Replacement of Components - Engine Removed

Special Tools
998 5972
999 2520
999 2810
999 5112
999 5297
999 5186
999 5642
999 5463

Remove starter motor





- Pull of the cap off
- Remove the bracket inlet manifold
- Disconnect the wiring from the starter motor
- Remove the bolts and the starter motor.

Remove transmission





Undo torque converter screws. Undo the transmission screws to and from the engine where the flywheel housing is mounted on the engine block.

Warning When removing the transmission use lifting gear 998 5972 with the support 999 5463 to support the transmission and prevent damage.

Remove flange plate





See Replacing flange plate, refer to Transmission and Drivetrain.

Mount engine on stand





Use stand 999 2520 and support 999 5297.
Remove the lifting tools.
Install the correct quantity of washers to compensate for the transmission guide pins.

Transfer engine components at left side





- The upper cover
- The coils and leads
- The Camshaft Position (CMP) sensor
- The lifting eve.

Transfer engine components at exhaust side





- The preheater plate
- The exhaust manifold
- The right engine mounting at the distribution side
- The thermostat housing, oil cooler with hoses
- The bracket, drive shaft bearing
- Water pipes.

Transfer engine components at air intake side





- The oil pressure sensor
- The dipstick and the pipe
- The alternator
- The intake manifold complete with water hose connection
- The thermostat housing complete
- The knock sensor
- The oil trap and the hoses
- The engine mountings with lifting eye
- Starter motor leads.

Install drive plate
See Replacing flange plate, refer to transmission and Drivetrain.

Install transmission





Torque converter, tighten to 50 Nm.
Plug the old engine in the same way as the new engine.
Install the cover plate exhaust side.
Install speed sensor and tighten 20 Nm.
Place wiring guide and tighten.

Install starter motor





- Install the starter motor and tighten the bolts. Tighten to 50 Nm
- Install the bracket and tighten tension free to the intake manifold
- Connect the wiring
- Place the protective cover.