To Separate the Engine From the Gearbox

1. Clean the outside of the engine and gearbox.
2. Drain the engine oil. Remove the EGR pipe
3. Remove the flywheel housing cover. Remove the oil dipstick pipe. Remove the oil return pipe from the turbocharger.
4. Remove the starter motor. Remove the stay plate for the starter motor.





5. Withdraw the clutch shaft using sliding hammer 83 90 270 and adapter 87 90 529.





6. Remove the three slave cylinder mounting bolts.





7. Remove all joint bolts between the engine and gearbox. Release the oil filler pipe bracket at the throttle control in the intake manifold.





8. Carefully lift the engine off the gearbox (see figure), at the same time removing the release bearing guide sleeve.
9. Remove the oil pump suction pipe with 0-ring.

CAUTION: If the engine does not separate easily from the gearbox, do not try to prise it away until you have checked that all bolts have been removed.

BEFORE MOUNTING THE ENGINE ON THE GEARBOX
- Make sure that the joint faces of the engine and gearbox are thoroughly clean.
- Make sure that the two locating sleeves are fitted to the gearbox.





- Fit a new gasket to the gearcase joint face. Apply sealing compound to both grooves in the gasket as shown in the upper figure.





- Apply thread sealing compound to the six bolts marked in the figure.
Assemble in the reverse order.

NOTE: The guide sleeve for the release bearing must be held in position against the clutch as the engine is being lowered onto the gearbox.





Tightening torque for the engine/gearbox joint bolts: 25 Nm +/- 13 Nm (18.5 +/- 2.2 lb ft)