Replacing the engine (power train on the subframe)
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Replacing the engine (power train on the subframe)
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Drain the oil from the engine and the fluid from the gearbox.
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1.
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Detach the generator electrical connections and remove the generator.
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2.
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Remove the generator bracket.
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3.
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Remove the right-hand drive shaft with intermediate shaft.
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4.
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Remove the bearing anchorage of the intermediate shaft.
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5.
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Remove the engine mounting from the engine.
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6.
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Remove the drive belt.
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7.
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Remove the power steering pump. Let the servo hoses remain on the pump.
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8.
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Unplug the control module connectors and disconnect the ground cable.
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9.
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Unhook the power steering reservoir and servo hose clips.
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10.
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Remove the A/C bracket and the turbocharger delivery pipe mounting.
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11.
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Remove the power steering pump bracket.
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12.
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Remove the secondary air injection pump complete with connectors, hoses and mountings.
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13.
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Detach the turbocharger delivery hose from the turbocharger.
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14.
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Detach the coolant hoses from the oil cooler. Collect any fluid spill.
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15.
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Detach the coolant pipe with hoses from the thermostat housing.
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16.
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Remove the starter motor with electrical connections.
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17.
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Aut:
Remove the bolts holding the torque converter in place.
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18.
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Remove the wiring harness between the starter motor and generator as well as the one from the rear of the intake manifold. Release the two clips from the back of the engine and the cable duct on the gearbox.
Man:
Remove the cable mounting from the gearbox.
Aut:
Remove the clamp and ground cable from the plate bracket and unplug the connector from the gear selector position sensor/control module.
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19.
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Detach the 7-pin connector and the cable duct from the intake manifold.
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20.
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Remove the upper heat shield from the turbocharger.
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21.
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Remove the lower heat shield from the turbocharger.
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22.
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Unplug the connectors of the heated oxygen sensors.
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23.
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Detach the upper oxygen sensor from the catalytic converter.
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24.
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Remove the catalytic converter with mounting.
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25.
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Remove the upper mounting of the catalytic converter from the engine.
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26.
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Remove the coolant pipe between the heat exchanger and thermostat housing.
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27.
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Unplug the connectors and remove the engine control module with mounting.
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29.
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Remove the bolts holding the torque arms to the subframe.
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30.
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Raise the engine from the subframe.
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31.
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Remove the 4 lower bolts of the gearbox.
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32.
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Place the engine on the floor.
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33.
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Remove the gearbox bolts and lift away the gearbox.
Aut:
Press the torque converter against the gearbox.
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35.
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Transfer the crankcase ventilation hose.
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Note
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Read the engine designation (L or E) and the serial number on the old engine and stamp in the equivalent on the new one.
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1.
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Aut:
Turn the torque converter so that the bolt holes align with the holes on the driver plate and turn the engine so that the oval hole in the driver is centred at the starter motor opening. Fit
87 92 574 Holder
to hold the torque converter in place during fitting. Lubricate the torque converter guide pin with grease.
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2.
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Make sure the two guide sleeves are fitted on the engine and apply grease to the guide sleeves.
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3.
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Install the gearbox on the engine.
Aut:
Remove
87 92 574 Holder
just before the gearbox is in place.
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4.
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Tighten the upper bolts between the engine and gearbox.
Aut:
Fit the plate bracket for the ground cable.
Tightening torque: 19 Nm (14 lbf ft)
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6.
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Fit the bolts that hold the torque arms to the subframe.
Tightening torque, rear torque arm: 80 Nm (59 lbf ft)
Tightening torque, front torque arm: 60 Nm + 90° (44 lbf ft + 90°)
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7.
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Fit the lower bolts between the engine and gearbox.
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8.
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Aut:
Press the torque converter against the driver plate. Fit the plug.
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9.
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Aut:
Apply
Thread locking adhesive, Loctite 242
to the bolts holding the torque converter to the driver plate.
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Note
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Use the original bolts with corresponding washers. The torque converter will be ruined if the bolts that are used are too long.
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10.
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Aut
: Turn the crankshaft clockwise with the pulley and tighten the bolts one at a time starting with the oval hole in the driver plate.
Tightening torque: 62 Nm (46 lbf ft)
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11.
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Fit the coolant pipe between the heat exchanger and thermostat housing. Use a new O-ring coated with acid-free vaseline.
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12.
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Position the wiring harness.
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13.
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Aut:
Plug in the connector of the gear selector position sensor/control module. Fit the clamp and ground cable to the plate bracket.
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14.
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Man:
Fit the cable mounting to the gearbox.
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15.
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Connect the two clips on the rear of the engine and fit the cable duct on the gearbox.
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16.
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Fit the engine control module with mounting.
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17.
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Fit the cable duct of the intake manifold and plug in the 7-pin connector.
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18.
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Fit the starter motor and connect the leads.
Tightening torque 47 Nm (35 lbf ft)
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19.
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Fit the coolant pipe to the thermostat housing. Use a new O-ring coated with acid-free vaseline.
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20.
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Attach the coolant hoses to the oil cooler.
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21.
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Attach the turbocharger delivery hose to the turbocharger.
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22.
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Install the secondary air injection pump complete with connectors, hoses and mountings.
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23.
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Fit the upper mounting of the catalytic converter to the engine.
Tightening torque, M10: 42 Nm (30 lbf ft)
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24.
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Fit the catalytic converter with bracket. Use
90 513 210 Universal paste
on the nut threads. Fit the upper heated oxygen sensor.
Tightening torque, flange to turbocharger: 25 Nm (18 lbf ft)
Tightening torque, mounting to oil sump: 19 Nm (14 lbf ft)
Tightening torque, mounting to exhaust flange: 40 Nm (30 lbf ft)
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25.
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Plug in the connectors of the heated oxygen sensors.
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26.
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Fit the upper and lower heat shield to the turbocharger.
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27.
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Fit the power steering pump bracket.
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28.
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Fit the A/C bracket and the turbocharger delivery pipe mounting.
Tightening torque, A/C bracket: 38 Nm (28 lbf ft)
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29.
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Hook on the power steering fluid reservoir; secure the hose with the clip.
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30.
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Plug in the engine control module connectors and connect the ground cable.
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31.
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Fit the power steering pump.
Tightening torque: 19 Nm (14 lbf ft)
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32.
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Fit the drive belt.
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33.
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Attach the engine mounting to the engine.
Tightening torque 93 Nm (69 lbf ft)
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34.
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Fit the bearing anchorage of the intermediate shaft.
Tightening torque 24 Nm (18 lbf ft).
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35.
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Fit the generator bracket.
Tightening torque, M8: 22 Nm (16 lbf ft)
Tightening torque, M10: 38 Nm (28 lbf ft)
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36.
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Fit the generator and its electrical connections.
Tightening torque 24 Nm (18 lbf ft).
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37.
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Install the right-hand drive shaft with intermediate shaft.
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