Transaxle, Remove and Replace
Removal and fitting ot ZF 4 HP 18 automatic transmission is shown in a car with a B234 engine, equipped with turbo and air conditioning (A/C).
Important: 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 wings to prevent the paint work becoming damaged or dirty.
2 Detach battery cables.
3 Remove battery.
4 Up to M1991
Remove the washer fluid reservoir. Plug the outlet so that the fluid does not run out.
5 Remove the clip holding the throttle cable in the grommet and move. the cable to one side.
6 From M1988
Detach the front electrical distribution box and move it to one side.
7 Detach the positive terminal (without detaching the cables).
8 Remove the two clips from the positive lead on the battery tray.
9 Up to M1989
Detach the fuel filter clip and move the filter to one side. The filter is located on the battery tray.
10 Unplug the connector from the ABS control module.
11 Remove the battery tray.
12 Remove the hose between the turbocharger delivery pipe and the transmission. Then plug the hole on the transmission.
13 Detach the hose from the bypass valve.
14 From M1991
Unplug the intake air temperature connector on the turbocharger delivery pipe.
15 Undo the hose clips and remove the turbocharger delivery pipe.
16 Cars with LH multi port fuel injection system
Remove the mass air flow sensor connector and then remove the mass air flow sensor.
17 Remove the kick-down cable from the throttle body.
Cars with TCS
Remove the kick-down cable from the KDW motor.
18 Remove the selector arm from the transmission. Do not split the universal joint.
19 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.
20 Undo the nut and press out the selector cable rubber bushing trom its bracket on the gear- case.
21 Place a receptacle under the car so that the fluid can be collected.
22 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.
23 Cars with turbo
Remove the clip holding the turbo fluid pressure pipe to the transmission.
24 Detach the battery ground cable from the transmission.
25 Cars with mechanical speedometer
Detach the speedometer cable from the transmission.
Cars with electronic speedometer
Unplug the connector on the vehicle speed sensor cable. The connector is located behind the bulkhead panel.
26 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.
27 Engine version B202
Remove the upper starter motor screw.
Engine version B234
a. Remove the starter motor. Start by removing the upper screw. Loosen the screw using a starter motor spanner and then unscrew it using a flexible extension.
b. Remove the lower screw and the support for the intake manifold. Place the starter motor on the steering gear.
28 Undo the starter motor support beside the intake manifold.
29 Remove the screws in the upper end of the support in the wheel housing.
30 Place lifting beam 83 93 977 on the wheel housings. Make sure that the beam is in contact with the edges of the wings. Place the hook in the engine's lifting eye and lightly tension using the beam wing nuts.
31 Raise the car.
32 Remove the left-hand front wheel.
33 Remove the wheel arch trim and the front part of the wing liner.
34 Remove the left-hand and centre air deflector.
35 Remove the screws holding the torque converter to the drive plate. These are accessed via the hole for the starter motor.
Note: The motor must be turned in order to access the screws. The spanner is inserted beside the right-hand wing liner which has been detached on the lower edge.
36 Use tool 87 91 816 to fix the torque converter.
37 Remove the remaining screws in the partition surface (accessible from underneath).
38 Remove the three screws securing the ball joint to the suspension arm.
39 Remove the nut on the anti-roll bar bracket in the suspension arm. Remove both the screws securing the anti-roll bar bearing.
40 Remove the nut from the screw in the front engine mounting. Keep the two washers.
41 Remove the support beside the wheel housing (upper part is already detached).
42 Undo the screw in the front joint of the subframe and remove the two screws securing the joint.
43 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.
44 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.
45 Remove the screws from both joints and remove the subframe.
46 Remove the clip from around the universal joint rubber gaiter. Clips without a screw are cut away using pliers. Take care not to damage the rubber gaiter. Separate the universal joint and let the shaft hang down. Place the protective cover on the universal joint and driver.
Important: Keep clean when working with universal joints. Sand or dirt, even in small quantities, considerably reduces the service life of universal joints.
47 Lower the car.
48 Remove the bleeding plug from the topside of the transmission.
49 Fit lifting sling 87 91 451 to the transmission and place lifting cable 87 92 442 in the sling.
50 Hook the cable onto the lift and tension it.
51 Remove the last screw from the partition surface, tighten and lower the transmission.
Important: If the transmission is to be dispatched as an exchange transmission, the torque converter should always be attached using a transit support.
Warranty and part cost are not reimbursed if the transit support is not fitted.
When making a claim for reimbursement, the test form should be enclosed.
Fitting
Engine version B234
Before starting to fit, make sure that the intermediate shaft is in position on the right-hand driver and that the aluminium tube has been pushed onto the seal.
Engine version B202
Before starting to fit, make sure that the intermediate shaft is in position on the right-hand driver.
All cars
The car must be down and the engine suspended in the lifting beam.
1 The torque converter must be positioned so that the screw holes for the driver plate align with the holes in the torque converter.
Attach the torque converter using tool 87 91 816.
2 If the engine mounting has been removed from the transmission
The engine mounting must be fitted so that both arrows are aligned.
3 Insert locating stud 83 92 128 in the upper hole in the partition surface in the engine body.
4 Detach the bleeding mechanism. Then fit lifting sling 87 91 451 to the transmission and fit lifting cable 87 92 442. Hook the cable onto the sling and lift the transmission into fifting position.
5 Apply grease to pin. Position the transmission on the locating stud in the partition surface and check that the pin on the torque converter is guided into position.
Engine version B234
Make sure that the aluminium tube is sealed against the transmission.
6 Fit a screw in the partition surface.
7 Remove the locating stud and lifting sling. Remove tool 87 91 816.
8 Screw the bleeding mechanism on to the transmission.
9 Attach the two screws to the upper end of the support in the wheel housing. Do not tighten.
10 Raise the car.
11 Remove the protective covers and fill the driver with grease. Then fit the drive shaft.
12 Fit the universal joint rubber gaiter with a new clip (if clip cannot be reused).
Important: Keep clean when working with universal joints. Sand or dirt, even in small quantities, considerably reduces the service life of universal joints.
13 Suspend the subframe and attach the two joints, each with one screw.
14 Raise the subframe. Make sure that the metal clip on the rear of the subframe is correctly positioned.
15 Fit the screw in the engine mounting and make sure that the washers are correctly positioned. Do up the nut.
16 Fit the two screws to the front corner of the subframe.
17 Fit the four screws to the rear corner of the subframe.
18 Then fit the two screws holding the rear joint. One of the screws also secures the steering gear.
19 Fit the two screws holding the front joint.
20 Torque tighten all screws in the subframe (12 screws).
- Tightening torque, front attachment: 55 ± 8 Nm (41 ± 6 lbf ft).
- Tightening torque, rear attachment: 55 ± 8 Nm (41 ± 6 lbf ft).
21 Fit the lower end of the wheel housing support to the subframe
- Tightening torque: 50 ± 7 Nm (37 ± 5 lbf ft).
22 Fit the screws securing the anti-roll bar bearing.
- Tightening torque: 29,5 ± 4,5 Nm (21,5 ± 3,5 lbf ft).
23 Fit the three screws securing the ball joint to the suspension arm. Use new locknuts.
- Tightening torque: 30 ± 4 Nm (22 ± 3 lbf ft).
24 Fit the nut securing the anti-roll bar bracket to the suspension arm.
- Tightening torque: 23,5 ± 3,5 Nm (17,5 ± 2,5 lbf ft).
25 Fit (but do not tighten) the three screws in the torque converter, beside the starter motor. Then torque tighten the screws. Use Loctite 242 locking compound.
- Tightening torque, 19 mm screw head: 58 ± 9 Nm (43 ± 6 lbf ft).
- Tightening torque, 17 mm screw head: 38 ± 5 Nm (28 ± 3.7 lbf ft).
26 Fit the one starter motor screw from underneath.
27 Torque tighten the remaining screws in the partition surface which are accessible from underneath.
- Tightening torque: 70 ± 20 Nm (50 ± 15 lbf ft).
28 Lower the car and remove the lifting beam.
29 Fit the kick-down cable to the throttle body.
Cars with TCS
Fit the kick-down cable to the KDW motor.
30 Adjust the kick-down cable. Adjustments
31 Fit the nut to the engine mounting screw and tighten.
- Tightening torque: 7O ± 21 Nm (5O ± 15.5 lbf ft).
32 Tighten the two screws tor the support at the wheel housing.
- Tightening torque: 25,5 ± 3,5 Nm (19 ± 2,5 lbf ft).
33 Not engine version B234
a. Refit and tighten the screws in the partition surface. Refit the screw in the starter motor.
b. Tighten the screw in the support beside the throttle body.
- Tightening torques, screws in partition surface: 70 ± 20 Nm (5O ± 15 lbf ft).
Engine version B234
Fit the starter motor. Start by fitting the upper screw. Use a flexible extension and tighten the screw using a starter motor spanner. Fit the lower screw with the support for the intake manifold.
34 Cars with electronic speedometer
Plug in the connector on the cable for the vehicle speed sensor.
Cars with mechanical speedometer
Fit the speedometer cable.
Important: Make sure that the selector cable, kick-down cable and the cable to the speedometer are correctly located.
35 Fit the selector lever rubber bushing to the bracket on the gearcase, tighten the nut and fit the selector arm.
- Tightening torque: 18 ± 3 Nm (10 ± 2.2 lbf ft).
36 Cars with turbo
Fit the clip securing the turbo fluid pressure pipe to the transmission.
37 Fit the battery ground lead to the transmission.
38 Cars with LH multi port fuel injection system
Insert the mass air flow sensor.
39 Fit the turbocharger delivery pipe.
40 Fit the hose to the charge air bypass valve.
41 From M1991
Refit the connector to the temperature sensor.
42 Fit the hose between the turbocharger delivery pipe and the transmission.
43 Fit the battery tray.
44 Up to M1989
Fit the fuel filter.
45 Cars with ABS
Screw on the support for the hydraulic unit on the battery tray.
46 From M1992
Fit the connector to the ABS control module and clip on the cable.
47 Fit the positive lead using the two clips on the battery tray.
48 Fit the positive terminal.
49 Up to M1991
Fit the washer fluid reservoir, plug in connectors and hose.
50 Fit the front electrical distribution box.
51 Fit the battery.
52 Fit the throttle cable to the throttle body.
53 Connect battery leads.
54 Fit the left-hand and centre air deflectors.
55 Fit the front part of the wing liner.
56 Fit the wheel arch trim.
Check that the wing liner on the right-hand side is fitted if it has been removed.
57 Fit the wheel.
- Tightening torque: 120 Nm (89 lbf ft).
58 Fill with transmission fluid. Then clean the transmission cooling system using flushing equipment 87 91 824.
59 Check and adjust play in the selector lever.
60 Cars with TCS
Calibrate the TCS system using the ISAT scan tool.
61 Remove the protective cover from the wing.
62 Check fluid level in the transmission and test drive the car.
Important: After carrying out repairs inside transmission and after changing to a new transmission, flushing equipment 87 91 824 should be connected to the transmission cooling system before starting the engine. Otherwise, there is a risk of damage.