Engine - Removal, Replacement and Installation: Other Volvo V50 I рестайлинг

ENGINE, INSTALLING

See ENGINE, INSTALLING

See ENGINE, INSTALLING

See ENGINE, INSTALLING

See ENGINE, INSTALLING

CYLINDER HEAD

Special tools 999 7107 Support Tool number: 999 7107 Tool description: Support Tool boards: 21 999 5454 PRESS TOOL (2) (CYLINDER HEAD) B6304/B5254 Tool number: 999 5454 Tool description: PRESS TOOL (2) (CYLINDER HEAD) B6304/B5254 Tool boards: 21 999 5670 Pliers (removing valve/camshaft cover) B4184-B6304 Tool number: 999 5670 Tool description: Pliers (removing valve/camshaft cover) B4184-B6304 Tool boards: 21 951 2050 BEVEL PROTRACTOR Tool number: 951 2050 Tool description: BEVEL PROTRACTOR Tool boards: 08 951 2767 Roller (Applying liquid gasket) B234, 5234, 6304 Tool number: 951 2767 Tool description: Roller (Applying liquid gasket) B234, 5234, 6304 Tool boards: 08

Scheme 46

Scheme 47

Scheme 48

Perform cooling system draining, charging and bleeding, see COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING

Scheme 49

see 9997107

Remove the following items

1. air cleaner (ACL) housing, see «AIR CLEANER HOUSING»(ref-466651-S39773552372012042500000)
2. spark plugs, see «SPARK PLUGS»(ref-466594-S00903943092012042500000)
3. VVT unit, see «VVT UNIT»(ref-466659-S01783344482012042500000)
4. fuel injector, see «FUEL INJECTOR»(ref-466648-S15230491562012042500000)
5. exhaust manifold, see «EXHAUST MANIFOLD»(ref-466651-S26620069062012042500000)
6. the intake manifold, see «INDUCTION PIPE»(ref-466651-S17079850652012042500000)
7. VVT solenoid, see «VVT SOLENOID»(ref-466659-S08868277172012042500000)

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

see 9995454

Scheme 56

see 9995454

Scheme 57

Scheme 58

see 9995670

Scheme 59

Scheme 60

Note. Note the position of each component before removal.

Scheme 61

Note. Note the position of the component before removal.

Scheme 62

Scheme 63

Use: Gasket solution, 1161847

Scheme 64

Torque: Cylinder head

Stage 1: 20 Nm

Stage 2: 60 Nm

Stage 3: 130 degree

see 9512050

Scheme 65

Note. Make sure that this component is installed to the noted removal position.

Use: Engine oil

Note. This step is only necessary if adjustment is required

Perform valve clearance, see VALVE CLEARANCE

Scheme 66

Note. Make sure that this component is installed to the noted removal position.

Use: Engine oil

Scheme 67

Scheme 68

Note. Make sure that the mating faces are clean and free of foreign material.

Use: Gasket solution, 1161847

see 9512767

Use: Chemical gasket, 1161059

Scheme 69

Torque: M7

17 Nm

Torque: M6

10 Nm

Scheme 70

1. Torque: M10 50 Nm
2. Torque: M8 24 Nm

Torque: M6

10 Nm

Install the following items

1. VVT unit, see «VVT UNIT»(ref-466659-S01783344482012042500000)
2. exhaust manifold, see «EXHAUST MANIFOLD»(ref-466651-S26620069062012042500000)
3. air cleaner (ACL) housing, see «AIR CLEANER HOUSING»(ref-466651-S39773552372012042500000)
4. fuel injector, see «FUEL INJECTOR»(ref-466648-S15230491562012042500000)
5. spark plugs, see «SPARK PLUGS»(ref-466594-S00903943092012042500000)
6. the intake manifold, see «INDUCTION PIPE»(ref-466651-S17079850652012042500000)
7. VVT solenoid, see «VVT SOLENOID»(ref-466659-S08868277172012042500000)

Scheme 71

Torque: M10

50 Nm

Perform cooling system draining, charging and bleeding, see COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING

Special tools 999 7107 Support Tool number: 999 7107 Tool description: Support Tool boards: 21 999 5454 PRESS TOOL (2) (CYLINDER HEAD) B6304/B5254 Tool number: 999 5454 Tool description: PRESS TOOL (2) (CYLINDER HEAD) B6304/B5254 Tool boards: 21 999 5670 Pliers (removing valve/camshaft cover) B4184-B6304 Tool number: 999 5670 Tool description: Pliers (removing valve/camshaft cover) B4184-B6304 Tool boards: 21 951 2050 BEVEL PROTRACTOR Tool number: 951 2050 Tool description: BEVEL PROTRACTOR Tool boards: 08 951 2767 Roller (Applying liquid gasket) B234, 5234, 6304 Tool number: 951 2767 Tool description: Roller (Applying liquid gasket) B234, 5234, 6304 Tool boards: 08

Drain cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING

see 9997107

Remove the following items

1. air cleaner (ACL) housing, see «AIR CLEANER HOUSING»(ref-466651-S14347234182012042500000)
2. VVT unit, see «VVT UNIT»(ref-466659-S01783344482012042500000)
3. fuel injector, see «FUEL INJECTOR»(ref-466648-S10967212142012042500000)
4. exhaust manifold, see «EXHAUST MANIFOLD»(ref-466651-S24624854932012042500000)
5. the intake manifold, see «INDUCTION PIPE»(ref-466651-S36642192012012042500000)
6. VVT solenoid, see «VVT SOLENOID»(ref-466659-S08868277172012042500000)
7. spark plugs, see «SPARK PLUGS»(ref-466594-S08627550642012042500000)

see 9995454

see 9995454

see 9995670

Note. Note the position of each component before removal.

Note. Note the position of each component before removal.

Use: Gasket solution, 1161847

see 9512050

Torque: Cylinder head

Stage 1: 20 Nm

Stage 2: 60 Nm

Stage 3: 130 degree

Note. Make sure that these components are installed to the noted removal position.

Use: Engine oil

Note. This step is only necessary if adjustment is required

Perform valve clearance, see VALVE CLEARANCE

Note. Make sure that these components are installed to the noted removal position.

Use: Engine oil

Note. Make sure that the mating faces are clean and free of foreign material.

Use: Gasket solution, 1161847

see 9512767

Use: Chemical gasket, 1161059

Torque: M7

17 Nm

Torque: M6

10 Nm

1. Torque: M10 50 Nm
2. Torque: M8 24 Nm

Torque: M6

10 Nm

Install the following items

1. VVT unit, see «VVT UNIT»(ref-466659-S01783344482012042500000)
2. exhaust manifold, see «EXHAUST MANIFOLD»(ref-466651-S24624854932012042500000)
3. air cleaner (ACL) housing, see «AIR CLEANER HOUSING»(ref-466651-S14347234182012042500000)
4. fuel injector, see «FUEL INJECTOR»(ref-466648-S10967212142012042500000)
5. spark plugs, see «SPARK PLUGS»(ref-466594-S08627550642012042500000)
6. the intake manifold, see «INDUCTION PIPE»(ref-466651-S36642192012012042500000)
7. VVT solenoid, see «VVT SOLENOID»(ref-466659-S08868277172012042500000)

Torque: M10

50 Nm

Fill cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING

See CYLINDER HEAD

Remove right front wheel, see WHEELS

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

To install, reverse the removal procedure.

Remove the auxiliaries belt, see ACCESSORY DRIVE BELT

Scheme 78

Scheme 79

Torque: Belt tensioner accessory drive belt

42 Nm

Note. Only tighten the bolt finger tight at this stage.

Scheme 80

1. Torque: Belt tensioner accessory drive belt 42 Nm

Scheme 81

Install the auxiliaries belt, see ACCESSORY DRIVE BELT

CAMSHAFT SEAL

Special tools 999 5651 Extractor (crankshaft rear seal) D5252T Tool number: 999 5651 Tool description: Extractor (crankshaft rear seal) D5252T Tool boards: 21 999 7364 Drift Tool number: 999 7364 Tool description: Drift Tool boards: 21 999 5718 Drift (installing/sealing camshaft with VVT) Tool number: 999 5718 Tool description: Drift (installing/sealing camshaft with VVT) Tool boards: 21

Scheme 82

Remove the variable valve timing unit, see VVT UNIT

Scheme 83

see 9995651

Scheme 84

see 9997364

Scheme 85

see 9995718

To install, reverse the removal procedure.

CAMSHAFTS

Special tools 999 7107 Support Tool number: 999 7107 Tool description: Support Tool boards: 21 999 5454 PRESS TOOL (2) (CYLINDER HEAD) B6304/B5254 Tool number: 999 5454 Tool description: PRESS TOOL (2) (CYLINDER HEAD) B6304/B5254 Tool boards: 21 999 5670 Pliers (removing valve/camshaft cover) B4184-B6304 Tool number: 999 5670 Tool description: Pliers (removing valve/camshaft cover) B4184-B6304 Tool boards: 21 951 2767 Roller (Applying liquid gasket) B234, 5234, 6304 Tool number: 951 2767 Tool description: Roller (Applying liquid gasket) B234, 5234, 6304 Tool boards: 08

see 9997107

Remove the following items

1. spark plugs, see «SPARK PLUGS»(ref-466594-S00903943092012042500000)
2. camshaft seal, see «CAMSHAFT SEAL»(ref-466659-S12228556212012042500000)

see 9995454

see 9995454

see 9995670

Note. This step is only necessary if adjustment is required

Perform valve clearance, see VALVE CLEARANCE

Note. Make sure that these components are installed to the noted removal position.

Use: Engine oil

Use: Gasket solution, 1161847

see 9512767

Use: Chemical gasket, 1161059

Torque: M7

17 Nm

Torque: M6

10 Nm

Install the following items

1. camshaft seal, see «CAMSHAFT SEAL»(ref-466659-S12228556212012042500000)
2. VVT unit, see «VVT UNIT»(ref-466659-S01783344482012042500000)
3. timing belt, see «TIMING BELT»(ref-466659-S02206976462012042500000)
4. spark plugs, see «SPARK PLUGS»(ref-466594-S00903943092012042500000)
5. ignition coil, see «IGNITION COIL»(ref-466594-S35951716902012042500000)

TIMING BELT

Special tools 999 5433 COUNTERHOLD (VIBRATION DAMPENER)B6304 B5254 Tool number: 999 5433 Tool description: COUNTERHOLD (VIBRATION DAMPENER)B6304 B5254 Tool boards: 21

Note. Removal steps in this procedure may contain installation details.

Remove the following items

1. Engine support insulator, right, see «ENGINE SUPPORT INSULATOR, RIGHT»(ref-466659-S38257567102012042500000)
2. Tensioner accessory drive belt, see «ACCESSORY DRIVE BELT TENSIONER»(ref-466659-S19986261482012042500000)

Scheme 86

Torque: M6

10 Nm

Scheme 87

Scheme 88

see 9995433

Scheme 89

see 9995433

Scheme 90

Scheme 91

Scheme 92

Scheme 93

1. Torque: M8 24 Nm

Scheme 94

Note. The component can be reused unless it has been subjected to abnormal mechanical stress, damage or oil contamination.

Torque: M8

24 Nm

Scheme 95

Scheme 96

Scheme 97

To install, reverse the removal procedure.

Note. Removal steps in this procedure may contain installation details.

Scheme 98

Torque: M6

10 Nm

Scheme 99

Scheme 100

Torque: M6

10 Nm

To install, reverse the removal procedure.

VVT UNIT

Special tools 999 5452 CAMSHAFT ADJUSTMENT TOOL(alignment-camshaft)B6304 Tool number: 999 5452 Tool description: CAMSHAFT ADJUSTMENT TOOL(alignment-camshaft)B6304 Tool boards: 21 999 5451 ADJUSTMENT TOOL(ALIGNMENT-CRANKSHAFT) B6304 B5254 Tool number: 999 5451 Tool description: ADJUSTMENT TOOL(ALIGNMENT-CRANKSHAFT) B6304 B5254 Tool boards: 21

Scheme 101

Remove the following items

1. air cleaner (ACL) housing, see «AIR CLEANER HOUSING»(ref-466651-S39773552372012042500000)
2. timing belt, see «TIMING BELT»(ref-466659-S02206976462012042500000)
3. starter motor, see «STARTER MOTOR»(ref-466689-S19537932362012042500000)

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

see 9995452

Scheme 107

Replace camshaft seal, see CAMSHAFT SEAL

Note. Only tighten the bolts finger tight at this stage.

Scheme 108

see 9995451

Install timing belt, see TIMING BELT

Scheme 109

Torque: VVT unit, center screw

120 Nm

Scheme 110

1. Torque: M10 50 Nm
2. Torque: M6 10 Nm

Install the following items

1. starter motor, see «STARTER MOTOR»(ref-466689-S19537932362012042500000)
2. timing belt, see «TIMING BELT»(ref-466659-S02206976462012042500000)

Scheme 111

Torque: M6

10 Nm

Scheme 112

Torque: M6

10 Nm

Install the air filter housing, see AIR CLEANER HOUSING

ACCESSORY DRIVE BELT

See ACCESSORY DRIVE BELT

ACCESSORY DRIVE BELT TENSIONER

See ACCESSORY DRIVE BELT TENSIONER

See CAMSHAFT SEAL

See CAMSHAFTS

See TIMING BELT

VVT SOLENOID

See VVT SOLENOID

Special tools 999 5452 CAMSHAFT ADJUSTMENT TOOL(alignment-camshaft)B6304 Tool number: 999 5452 Tool description: CAMSHAFT ADJUSTMENT TOOL(alignment-camshaft)B6304 Tool boards: 21 999 5451 ADJUSTMENT TOOL(ALIGNMENT-CRANKSHAFT) B6304 B5254 Tool number: 999 5451 Tool description: ADJUSTMENT TOOL(ALIGNMENT-CRANKSHAFT) B6304 B5254 Tool boards: 21

Remove the following items

1. air cleaner (ACL) housing, see «AIR CLEANER HOUSING»(ref-466651-S39773552372012042500000)
2. timing belt, see «TIMING BELT»(ref-466659-S40084495992012042500000)
3. starter motor, see «STARTER MOTOR»(ref-466689-S19537932362012042500000)

see 9995452

Scheme 113

Note. Only tighten the bolts finger tight at this stage.

see 9995451

Install timing belt, see TIMING BELT

Scheme 114

1. Torque: M6 10 Nm
2. Torque: VVT unit, center screw 120 Nm

1. Torque: M10 50 Nm
2. Torque: M6 10 Nm

Install the following items

1. starter motor, see «STARTER MOTOR»(ref-466689-S19537932362012042500000)
2. timing belt, see «TIMING BELT»(ref-466659-S02206976462012042500000)

Torque: M6

10 Nm

Torque: M6

10 Nm

Install the air filter housing, see AIR CLEANER HOUSING

See ACCESSORY DRIVE BELT

See ACCESSORY DRIVE BELT TENSIONER

See CAMSHAFT SEAL

See CAMSHAFTS

Special tools 999 5433 COUNTERHOLD (VIBRATION DAMPENER)B6304 B5254 Tool number: 999 5433 Tool description: COUNTERHOLD (VIBRATION DAMPENER)B6304 B5254 Tool boards: 21

Note. Removal steps in this procedure may contain installation details.

Remove the following items

1. the auxiliaries belt, see «ACCESSORY DRIVE BELT TENSIONER»(ref-466659-S19986261482012042500000)
2. Engine support insulator, right, see «ENGINE SUPPORT INSULATOR, RIGHT»(ref-466659-S38257567102012042500000)

Torque: M6

10 Nm

Torque: M6

10 Nm

see 9995433

1. Torque: Center nut vibration damper (crankshaft) 180 Nm
2. Torque: Oscillation damper, flange screw • Stage 1: 25 Nm • Stage 2: 60 degree

Scheme 115

Torque: M8

24 Nm

Scheme 116

Note. The component can be reused unless it has been subjected to abnormal mechanical stress, damage or oil contamination.

To install, reverse the removal procedure.

See VVT SOLENOID

See VVT UNIT

See ACCESSORY DRIVE BELT

See ACCESSORY DRIVE BELT TENSIONER

See CAMSHAFT SEAL

See CAMSHAFTS

See TIMING BELT

See VVT SOLENOID

See VVT UNIT

See ACCESSORY DRIVE BELT

See ACCESSORY DRIVE BELT TENSIONER

Special tools 999 5651 Extractor (crankshaft rear seal) D5252T Tool number: 999 5651 Tool description: Extractor (crankshaft rear seal) D5252T Tool boards: 21 999 5718 Drift (installing/sealing camshaft with VVT) Tool number: 999 5718 Tool description: Drift (installing/sealing camshaft with VVT) Tool boards: 21

Remove the variable valve timing unit, see VVT UNIT

see 9995651

see 9995718

Scheme 117

To install, reverse the removal procedure.

See CAMSHAFTS

See TIMING BELT

See VVT SOLENOID

Special tools 999 5452 CAMSHAFT ADJUSTMENT TOOL(alignment-camshaft)B6304 Tool number: 999 5452 Tool description: CAMSHAFT ADJUSTMENT TOOL(alignment-camshaft)B6304 Tool boards: 21 999 5451 ADJUSTMENT TOOL(ALIGNMENT-CRANKSHAFT) B6304 B5254 Tool number: 999 5451 Tool description: ADJUSTMENT TOOL(ALIGNMENT-CRANKSHAFT) B6304 B5254 Tool boards: 21

Remove the following items

1. air cleaner (ACL) housing, see «AIR CLEANER HOUSING»(ref-466651-S14347234182012042500000)
2. timing belt, see «TIMING BELT»(ref-466659-S02206976462012042500000)
3. starter motor, see «STARTER MOTOR»(ref-466689-S23088816552012042500000)

Scheme 118

see 9995452

Note. Only tighten the bolts finger tight at this stage.

see 9995451

Install timing belt, see TIMING BELT

Torque: VVT unit, center screw

120 Nm

1. Torque: M10 50 Nm
2. Torque: M6 10 Nm

Install the following items

1. starter motor, see «STARTER MOTOR»(ref-466689-S23088816552012042500000)
2. timing belt, see «TIMING BELT»(ref-466659-S40084495992012042500000)

Torque: M6

10 Nm

Install the air filter housing, see AIR CLEANER HOUSING

See ACCESSORY DRIVE BELT

See ACCESSORY DRIVE BELT TENSIONER

See CAMSHAFT SEAL

See CAMSHAFTS

See TIMING BELT

See VVT SOLENOID

See VVT UNIT

See ACCESSORY DRIVE BELT

See ACCESSORY DRIVE BELT TENSIONER

See CAMSHAFT SEAL

See CAMSHAFTS

See TIMING BELT

See VVT SOLENOID

See VVT UNIT

CARRIER PLATE

Special tools

see 9995112

see 9995678

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

REMOVING THE TRANSMISSION

Remove the transmission according to: TRANSMISSION, REMOVING .

REMOVING THE CARRIER PLATE

Remove the engine speed (RPM) sensor together with the bracket. Place the engine speed (RPM) sensor to one side.

Scheme 119

Block the carrier plate using gear sector see 9995112 .

Remove

1. all screws
2. the carrier plate
3. gear sector see «9995112»(ref-460875-S36509387272012033000000) .

Scheme 120

Check the crankshaft seal for leakage.

Note. For tightening torques, see: TIGHTENING TORQUE .

Scheme 121

Note. Check that the contact surfaces on the crankshaft and drive flange plate are completely clean.

Use: see 9995678 , which consists of 3 x clevis pins with nuts.

Install

1. the 3 x clevis pins belonging to: see «9995678»(ref-460875-S21852882082012033000000) distributed as shown in the illustration.
2. the carrier plate.

Note. Check that the guide pin on the crankshaft is positioned directly opposite the hole in the drive flange plate.

Locate the gear sector see 9995112 against the flexplate.

Pull the flexplate against the crankshaft using the 3 x nuts belonging to: see 9995678 .

Install 7 x new screws. Tighten. See: TIGHTENING TORQUE

Remove the 3 nuts and the studs.

Install

1. the remaining 3 x new screws. Tighten. See: «TIGHTENING TORQUE»(ref-466839-S06570312852012042500000)
2. the engine speed (RPM) sensor and bracket. Tighten.

INSTALLING THE TRANSMISSION

Install the gearbox. See: TRANSMISSION, INSTALLING .

CRANKSHAFT FRONT SEAL

Special tools 999 5304 SEPARATOR (DRIVE FLANGE) M45-M47 II. Tool number: 999 5304 Tool description: SEPARATOR (DRIVE FLANGE) M45-M47 II. Tool boards: 43 999 5919 PULLER (SEAL-PINION, CAM-CRANKSHAFT)B200-6304 Tool number: 999 5919 Tool description: PULLER (SEAL-PINION, CAM-CRANKSHAFT)B200-6304 Tool boards: 46 999 5747 Socket (remov./inst. oil pump/crankshaft) B 4164- Tool number: 999 5747 Tool description: Socket (remov./inst. oil pump/crankshaft) B 4164- Tool boards: 21

Scheme 122

Scheme 123

Remove timing belt, see TIMING BELT

Scheme 124

see 9995304

Scheme 125

see 9995919

Scheme 126

see 9995747

Scheme 127

Note. The component can only be installed in 1 position.

Install timing belt, see TIMING BELT

CRANKSHAFT SEAL, REAR

Special tools 999 5651 Extractor (crankshaft rear seal) D5252T Tool number: 999 5651 Tool description: Extractor (crankshaft rear seal) D5252T Tool boards: 21 999 7174 Drift Tool number: 999 7174 Tool description: Drift Tool boards: 23

Scheme 128

Remove drive flange plate, see CARRIER PLATE

Scheme 129

see 9995651

Scheme 130

see 9997174

Install carrier plate, see CARRIER PLATE

See CRANKSHAFT FRONT SEAL

Special tools 999 5651 Extractor (crankshaft rear seal) D5252T Tool number: 999 5651 Tool description: Extractor (crankshaft rear seal) D5252T Tool boards: 21 999 7174 Drift Tool number: 999 7174 Tool description: Drift Tool boards: 23

Remove flywheel, see FLYWHEEL

see 9995651

see 9997174

Install flywheel, see FLYWHEEL

FLYWHEEL

Special tools 999 5678 Special screw (flywheel) B4184-B6304 Tool number: 999 5678 Tool description: Special screw (flywheel) B4184-B6304 Tool boards: 21

Note. Removal steps in this procedure may contain installation details.

Remove clutch plate and pressure plate, see CLUTCH DISC AND PRESSURE PLATE

Scheme 131

Torque: M7

17 Nm

Scheme 132

Scheme 133

Note. Make sure that the locating pin on the crankshaft is aligned with the guide hole in the flywheel or flexplate.

see 9995678

Scheme 134

Torque: Flywheel

Stage 1: 45 Nm

Stage 2: 65 degree

Scheme 135

Torque: Flywheel

Stage 1: 45 Nm

Stage 2: 65 degree

To install, reverse the removal procedure.

Special tools

see 9995112

see 9995678

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Remove the transaxle. See: TRANSMISSION, REMOVING (B5254T3, AW55-50/51SN; 2005-2007), or TRANSMISSION, REMOVING (B5254T3, AW50/51 AWD; 2005-2007)

Remove the engine speed (RPM) sensor together with the bracket. Place the engine speed (RPM) sensor to one side.

Block the carrier plate using gear sector see 9995112 .

Remove

1. all screws
2. the carrier plate
3. gear sector see «9995112»(ref-460875-S36509387272012033000000) .

Check the crankshaft seal for leakage.

Note. For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE CARRIER PLATE

Note. Ensure that the mating surfaces on the crankshaft and carrier plate are completely clean.

Use: see 9995678 , which consists of 3 x clevis pins with nuts.

Install

1. the 3 x clevis pins belonging to: see «9995678»(ref-460875-S21852882082012033000000) distributed as shown in the illustration.
2. the carrier plate.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the carrier plate.

Locate the gear sector see 9995112 against the flexplate.

Pull the flexplate against the crankshaft using the 3 x nuts belonging to: see 9995678 .

Install 7 x new screws. Tighten. See: TIGHTENING TORQUE

Remove the 3 nuts and the studs.

Install

1. the remaining 3 x new screws. Tighten. See: «TIGHTENING TORQUE»(ref-466839-S06570312852012042500000)
2. the engine speed (RPM) sensor and bracket. Tighten.

Install the transaxle. See: TRANSMISSION, INSTALLING (B5254T3, AW55-50/51SN; 2005-2007), or TRANSMISSION, INSTALLING (B5254T3, AW50/51 AWD; 2005-2007)

See CRANKSHAFT FRONT SEAL

Special tools 999 5651 Extractor (crankshaft rear seal) D5252T Tool number: 999 5651 Tool description: Extractor (crankshaft rear seal) D5252T Tool boards: 21 999 7174 Drift Tool number: 999 7174 Tool description: Drift Tool boards: 23

Remove drive flange plate, see CARRIER PLATE

see 9995651

see 9997174

Install carrier plate, see CARRIER PLATE

See CRANKSHAFT FRONT SEAL

Special tools 999 5651 Extractor (crankshaft rear seal) D5252T Tool number: 999 5651 Tool description: Extractor (crankshaft rear seal) D5252T Tool boards: 21 999 7174 Drift Tool number: 999 7174 Tool description: Drift Tool boards: 23

Remove flywheel, see FLYWHEEL

see 9995651

see 9997174

Install flywheel, see FLYWHEEL

See FLYWHEEL

See CARRIER PLATE

See CRANKSHAFT FRONT SEAL

See CRANKSHAFT SEAL, REAR

See CARRIER PLATE

See CRANKSHAFT FRONT SEAL

See CRANKSHAFT SEAL, REAR

See CRANKSHAFT FRONT SEAL

See CRANKSHAFT SEAL, REAR

See FLYWHEEL

OIL PAN

Special tools 999 7273 Guide pin Tool number: 999 7273 Tool description: Guide pin Tool boards: 21 951 2767 Roller (Applying liquid gasket) B234, 5234, 6304 Tool number: 951 2767 Tool description: Roller (Applying liquid gasket) B234, 5234, 6304 Tool boards: 08

Scheme 136

Note. Removal steps in this procedure may contain installation details.

Remove the auxiliaries belt, see ACCESSORY DRIVE BELT

Scheme 137

Torque: M8

24 Nm

Scheme 138

Torque: M10

50 Nm

Scheme 139

Torque: M10

50 Nm

Scheme 140

Torque: M6

10 Nm

Scheme 141

Torque: M7

17 Nm

Scheme 142

Scheme 143

see 9997273

Scheme 144

Scheme 145

Use: Cleaning agent, 1161721

see 9512767

Use: Chemical gasket, 1161059

Scheme 146

Torque: M7

17 Nm

To install, reverse the removal procedure.

Special tools 999 7273 Guide pin Tool number: 999 7273 Tool description: Guide pin Tool boards: 21 951 2767 Roller (Applying liquid gasket) B234, 5234, 6304 Tool number: 951 2767 Tool description: Roller (Applying liquid gasket) B234, 5234, 6304 Tool boards: 08

Remove the auxiliaries belt, see ACCESSORY DRIVE BELT

Scheme 147

Scheme 148

see 9997273

Use: Cleaning agent, 1161721

see 9512767

Use: Chemical gasket, 1161059

Torque: M7

17 Nm

To install, reverse the removal procedure.

Note. Removal steps in this procedure may contain installation details.

Scheme 149

Remove the following items

1. Torque: M12 80 Nm
2. Torque: Bottom torque rod (screw M10) 60 Nm

To install, reverse the removal procedure.

ENGINE SUPPORT INSULATOR, LEFT

Special tools 999 5185 HOOK (LIFTING OUT ENGINE-TO 2810) Tool number: 999 5185 Tool description: HOOK (LIFTING OUT ENGINE-TO 2810) Tool boards: 21 999 7103 Lifting beam Tool number: 999 7103 Tool description: Lifting beam Tool boards: 21 999 7102 Lifting yoke Tool number: 999 7102 Tool description: Lifting yoke Tool boards: 21

Note. Removal steps in this procedure may contain installation details.

Remove the air filter housing, see AIR CLEANER HOUSING

Remove battery, see BATTERY

Scheme 150

see 9995185 see 9997103

Scheme 151

see 9997102

Scheme 152

Remove the following items

1. Torque: Engine pad, left side (4 nuts M10) • Stage 1: 34 Nm • Stage 2: 60 degree
2. Torque: M8 24 Nm
3. Torque: M6 10 Nm

Scheme 153

Torque: Engine pad, left side (screw M12)

80 Nm

To install, reverse the removal procedure.

Note. Removal steps in this procedure may contain installation details.

Scheme 154

Scheme 155

Torque: Engine pad to frame member

90 Nm

Scheme 156

Torque: Engine pad to engine, screw

133 Nm

To install, reverse the removal procedure.

Special tools 999 7103 Lifting beam Tool number: 999 7103 Tool description: Lifting beam Tool boards: 21 999 5185 HOOK (LIFTING OUT ENGINE-TO 2810) Tool number: 999 5185 Tool description: HOOK (LIFTING OUT ENGINE-TO 2810) Tool boards: 21 999 7102 Lifting yoke Tool number: 999 7102 Tool description: Lifting yoke Tool boards: 21

Note. Removal steps in this procedure may contain installation details.

Remove the air filter housing, see AIR CLEANER HOUSING

Remove battery, see BATTERY

see 9997103 see 9995185

see 9997102

Remove the following items

1. Torque: Engine pad, left side (4 nuts M10) • Stage 1: 34 Nm • Stage 2: 60 degree
2. Torque: M8 24 Nm
3. Torque: M6 10 Nm

Scheme 157

Torque: Engine pad, left side (screw M12)

80 Nm

To install, reverse the removal procedure.

ENGINE SUPPORT INSULATOR, RIGHT

See ENGINE SUPPORT INSULATOR, RIGHT

See ENGINE SUPPORT INSULATOR, LEFT

See ENGINE SUPPORT INSULATOR, RIGHT

FRONT BUSHING SUBFRAME FRONT

Special tools

see 9997054

see 9997034

see 9997132

see 9997131

see 9997130

see 9997134

see 9997133

see 9997138

see 9997137

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

PREPARATORY WORK

Remove the wheel.

Remove the sub-frame. See

Scheme 158

Press the control arm into place.

Install the hydraulic cylinder.

Use: see 9997054 with: see 9997034 , nut M12: see 9997132 , socket: see 9997131 and drift: see 9997130 .

Pull the bushing out.

Scheme 159

Press the control arm into place.

Install the hydraulic cylinder.

Use: see 9997054 with: see 9997034 , nut M12: see 9997132 , socket: see 9997136 and drift: see 9997135 .

Pull the bushing out.

Scheme 160

Install the hydraulic cylinder.

Use: see 9997054 with: see 9997034 , nut: see 9997132 , socket: see 9997134 , lock ring: see 9997134 and ring: see 9997133 .

Pull in the bushing until it is centered in the link arm. Pull the bushing in approximately half-way and then remove: see 9997134 .

Then pull the bushing in so that it bottoms out against the flange

Scheme 161

Install the control arm.

Use: see 9997054 with: see 9997034 , nut: see 9997132 , socket: see 9997138 , drift: see 9997135 lock ring: see 9997138 and ring: see 9997137 .

Note. The bushings shall be installed with the markings in line across the length of the car.

Pull the bushing in approximately half-way and then remove: see 9997138 .

Then pull the bushing in so that it bottoms out against the flange.

INSTALLING THE SUB-FRAME

Install the sub-frame. See

Install the wheel according to: WHEELS .

Note. Removal steps in this procedure may contain installation details.

Scheme 162

Remove the following items

1. Torque: M12 80 Nm
2. Torque: M12 80 Nm

To install, reverse the removal procedure.