Removing Engine From Transmission and Mounting Engine On Transmission

Removing engine from transmission and mounting engine on transmission








Preliminary work

1. Engine removed. Engine/transmission unit is on the lifting platform.

Mounting engine on transmission

1. Insert special tool centering pin 9689 into the torque converter. Roughly position the torque converter and drive plate so that the centering pin passes through a bore on the drive plate.





Torque converter centering pin

2. Tie the upper ATF line to the engine with a piece of wire or cable.
3. Check the position of the transmission. Position the transmission on a suitable wooden block if necessary (as for removal) and secure it with a piece of wire or cable.





Securing transmission to prevent it from tipping over





Wooden block placed underneath

4. Lift the engine with the workshop crane and move it into installation position with respect to the transmission. Suspend the engine so that it is lower at the back than at the front with respect to the transmission -1 lower, 2 higher-. Put engine and transmission together. Dowel sleeves must slip perfectly into the bores.





Suspending engine

5. Mount the engine without the engine carrier on the transmission.
6. Secure the engine/transmission unit using two screws.
7. Screw the transmission to the engine. Also fit sheetmetal holders for catalytic converters on V8 naturally aspirated engines.
8. Lift the engine/transmission unit, fit the lower ATF line and move the two ATF lines roughly into installation position.
9. Fit engine carrier. Screw engine mountings to the engine carrier. - Tightening torque: 60 Nm (44 ftlb.)





Engine mounting screws

10. Remove wooden block from under the transmission.

Information
The connection piece for the front-axle final drive vent line must not break off when lowering the engine onto the front-axle carrier! Check this by carrying out a visual inspection.

11. Lower engine with engine carrier onto the front-axle carrier. Make sure that the engine carrier is positioned correctly on the support dome of the lifting platform.
12. Position torque converter correctly with respect to the drive plate. Remove centering pin.
13. If the torque converter turns accidentally, remove rubber strap at the side of the transmission bell housing and turn it back into position using a mirror -1- and screwdriver -2-.





Turning torque converter

14. Screw on torque converter.
15. Fit ATF lines.
16. Fit coolant pipe on converter bell housing -arrow-. - Tightening torque: 9 Nm (6.5 ftlb.)





Coolant pipes on converter bell housing

17. Connect two coolant hoses. Secure the spring band clamps -1 and 2-.





Coolant hoses

18. Connect cable plug on reference mark sender (TDC sender) at the top at the engine cable duct to the engine wire harness and clip it in -1-.





Cable plug on reference mark sender

19. Fit reference mark sender at the transmission bell housing -arrow-. - Tightening torque: 10 Nm (7.5 ftlb.)





Reference mark sender

20. Clip invent lines at the coolant guide --.





Vent lines

21. Fit cardan shaft.
22. Provisionally route PDCC lines and move them into installation position.
23. Insert line -5- into the tandem pump -arrow A- and screw in union nut -4- but do not tighten it.





Securing lines on tandem pump

24. Position line -3- on the tandem pump -arrow B- and screw in banjo bolt -1- with new sealing rings -2-, but do not tighten it.
25. Push line bracket -2- with PDCC lines onto the threaded bolts -arrow- and secure with the fastening nuts -1-.





Securing line bracket for PDCC lines

26. Clip lines -2 to 5- into the line bracket -arrows- and secure with the fastening screws -1-.





Securing lines on air conditioning compressor

27. Fit PDCC lines into the pump.
28. Plug in connector -arrow B- until the locking lug -arrow a- engages securely and press it into the holder on the air conditioning compressor -arrow A-.





Plugging in connector





Boost pressure pipe

29. Fit left pressure pipe on the turbocharger. To do this, clip in vent line and fit clamp -1 and 2-.
30. Fit sheetmetal holder for left catalytic converter (Turbo only) -9-. - Tightening torque: 23 Nm (17 ftlb.).





Holder for catalytic converter - Turbo engine

31. Fit catalytic converters on both sides to the exhaust manifolds or turbochargers. Fit the lambda sensor cables leading to the catalytic converters (one cable -1- on naturally aspirated engine, two cables on Turbo engine -1-) while you work. To do this, replace five nuts on the flange -2- -2- and fit one screw on the sheetmetal holder under the catalytic converters -3- -3-. - Tightening torque: 23 Nm (17 ftlb.) - Tightening torque: 23 Nm (17 ftlb.)





Catalytic converter - Turbo engine





Catalytic converter - naturally aspirated engine


Subsequent work

1. Install engine.