detach the upper anti-roll bar ball joints. Use a 17 mm spanner to prevent the gaiter from twisting. If the spanner is too wide to fit between the gaiter and the suspension strut, it must be ground narrower.





30. Remove the torque arm from the subframe and remove the rear support plates.
31. Assemble the holder, using tools 83 95 170, 83 95 196 and 83 95 188 Lifting trolly
32. Position the lifting trolley with lifting table and holder under the subframe. Raise the lifting table, being careful to position it correctly.
33. Remove the last 4 bolts securing the subframe.
34. Lower the subframe approx. 5 cm so that the two front clamps holding the power steering delivery pipe in place can be removed. Remove the clamps, lower the subframe and move the lifting trolley out of the way.
35. 4-cyl: Remove the splash plate (secured with two bolts to the gearcase) to access the torque converter mounting on the drive plate.
V6: Remove the plug (under the starter motor) covering the bolts to the torque converter.





36. Undo the 6 bolts securing the torque converter to the drive plate. Rotate the plate together with the pulley.

NOTE: The crankshaft must be rotated to access all the bolts.

37. Press the torque converter against the gearcase and fit the([E Converter holder87 92 574 to keep the torque converter in place while dismantling the gearbox.





38. Disconnect the ground leads.
39. Remove the torque arm with bracket.
40. Drain the transmission fluid, fit the drain plug.
Tightening torque: 40 Nm (30 ft. lbs.)
41. Disconnect the oil cooler inlet and outlet hoses. Plug the inlet and outlet passages on the gearbox and also plug the hoses. Use plug no. (10) 91 32 929 and seal no. (10) 91 32 937.





42. Remove the left drive shaft using Dismantling tool, drive shafts 87 92 616.
43. Suspend the shaft by means of a cable tie.
44. Lower the car to the floor.





45. Remove the left-hand engine pad.
46. Lower the unit approx. 100 mm so that the gearbox clears the structural member. Remove the gearbox bracket from the gearbox.
47. Raise the car.

Part 1 Of 2:

Part 2 Of 2:

48. Fit lifting tool MKM-886, part no. 87 92 608, onto a pillar-type jack. Adjust the tool so that it centers on the lifting lug on top the gearcase and secure it to the lifting lugs as shown in the illustration. Use bolts that are approx. 20 mm longer than those removed.





49. Remove the remaining bolts securing the gearbox to the engine.
50. Pull out and lower the gearcase.

IMPORTANT: The pillar-type jack may tip over. Exercise care.

51. Lift off the gearcase from the jack with an engine lift and;i6l Lifting cab 87 92 442 while detaching the lifting tool from the gearcase.

Fitting
When fitting a new gearbox, transfer the holder for the torque converter from the new gearbox to the old on





1. Turn the torque converter so that the bolt holes line up with the holes in the drive plate.
Fit Converter holder 87 92 574 to keep the torque converter in place during assembly.
2. Make sure the two guide sleeves are on the engine and apply anti-corrosion agent to the sleeves. Fit the new drive shaft seals, lubricate them before fitting.
3. Lift up the gearbox with an engine lift and Lifting cab 87 92 442.





4. Fit Lifting tool MKM-88687 92 608 onto a pillar-type jack.

Part 2 Of 2:

5. Adjust the tool so that it centers on the lifting lug on top of the gearcase and secure it to the gearbox.

IMPORTANT: The pillar-type jack may tip over. Exercise care.





6. Fit protective collar83 95 162 in the right-hand shaft seal in the gearbox to protect the seal when the gearbox is being fitted. Lubricate the seal.
7. Place the gearbox in position.

IMPORTANT: Push the gearbox into place until approx. 20 mm remains and then remove tool 83 95 162.





8. Tighten the bottom bolts between the engine and the gearbox.
Tightening torque: 75 Nm (55 ft. lbs.)
B6: Tighten the bolts between the oil pan and the gearbox.
Tightening torque: 47 Nm (34 ft. lbs.)
9. Remove the lifting beam from the gearbox and move the jack out of the way. Refit the bolts on the gearbox.
Tightening torque 24 Nm (18 ft. lbs.)
10. Lower the car and fit the engine pad mounting on the gearbox.
Tightening torque: 84 Nm (62 ft. lbs.)
Lift the unit. Do not lift higher than necessary, it will only make fitting the subframe more difficult. Fit the bolts that secure the engine pad to the body. Start with the small bolt.
Tightening torque, bolts: 63 Nm (46 ft. lbs.)
Tightening torque, nut: 84 Nm (62 ft. lbs.)





11. Fit protective collar 83 95 162 in the sealing ring. Lubricate the sealing ring.
12. Make sure that the drive shaft is clean and then align it with the tool.

IMPORTANT: Insert all but 20 mm of the drive shaft in the gearbox and then withdraw the tool before the shaft's sealing surface reaches the shaft seal.

13. Push in the rest of the shaft until the circlip clicks in.
14. Raise the car.





15. Remove tool 87 92 574, which is keeping the torque converter in place, and press it against the drive plate. Fit the plug.
16. Apply lock compound, Loctite 242 part no 74 96 268 on the bolts that secure the torque converter to the drive plate.

NOTE: Use the original bolts and their washers. If excessively long bolts are fitted, the torque converter will be damaged. The length of the bolts should be 10 mm, measured from the washer.

17. Fit the 6 bolts without tightening them.
Rotate the engine with the pulley
18. Tighten them when they are all fitted in place.
Tightening torque: 30 Nm (22 ft. lbs.)
19. 4-cyl: Fit the splash plate.
Fit the plug.





20. Fit the fluid cooler hoses. The hoses should be horizontal so that they do not chafe against the subframe. Use new seals, greased with Vaseline.
Tightening torque: 27 Nm (20 ft. lbs.)
21. Fit the bracket for the torque arm on the gearbox.
22. Connect the ground cable to the bracket and to the gearbox.
23. Place the subframe on the lifting trolley and raise it slightly.





24. Fit the power steering delivery pipe's clamps.
25. Raise the subframe and guide it into position by means of the holder's studs. At the same time, guide the following into place:
- The radiator core's studs
- The AC pipes
- Outer ball joints
26. Fit the bolts to the subframe and fit the rear support plates. Adjust the subframe so that the guide pins on the holder are align( with the holes in the body before tightening the bolts.
Tightening torques:
Subframe bolts 100 Nm (74 ft. lbs.) ± 45
Support plate bolts: 60 Nm (44 ft. lbs.)

NOTE: Make sure that the transmission fluid cooler hoses do not rest against the subframe.

27. Remove the lifting trolley.





28. Fit the bolts securing the outer ball joint to the steering knuckle housing.
29. Tighten the bolts.
Tightening torque: 85 Nm (63 ft. lbs.)
30. Tighten the anti-roll bar link. If the spanner is too wide to fit between the gaiter and the suspension strut, it must be ground narrower.
Tightening torque 92 Nm (68 ft. lbs.)





31. Fit the steering gear bolts and tighten them.
Tightening torque: 90 Nm (66 ft. lbs.)
32. Remove the strap round the radiator core.
33. 4-cyl: Fit the engine oil cooler. Tighten the air filter housing.
34. Position the rear engine cushion. Screw in the front bolts but do not tighten them.





35. Bolt the rear engine mounting in place.
Tightening torque: 70 Nm (52 ft. lbs.)
36. Tighten the torque arm on the subframe
Tightening torque 26 Nm (19 ft. lbs.)
37. Fit the front exhaust system.
Tightening torque 4-cyl: 25 Nm (18.4 ft. lbs.)
Tightening torque V6: to the turbo 24 Nm (18 ft. lbs.) to the exhaust manifold 40 Nm (30 ft. lbs.)
38. Run the wiring for the oxygen sensor into the engine bay.
39. Fit the covers.
40. Lower the car to the floor.
41. Remove the lifting beam. V6: Remove the lifting tool and its mountings from the engine.
42. Connect the oxygen sensors





43. Shake the unit to ensure there is no tension in the engine pad
Tighten the rear engine pad retaining nut and 3 bolts.
Tightening torque: bolts 24 Nm (18 ft. lbs.)
Tightening torque: nut 45 Nm (33 ft. lbs.)





44. Fit the bolts securing the gearbox to the engine and tighten them.
Tightening torque: 70 Nm (52 ft. lbs.)
V6: Screw on the cable channel to the engine and gearbox.
45. Clean and fit the dipstick tube.
46. Fit the gearbox's breather hose.
47. Fit the shifting cable to the bracket on the gearbox. Fit the clamp.
48. Fit the shifting cable to the selector lever in position P.
49. Check the position of the selector lever and adjust if necessary.





50. Raise the car. Undo the bolt to the front torque rod and center the rubber pad in the rod. Tighten the bolt.
Tightening torque: 47 Nm (34 ft. lbs.)
Lower the car to the floor.
51. Plug in the gearbox's connectors.





52. Fit the battery tray, battery and battery cover.
53. Fit the cover over the intake manifold.
54. Fit the grille.
55. Fit the front wheels. Tighten the bolts using a torque wrench.

NOTE: The wheels must hang freely

Tightening torque: 110 Nm (81 ft. lbs.)
56. Fill with transmission fluid, Texaco Texamatic DEXRON 111 (7045 EU, TL1863 US), to the correct level.
57. If the gearbox has been changed and dirt is found in the oil, flushing equipment 87 91 824 must be connected before the car is started.
58. Test drive the car with varying engine loads and rpm and read any trouble codes that are generated. Also check the position the steering wheel when driving straight ahead on a level road. Adjust if needed.
59. Set the right time on the clock.