Things to be done:
Replacing autobox with the Getrag
VEMS EFI installation
Engine rebuild, pistons, rods etc
Brakes,
Suspension.
Hopefully its all done for the next jahrestreffen!
This is a summary of my project thread on the mercedes190.co.uk forum, first pictures are from january 2007, and the last picture from saturday last week.
I will do updates on both forums in the future. (im not very goot at writing in german but i can understand it in writing)
![Bild](http://www.jm-motorsport.se/bilder/DSC_3342.jpg)
First on the agenda was replacing the autobox with a schaltgetriebe:
Shifter bushings from Jesper
![Bild](http://www.jm-motorsport.se/bilder/bussning-4.jpg)
![Bild](http://www.jm-motorsport.se/bilder/bussning-3.jpg)
![Bild](http://www.jm-motorsport.se/bilder/bussning-1.jpg)
![Bild](http://www.jm-motorsport.se/bilder/bussning-2.jpg)
Evo 2 Brembo brakes:
![Bild](http://www.jm-motorsport.se/bilder/DSC00188.jpg)
![Bild](http://www.jm-motorsport.se/bilder/DSC00189.jpg)
New Clutch kit:
![Bild](http://www.jm-motorsport.se/bilder/DSC_3407.jpg)
![Bild](http://www.jm-motorsport.se/bilder/DSC_3408.jpg)
New parts for the schaltgetribe conversion:
![Bild](http://www.jm-motorsport.se/bilder/DSC_3409.jpg)
Realese bearing from clutch kit installed
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3428.jpg)
This is the writeup for replacing the autobox we did on the english forum
To be able to get the gearbox out from under the car, jack the car up at least 50 cm.
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3430.jpg)
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3431.jpg)
Disconnnect the two vacum pipes and then remove the magnetic valve that controls S/E
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3432.jpg)
Plug black/white hose from magnetic valve to yellow thing.
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3434.jpg)
Remove hose from gearbox to the 4th cylinder inlet pipe on manifold, plug this.
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3435.jpg)
Magnetic valve removed, not to be used again.
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3436.jpg)
Remove linkage between gearbox and throttle body
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3438.jpg)
Get underneath the car and remove the drain plug from the gearbox,
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3439.jpg)
Remove exhaust pipe
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3445.jpg)
Remove pipes between gearbox and oilcooler (upper)
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3447.jpg)
Lower
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3448.jpg)
all the way back to gearbox
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3449.jpg)
same pipes
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3452.jpg)
Disconnect this connector from gearbox to i havent got a clue
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3454.jpg)
Remove plastic cover on sump to get to the flywheels 6 bolts. Turn the crank to get to the next bolt. reapeat until all bolts have been removed.
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3459.jpg)
Drain converter from oil,
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3463.jpg)
Pipes and hoses removed and not longer needed
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3465.jpg)
Remove heat shield to get to the propshaft
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3474.jpg)
Remove propshaft
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3475.jpg)
Remove gearbox bolts, beware its heavy use something to support it with (59 kg).
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3476.jpg)
Gearbox removed
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3477.jpg)
automatic (short) and manual (long) propshafts,
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3479.jpg)
Remove the 8 bolts from flywheel
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3481.jpg)
Flywheel and clutch
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3483.jpg)
Flywheel stretch bolts
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3484.jpg)
New grooved ball bearing
http://www.jm-motorsport.se/bilder/gearbox/DSC_3486.jpg
This is where you install it
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3487.jpg)
New ball bearing installed, make sure its sits correctly in place, us a hammer and light force to tap it in.
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3488.jpg)
Mount flywheel
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3490.jpg)
30nm and then 90 degrees
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3493.jpg)
Clutch alignment tool
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3497.jpg)
Tighten pressure plate bolts and keep the alignment tool in while doing it
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3496.jpg)
To install the hydralic pipe you will need one of these:
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3498.jpg)
Install pipe
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3499.jpg)
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3500.jpg)
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3501.jpg)
Fill up gearbox with a suitable oil, 1.6L
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3502.jpg)
Mount
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3503.jpg)
Old and new
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3504.jpg)
Raise the gearbox,
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3507.jpg)
DO keep a pair of gogels around, you will other wise have problems to see
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3508.jpg)
Looong extensions are a must to reach all bolts
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3509.jpg)
Open the contact for the lightswitch
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3510.jpg)
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3511.jpg)
Solder in a lead between these cables
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3512.jpg)
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3513.jpg)
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3514.jpg)
Get the hose thru the rubber
Emty the canister whit breakfluid and cut of the side "valve"
and fit the clutch hose
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3515.jpg)
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3517.jpg)
Fit the the hose to the clutch and mount the pedal asembly.
Also fit the pressure line to slave cylinder on gearbox
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3519.jpg)
Center the gearleaver with a 5,5mm drill
![Bild](http://www.jm-motorsport.se/bilder/gearbox/DSC_3520.jpg)
Plug this vaccum pipe
Reverse ligth switch
Its a litle hard to see the cut-out-line, but try,,,,other wise you cant fit it back.
And this is the result: GETRAG