Cylinder Block, Remounting External Components

Special Tools:
- Floor Stand tool No. 999 2520, or equivalent
- Lifting Yoke tool No. 999 2810, or equivalent
- Gear Segment tool No. 999 5112, or equivalent
- Fixture tool No. 999 5297, or equivalent
- Lifting Yoke tool No. 999 5428, or equivalent
- Lifting Lug tool No. 999 5459, or equivalent
- Lifting Lug tool No. 999 5464, or equivalent

NOTE: For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Reconditioning". Tools and Equipment

Procedure:

NOTE: Numbers in images do not refer to steps, but only to components to be remounted.

B5204, B5434T:

1. Refer to the illustration for installation of front components for Turbocharged models.

B5202, B5204, B5252, B5254:

2. Refer to the illustration for installation of intake side components for Non-Turbocharged models.

B5204T, B5234T:

3. Refer to the illustration for installation of intake side components for Turbocharged models.

B5202, B5204, B5252, B5454:

4. Refer to the illustration for installation of exhaust side components for Non-Turbocharged models.





5. Refer to the illustration for installation of exhaust side components for Turbocharged models.

B5202, B5204, B5252, B5254:

6. Refer to the illustration for installation of rear edge components for Non-Turbocharged models.





7. Refer to the illustration for installation of rear edge components for Turbocharged models.





8. Install flywheel/carrier plate:
- Use gear segment tool No. 999 5112 and special bolts tool No. 999 5593, or equivalents.

Manual Transmission Models:
- Install flywheel using three special bolts and tighten to 45 Nm (33 ft lb).
- Install the remaining standard bolts (new ones) and tighten to 45 Nm (33 ft lb).
- Replace the three special bolts with new standard bolts and tighten to: 45 Nm (33 ft lb).
- Tighten an additional: 65°

Automatic Transmission Models:
- Install carrier plate, tighten in two stages:
1st Stage: Tighten to: 45 Nm (33 ft lb)
2nd Stage: Tighten an additional: 50°





9. Install gearbox and starter motor:
- Installing gearbox, refer to Transmission and Drivetrain.
- Install starter motor.

Manual Transmission Models:
- Tighten clutch driven and pressure plates to: 30 Nm (22 ft lb)
- Install gearbox.
Tighten to: 50 Nm (37 ft lb)

Automatic Transmission Models:
- Install dipstick and tube.
- Tighten torque converter to carrier plate.
Tighten bolts alternately to: 50 Nm (37 ft lb)
- Install gearbox.
Tighten to: 50 Nm (37 ft lb)





10. Install engine in car:
- Install engine as described in Removal and Installation.