Removal

Engine, Removal (Stripped)

Special tools: 2870, 5006, 5033, 5115, 5185, 5186, 5871





Assuming bores, crankshaft etc. have been found to be in need of overhaul:
Remove engine complete with gearbox. Following procedure applies to engines with manual gearboxes.

Automatic gearboxes are similar.

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





Install left-hand engine mounting and support under intake manifold
Tighten components to cylinder block.





Remove lifting attachments
Lower engine onto engine mountings.

Remove hook 5115 and lifting yoke 5006.





Release wiring harness at rear of engine
Open cable clips on bulkhead.

Separate connectors at right-hand suspension strut tower and disconnect lead to terminal 1 on ignition coil.





Disconnect:
- leads connected to terminal lug of battery positive lead
- battery positive lead
- earth lead connection to top of side member
- lower coolant hose from water pump





Remove fan shroud
Cut tie around air preheating hose.





Undo hose connections at left-hand side of bulkhead
Disconnect heater hoses from pipe branches on bulkhead.

Open union between hose and pipe on fuel line. Soak up fuel spillage with paper.

NOTE: Seal open ends to prevent entry of dirt into fuel line.





Disconnect speed pick-up lead
Open cable clip on bulkhead.

Open connector.





Release throttle cable from pulley
Release locking clip on cable tensioner.

Unhook cable from pulley.





Remove:
- brake servo vacuum hose from branch on intake manifold
- EVAP valve hose from branch on bottom of intake manifold
- return line from fuel distribution pipe





Free engine wiring harness on left-hand side
Cut steering servo hose and wiring harness ties.

Undo cable clip at left-hand wheel housing.

Unhook servo reservoir from mounting bracket.

Open cable clip at connectors.

Separate wiring connectors at servo reservoir.





Disconnect knock sensor lead
Open cable clips on left-hand suspension strut housing.

Separate connectors at diagnostic unit. Work wiring free of servo hoses.





Remove servo pump
Remove drive belt.

Remove pump from mounting bracket.

Place pump on left-hand wheel housing.

Use paper or other material to protect wheel housing from scratches.

NOTE: Do not open any hose connections.





Attach lifting lug 5871 to rear of cylinder block
Remove dipstick tube support.

Remove flat washer on bolt.

Tighten lifting lug.





Support engine at rear
Use two support bars 5033, lifting yoke 5006, and lifting hooks 5115 and 51B6.

Lift engine using rear lifting lug 5871.





Disconnect battery leads from body
Undo clips on front crossmember and right-hand side member.

Work wiring free of anti-roll bar.

NOTE: On cars equipped with AC: Unbolt AC compressor from mounting bracket.






Remove clutch slave cylinder
Remove cylinder circlip.

Withdraw cylinder carefully from location in housing.

NOTE: Rubber boot retains plunger in cylinder. Secure boot with circlip.





Remove propeller shaft
Use socket 5244.

Separate front and rear universal joints.

Unbolt intermediate bearing from member.

Withdraw propeller shaft backwards.





Free gearbox wiring
Cut rear tie at gear ever mounting.

Separate wiring connectors.





Release gear lever
Undo lever locking bolt.

Remove pivot pin between lever and gear selector rod.

Remove circlip from lever sleeve under mounting.

Push up lever.

Remove bearing bushings and 0-ring.





Undo bolted joint at front of catalytic converter
Release oxygen sensor lead from rear clip.





Remove front exhaust pipe
Remove nuts in flanged joint with exhaust manifold.

Remove manifold.





Remove gearbox support member
Remove gearbox bump stop nut and bolts attaching member to side members.





Support gearbox on jack
Remove lifting attachments (5006, 5033, 5115 and 5185).

On cars equipped with AC: Tie aside compressor.





Lift engine
Use lifting tool 2810, and lifting hooks 5185 and 5186.

Adjust lifting yoke to ensure engine is balanced.

Remove jack under gearbox.





Lift out engine and gearbox
Adjust angle of lift throughout operation.

NOTE: Carefully check that drive unit is free of radiator, body and extra equipment (if any).