Replacement of Components - Engine Removed

Special Tools
999 2520
999 2810
999 5112
999 5297
999 5428
999 5429
999 5463

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 with transmission fixture 999 5463 as a support to avoid damage.

Install engine in stand





Use stand 999 2520 and fixture 999 5297.
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





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 and lifting yoke 999 2810, 999 5428.
Use gear sector 999 5112.
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: 50 Nm

Manual:
Torque clutch driven plate and pressure plate to: 30 Nm
The old motor is plugged in the same way as the new plug.

Lifting engine in
Special tools: 999 2810, 999 5428, 999 5462, 999 5474, 999 5488, 999 5533

Note! From autumn 93 onwards lifting arm 998 9734 is included in the kit for tool 999 2810. The lifting arm is required for removing and installing the turbo motor.