Engine on subframe, To remove - To fit
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Engine on subframe, To remove - To fit
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1.
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Set the engine in an engine lift.
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2.
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Remove the two lower catalytic converter retaining bolts and the three nuts for the turbo, remove the catalytic converter.
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3.
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Remove the generator with the upper bracket.
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4.
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Detach the bracket for the torque arm in the subframe.
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5.
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Remove the nut for the rear engine mounting.
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6.
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Suspend the left-hand drive shaft in the gearbox bracket using a cable tie.
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7.
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Lift the engine and gearbox from the subframe.
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8.
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Remove the rear engine mounting with gearchange linkage.
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9.
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Remove the two bolts and the stud from the intermediate shaft bracket and pull the shaft from the gearbox. Be careful not to damage the seal in the gearbox when the shaft is pulled out.
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11.
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Remove the three lower bolts in the engine/gearbox mating surface.
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12.
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Place the engine and gearbox on a working surface.
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13.
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Remove the starter motor and the cable duct.
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14.
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Remove the remaining bolts in the engine/gearbox mating surface.
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15.
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Pull out and lower the gearbox with help from an assistant.
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1.
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Lift up the gearbox with the help of an assistant and push the gearbox shaft into the clutch plate centre. Make sure that the two gearbox guide sleeves are in place on the engine.
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2.
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Fit the gearbox to the engine.
Tightening torque, upper and side bolts 70 Nm (52 lbf ft)
Tightening torque, lower bolts 40 Nm (30 lbf ft)
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3.
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Fit the starter motor with the cable duct and fit new cable ties, do not tension them yet as the battery cable will be routed in these later.
Tightening torque: 45 Nm (33 lbf ft)
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4.
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Lift up the engine and gearbox slightly from the working surface. Remove the protective plug from the drive shaft hole.
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5.
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Fit the intermediate shaft carefully in the gearbox so that the seal in the gearbox is not damaged. Fit the bracket for the intermediate shaft in the engine block.
Tightening torque: 47 Nm (35 lbf ft)
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6.
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Fit the rear engine mounting with gearchange linkage on the engine.
Tightening torque: 60 Nm +60° (44 lbf ft +60°)
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7.
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Lift up the engine and gearbox using an engine lift and position it on the subframe.
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8.
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Fit the torque arm to the subframe.
Tightening torque: 90 Nm + 90° (66 lbf ft + 90°)
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9.
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Fit the nuts to the rear engine mounting.
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10.
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Fit the generator with the upper bracket.
Tightening torque, M10 50 Nm (37 lbf ft)
Tightening torque, M8 28 Nm (21 lbf ft)
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11.
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Coat the studs with Molycote 1000 and fit the catalytic converter.
Tightening torque: 24 Nm (18 lbf ft)
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12.
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Remove the cable tie from the gearbox bracket and lower the left-hand drive shaft.
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13.
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Remove the engine lift.
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