Removal

Engine Replacement, Transfer Of Components

Special tools: 2520,2820, 5035, 5171, 5172, 5927




The following procedure assumes that the engine has been removed.

Procedure applies to cars with manual gearboxes.

Removal of automatic gearbox is similar.

CAUTION: Since some operations are carried out with engine freely suspended, ensure that lifting equipment is securely attached and in perfect condition.


Stripping of engine





Remove reinforcing bracket
Unbolt bracket between engine and gearbox.


Manual Gearbox




Remove gearbox
Detach gearbox from engine by separating flywheel housing from cylinder block.

Inspect clutch release bearing and seal on input shaft.





Remove pressure plate and clutch plate
Use gear sector 5112. Undo pressure plate joint evenly all round.

Inspect clutch components.

Automatic Gearbox




Remove:
- bolts securing torque converter to carrier plate
- ventilation grille over torque converter





Remove gearbox
Remove remaining bolts in torque converter housing.

Carefully pry torque converter free of carrier plate. Lower gearbox, inclining unit backwards very slightly to prevent torque converter slipping off shaft.






Remove speed pick-up and flywheel/carrier plate
Use gear sector 5112.

Remove flywheel/carrier plate.

NOTE: Speed pick-up must be removed before flywheel/carrier plate.





Mount engine in stand
Use stand 2520 and fixture 5297.

Remove lifting tool 2810 and bracket 5035.





Remove starter motor
Disconnect starter motor leads.





Remove oil trap
Disconnect oil trap hoses.

Remove trap and withdraw wiring harness between balance shaft housing and trap.





Disconnect:
- knock sensor
- temperature sensors under intake manifold.





Disconnect alternator leads
Remove protective cap over terminal B+.





Remove cable clip at left-hand engine mounting
Remove engine mounting.

Remove wiring harness bracket on transmission cover.





Release wiring harness on right-hand side
Remove bracket under right-hand balance shaft and disconnect earth lead at cylinder block.

Remove oil pressure switch connector.

Undo cable clip at bottom front of transmission cover.





Remove alternator
Remove auxiliary mounting bracket from cylinder block.

On cars equipped with AC: Remove compressor mounting bracket.





Remove intake manifold
Remove bolts securing manifold to cylinder head. Remove complete manifold and engine wiring harness.





Remove oil trap
Remove 0-rings between oil trap and cylinder block.





Remove:
- distributor housing
- heater hoses
- ignition lead cover plate
- ignition leads





Remove:
- exhaust manifold and lower heat shield
- right-hand engine mounting