XC90 2.5T AWD L5-2.5L Turbo VIN 59 B5254T2 (2003)
Installing flywheel and carrier plate
Caution! Ensure that the surface of the crankshaft and the mating surfaces for the flywheel / carrier plate are clean. Ensure that there is no
thread sealant residue in the screw holes.
Install:
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the flywheel and carrier plate
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the 3 studs 999 5678 Special screw See: Tools and Equipment/999 5678 Special Screw distributed as illustrated. Turn the short thread length
towards the crankshaft.
Note! Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole
is marked.
Caution! It is important that the flywheel and carrier plate bear on the crankshaft flange before the other screws are installed. Always use new
screws. Ensure that the thread sealant on the new screws is intact. If not apply a few drops of sealant 1161056 to the thread.
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Align gear sector: 999 5112 GEAR SECTOR See: Tools and Equipment/999 5112 Gear Sector.
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Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool 999 5678 Special screw See: Tools and Equipment/999
5678 Special Screw. The turned section of the nut must be turned towards the flywheel / carrier plate.
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Install the other screws. Tighten. See Tightening torque See: Specifications/Mechanical Specifications/Tightening Torque.
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Replace the 3 special screws with new standard screws. Tighten. See Tightening torque See: Specifications/Mechanical Specifications/Tightening
Torque.
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Then angle-tighten all 10 screws crosswise. Use 951 2050 BEVEL PROTRACTOR See: Tools and Equipment/951 2050 Bevel Protractor.
Tighten. See Tightening torque See: Specifications/Mechanical Specifications/Tightening Torque.
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Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.
Installing the gearbox
Install the gearbox:
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manual transmissions. See Transmission, installing See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement.
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automatic transmissions. See Gearbox, installing See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and
Repair/Removal and Replacement.
Checking the engine:
