Manual Transmission, Remove from Engine and
Install
Remove
1. |
Detach cooling module
• |
Remove coolant hose (2) from thermostat housing
|
• |
Remove coolant hose (1) from coolant pump
|
• |
Remove coolant hose from coolant compensation tank
|
• |
Lift away from front axle body
|
|
|
|
2. |
Detach shift guide
• |
Disconnect universal joint
– |
Remove retaining pin (1)
|
|
|
|
|
3. |
Remove drive shafts
• |
Knock out with KM-6003-1 in
conjunction with KM-313
|
|
|
|
4. |
Detach oxygen sensor wiring harness plug
• |
Unclip plug from bracket
|
• |
Unclip wiring harness (2) from bracket
|
|
5. |
Remove engine transport shackles (1)
|
6. |
Release heat shield (4)
|
|
|
7. |
Remove oil dipstick guide tube (1)
• |
Detach from exhaust manifold (3)
|
• |
Remove from cylinder block
|
|
|
|
8. |
Remove exhaust manifold (2)
|
|
|
9. |
Attach KM-2358
• |
to engine transport shackle on the transmission side, exhaust
side
|
|
10. |
Detach front engine damping block bracket (1) from
transmission
|
|
|
11. |
Detach rear engine damping block bracket (1) from
transmission
|
|
|
12. |
Lift engine with gearbox from front axle body
|
13. |
Release transmission
• |
crankshaft bearing bridge
|
• |
Remove wiring harness bracket
|
|
|
|
14. |
Detach transmission from engine
Note: Use a second
person
|
15. |
Attach engine to KM-412
• |
Attach KM-412-18 to engine (1)
|
• |
Attach engine to KM-412-18 (2) with
KM-412
– |
Tighten 8x bolted connections
|
|
|
|
|
16. |
Detach engine from KM-412
• |
Detach KM-412-18 from KM-412
– |
Slacken 8x screwed connections
|
|
• |
Remove KM-412-18 from engine
|
|
Install
17. |
Attach transmission to engine
Note: Use a second
person
|
18. |
Fasten transmission to engine
• |
To cylinder block base plate
|
|
19. |
Fit engine to front axle body
• |
Position engine with transmission on front axle body
|
• |
Attach front engine damping block bracket to transmission
|
• |
Attach rear engine damping block bracket to transmission
|
|
20. |
Fasten engine to front axle body
• |
Fasten front engine damping block bracket to transmission
|
• |
Fasten rear engine damping block bracket to transmission
– |
Tighten 2x bolt 80 Nm + 45° to
60°
|
|
|
21. |
Remove KM-2358
• |
from engine transport shackle on the transmission side, exhaust
side
|
|
22. |
Insert exhaust manifold gasket
|
23. |
Install exhaust manifold
• |
Tighten 9x nut 15 Nm (2
passes)
|
|
25. |
Install dipstick guide tube
|
27. |
Attach engine transport shackle
|
28. |
Connect oxygen sensor wiring harness plug
• |
Clip wiring harness plug into bracket
|
• |
Clip wiring harness into bracket
|
|
29. |
Attach dipstick guide tube
|
30. |
Install drive shafts
• |
Remove 2x transmission seals
|
|
31. |
Install shift guide
• |
Connect universal joint
|
|
32. |
Attach cooling module
• |
Position on front axle body
|
• |
Attach coolant hose to coolant pump
|
• |
Attach coolant hose to thermostat housing.
|
• |
Attach coolant hose to coolant expansion tank
|
|
|