To remove the car must be raised to the required height. In addition, a suitable garage lift is required to lower the box.
Withdrawal
1. Disconnect the negative cable (-) battery with the ignition off. The battery is located in the luggage compartment behind the cover on the right side. For BMW 316i, 318i, the battery is located in the engine compartment.
Disconnecting the battery clears the fault memory of some controls. If necessary, read the fault memory before disconnecting the battery. Refer to Section Troubleshooting. It is desirable to carry out work in the conditions of a service station.
2. Models 316i, 318i: Unscrew the mounting bolts and remove the ignition coils from the holders, moving them to the side so that when removing the manual transmission, do not damage the ignition cables.
3. Models 320i, 323i, 328i: Remove the fan with the holder from the radiator and move it up a little, refer to Section Removal and installation of the fan/fan shroud.
4. Models 320d, 320i, 323i, 328i: Remove the air box, refer to Section Removal and installation of the air intake box.
Lifting and placing the vehicle on stands is dangerous! Therefore, please read Section Jacking and towing
5. Remove the lower cover of the engine compartment, refer to Section Removal and installation of the bottom cover of an impellent compartment.
6. Remove the amplifier of the front of the car, refer to Section Removal and installation of a beam of a forward suspension bracket.
7. Turn away bolts of fastening and remove a reception pipe from a final collector, address to the Section Removal and installation of the exhaust system.
8. Disconnect the heat shield of the exhaust system in the area of the manual transmission from the bottom of the car.
9. Disconnect the universal joint flange from the manual transmission (arrows in the illustration). To avoid overtightening the flange, turn only the nuts, not the bolts, when loosening.
10. Turn away bolts of fastening and remove the central bearing of a cardan shaft (arrows in the illustration). While doing this, hold the shaft so that it does not fall.
11. Remove the cardan shaft from the gearbox flange.
When removing the clutch slave cylinder, slowly unload the rod, otherwise air will enter through the seal. Suspend the cylinder with the attached hose on the wire to the body. If air enters the hydraulic system, air must be removed from the system after installation.
12. Remove the working cylinder, refer to Section Removal and installation of the clutch slave cylinder.
13. Raise the manual transmission slightly with a garage lift and support it.
14. Turn away bolts of fastening and disconnect a cross-beam at the bottom and manual transmission.
15. Slowly lower the manual transmission with the garage lift until the engine almost touches the wall of the engine compartment.
16. Support the engine in front with a second lift so that it cannot tip over after removing the manual transmission.
17. Remove the retaining clips -4- on the shift rod from the side of the manual transmission and the shift lever. Remove the washers -5- of the switching rod, remove the rod.
18. Pull up with a screwdriver the retainer of the shift rod support finger on the box. Pull your finger out to the side.
19. Disconnect the reverse switch connector on the box. Release the reversing light and oxygen sensor cable from the holders on the box.
20. Remove the Torx screws securing the box flange (arrows in the illustration).
21. Remove the box from the guide bushings and input shaft back and remove it with the help of an assistant.
When removing and installing the box, do not allow it to hang on the input shaft, as this may damage the clutch disc. Pull the box back as far as it will go, rotate it about 10°counterclockwise and remove.
Installation
22. Before installation, check the clutch, refer to Section Removal and installation of clutch.
23. Check up ease of a course of the bearing of deenergizing of coupling. Lubricate the mating surfaces of the release lever with grease "ESSO UNIREX S2".
check the lubrication in the grooves of the input shaft splines. If the grease is sticky, the clutch disc must be replaced. Refer to Section Removal and installation of clutch.
24. Use a rag to wipe off grease from the input shaft splines. Then apply a thin layer of lubricant "ESSO UNIREX S2". Do not apply too much lubricant, as it may get on the friction surfaces and cause clutch failure. The required amount of lubricant corresponds to the grain size of the rice.
25. Shift into gear.
Make sure that both guide bushings -1- and -2- between the engine and gearbox are in place. Raise the box and slide it horizontally into the clutch. If, during installation, the box shaft does not enter the clutch disc, turn the shaft behind the propeller shaft flange by hand.
27. Screw in the flange mounting bolts with washers. Tightening torques are given in the Specifications.
28. Lubricate the shift rod bearing pin with grease "KLUBER POLYLUB GLY 801" and paste. Push down on the finger lock.
29. Place the washers on the finger, observing the correct position. The large surface of the washers -5- rests on the shift rod. Install the linkage to the shift lever and shift lever and secure with the retaining clips.
30. Dock the reverse switch connector and fix it. Route the reversing light and oxygen sensor cable in the holders on the box.
31. Install the clutch slave cylinder, refer to Section Removal and installation of the clutch slave cylinder.
32. Raise the box with a jack and fix the beam on the bottom and the box with the forces specified in the Specifications.
33. Remove the jack.
34. Secure the cardan shaft with new self-locking nuts to the box flange. The tightening torque of threaded connections depends on the strength class of the bolts, which is stamped on the bolt head (refer to Specifications).
35. Tighten the propeller shaft central bearing bolts to 20 Nm.
36. Slightly tighten the screw ring on the movable element of the cardan shaft with a torque of 10 Nm.
37. Attach the heat shield to the bottom. Install the exhaust system, refer to Section Removal and installation of the exhaust system.
38. Fill manual transmission with oil, refer to Section Checking the level / changing the oil in the rear axle gearbox.
39. Install the front end amplifier, refer to Section Removal and installation of a beam of a forward suspension bracket.
40. Models 320i, 323i, 328i: Attach a fan with a holder to the radiator, refer to Section Removal and installation of the fan/fan shroud.
41. Models 320d, 320i, 323i, 328i: Install the air collection box, refer to Section Removal and installation of the air intake box.
42. Fix the bottom cover of an impellent compartment.
43. Models 316i, 318i: Attach to ignition coil holder.
44. Connect the negative cable (-) battery with the ignition off. Set the clock.