Engine Replacement, Transferring Components

Engine replacement, transferring components (Turbo)

Special tools:
999 2520 FLOOR STAND 999 2520 Floor Stand
999 2810 LIFTING YOKE 999 2810 Lifting Yoke
999 5112 GEAR SECTOR 999 5112 Gear Sector
999 5297 ENGINE FIXTURE 999 5297 Engine Fixture
999 5428 LIFTING YOKE 999 5428 Lifting Yoke
999 5429 LIFTING EYE 999 5429 Lifting Eye
999 5463 FIXTURE 999 5463 Fixture

Exposing engine

Remove transmission




Automatic: Slacken off torque converter screws.

Remove 12 transmission screws from the engine at the flywheel mounting in the cylinder block.

Warning! When the transmission is released use the mobile jack 999 5972 FIXTURE 999 5972 Fixture with transmission fixture 999 5463 FIXTURE 999 5463 Fixture as a support to avoid damage.

Install engine in stand




Use stand 999 2520 FLOOR STAND 999 2520 Floor Stand and fixture 999 5297 ENGINE FIXTURE 999 5297 Engine Fixture.
Remove lifting tools.

Install the correct number of washers to compensate transmission guide pins.

Transferring rear components




1. Connector brackets
2. Torque control arm use new screws. Tighten screws in two stages:
Stage 1 50 Nm
Stage 2. 90° angle
3. Camshaft position (CMP) sensor
4. Distributor and ignition cables
5. Heater pipes
6. Engine speed (RPM) sensor
7. Flywheel/carrier plate
Transfer all vacuum hoses

Transferring exhaust side components

Exhaust Side Components:

1. Heat deflector plate
2. Exhaust pipe bracket
3. Exhaust manifold with turbocharger (TC)
4. Coolant pipe
5. Fuel line mounting brackets
6. Right engine mounting
7. Thermostat housing, oil cooler
8. Drive shaft bearing bracket

Transferring intake side components




1. Lifting eyes
2. Temperature sensor
3. Intake manifold knock sensors (KS) (torque 20 Nm )
4. Dipstick and pipe
5. Oil level sensor and oil pressure sensor
6. Front engine mounting
7. Flame trap with hose

Install carrier plate/flywheel




Lift the engine from the fixture, use mounting 999 5429 LIFTING EYE 999 5429 Lifting Eye and lifting yoke 999 2810 LIFTING YOKE 999 2810 Lifting Yoke , 999 5428 LIFTING YOKE 999 5428 Lifting Yoke.

Use gear sector 999 5112 GEAR SECTOR 999 5112 Gear Sector.

Use new screws and thread sealant.

Tighten in two stages:
1. Tighten to: 45 Nm
2. Angle-tighten: 50°

Install transmission





Automatic:
Tighten torque converter to: 50Nm .

Manual:
Torque clutch driven plate and pressure plate to: 30 Nm

The old motor is plugged in the same way as the new plug.