Removal
NOTE:- Model with a B234 engine, equipped with turbo and Air Conditioning (A/C) shown in the illustrations, others models similar.
- Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.
WARNING: Cables, hoses, line etc.. are secured using hard plastic cable ties. After tightening, the tie is cut short, leaving sharp ends at the fixing points. Be careful not to cut yourself on these sharp ends of the cable ties.
Removal
1. Place a protective cover over the fenders to prevent the paint work becoming damaged or dirty
- Remove engine covers if equipped as required
2. Detach battery cables.
3. Remove battery.
4. Remove the clip holding the throttle cable in the grommet and move the cable to one side.
5. Detach the front electrical distribution box and move it to one-side.
6. On 1994 models, detach the positive terminals without removing the cables.
7. Remove the two clips from the positive lead on the battery tray..
8. Unplug the connector from the Antilock Brake System (ABS) control module.
9. On 1995 through 1998 models, detach the cruise control cable from its lever.
10. Disconnect the positive cable from the battery tray and undo the positive lead clip.
- Pull the vacuum hose out of its clips on the battery tray.
11. Slightly lift the battery tray and disconnect the cruise control connector.
12. Remove the battery tray with the cruise control module and cable.
13. On all models, remove the battery tray.
14. On models with V6 engine, Detach the throttle cable and the kick down cable from the bracket, unclip the control rod, detach the bracket and move it to one side.
15. Undo the hose clips between the intake manifold and inlet pipe and between the resonating chamber and the mass air flow sensor, then slightly raise the intake manifold.
- Disconnect the vacuum hoses and electrical connector, then remove the intake manifold.
16. On models with turbocharger, remove the hose between the turbocharger delivery pipe and the transmission.
- Plug the hole in the transmission.
17. Disconnect the hose from the by-pass valve.
18. Disconnect the intake air temperature sensor connector on the turbocharger air delivery pipe.
19. Disconnect the hose clips and remove the turbocharger air delivery pipe.
20. On all models, Remove the kick-down cable from the throttle body.
21. Remove the selector arm from the transmission. Do not split the universal joint.
22. Remove the banjo screw for the hose to the intake side of the fluid cooler on the back of the transmission, then plug the hole.
23. Undo the nut and press out the selector cable rubber bushing from its bracket on the gear case.
24. Place a receptacle under the car so that the fluid can be collected.
25. Remove the banjo screw for the hose to the outlet side of the fluid cooler on the front of the transmission and plug the hole.
26. Detach the battery ground cable from the transmission.
27. Unplug the connector on the cable for the vehicle speed sensor.
28. Remove the screws in the partition surface which are accessible from above, except the front screw.
- One of these screws is also a retaining screw for the starter motor.
29. Remove the screws in the upper end of the support in the wheel housing.
30. Place lifting beam tool No. 83 93 977, or equivalent, on the wheel housings.
- Make sure that the beam is in contact with the edges of the fenders.
- Place the hook in the engine's lifting eye and lightly tension using the beam wing nuts.
31. Raise the car.
32. Remove the lefthand front wheel.
33. Remove the wheel arch trim and the front part of the fender liner.
34. Remove the lefthand and center air deflector.
35. Remove the cover plate from the transmission.
36. Remove the screws securing the torque converter to the drive plate.
- Access is via the hole for the starter motor.
- On models with V6 engine, the plastic plug under the starter motor must first be removed.
NOTE:
- The motor must be turned in order to access the screws.
- The wrench is inserted beside the righthand fender liner which has been detached on the lower edge.
37. Install holder tool No. 87 92 293, or equivalent, which secures the torque converter in position when the transmission is removed.
- The holder is installed with a 10 mm screw.
38. Remove the remaining screws in the partition surface (accessible from underneath).
39. Remove the three screws securing the ball joint to the suspension arm.
40. Remove the nut on the anti-roll bar bracket in the suspension arm.
- Remove both the screws securing the anti-roll bar bearing.
41. Remove the nut from the screw in the front engine mounting. Keep the two washers.
42. Remove the support at the wheel housing. The upper part has already been detached.
43. Undo the screw in the front joint of the subframe and remove the two screws holding the joint.
44. Undo the screw in the rear joint of the subframe and remove the two screws holding the joint.
- One of these screws also holds the steering gear.
45. Remove the two screws in the front corner and the four in the rear corner of the subframe.
- Carefully lower the subframe. Keep the metal clip.
46. Remove the screws from both joints and remove the subframe.
47. Remove the clip from around the universal joint gaiter.
- Clips with no screw must be cut off using pliers
- Take care not to damage the rubber gaiter.
- Separate the joint and let the shaft hang down.
- Place the protective cover on the universal joint and driver.
CAUTION:
- Keep area clean when working with universal joints.
- Sand or dirt, even in small quantities, considerably reduces the service life of universal joints.
48. Lower the car.
49. Remove the bleeding plug from the top side of the transmission.
50. Install lifting sling tool No. 87 91 451, or equivalent, to the transmission and insert lifting cable 87 92 442 in the lifting eye.
51. Hook the cable onto the lift and tension it.
52. Remove the last screw from the partition surface, tighten and lower the transmission.
NOTE: If the transmission is to be sent out or exchanged, the torque converter must always be attached using a transit support.