Removal
Special Tools:
- Lifting Yoke tool No. 999 2810, or equivalent
- Lifting Yoke tool No. 999 5428, or equivalent
- Lifting Eyelet tool No. 999 5459, or equivalent
- Extractor Fork tool No. 999 5462, or equivalent
- Lifting Eyelet tool No. 999 5464, or equivalent
- Sealing Plug tool No. 999 5488, or equivalent
- Holder tool No. 999 5533, or equivalent
NOTE:
- For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Service and Repair". Tools and Equipment
- Engines are now equipped with a reinforced front lifting eyelet, which means that eyelets tool No. 999 5459 and 999 5464, or equivalent have been replaced by lift arm tool No. 998 9734, or equivalent.
- This lift arm will be included in the kit for tool No. 999 2810, or equivalent.
Procedure
1. Drain coolant:
- Remove expansion tank cap.
- Raise car.
- Remove splashguard and air baffle under engine.
- Open engine and radiator nipples, use hoses to collect coolant.
- Close nipples.
2. Remove:
- left front wheel.
- track rod ends from axle shafts
- screws 2 x 3 holding ball joints to control arms
3. Remove:
- ABS-lead and brake pipe bracket screw
- left drive shaft, use extractor fork tool No. 999 5462, or equivalent to free drive shaft
- the two narrow black hoses from EVAP canister
- the white hose from the vacuum reservoir
4. Remove:
- right drive shaft and intermediate bearing cap from drive shaft, place carefully on steering servo pipes
- two right engine mounting screws (fold aside right wing liner first)
- torque rod/transmission bolt
NOTE: Install plugs tool No. 999 5488, or equivalent in the drive shaft holes.
5. Remove:
- two front exhaust pipe nuts and springs
- carriage bolts (2)
- speedometer connector
- collision shield, gearbox/engine mounting bolt
Lower car.
6. Remove:
- battery
- battery shelf
- fresh air hose from air cleaner (ACL) intake
- mass air flow (MAF) sensor connector
- HT lead between distributor/ignition coil
- throttle pulley cover
NOTE: If the car is fitted with cruise control, undo vacuum hose and wiring for the vacuum motor.
7. Disconnect hoses:
- disconnect throttle body (TB) inlet hose and idle air control (IAC) valve hose
- disconnect vacuum hose and crankcase ventilation hose on the inlet hose
8. Remove ACL:
- Disconnect connector and solenoid valve vacuum hoses.
- Remove preheating hose.
- Lift up and remove ACL.
- Remove throttle cable from throttle pulley.
- Remove torque rod.
9. Disconnect:
- two heater hoses from firewall
- brake servo hose
- two heated oxygen sensor (H02S) connectors
- rear engine mount upper nut
10. Remove:
Models with Manual Transmission:
- gear selector cables from gearbox mountings
- rubber mounted section of the gear selector cable mounting
Models with Automatic Transmission:
- Disconnect connector.
- Remove gear selector cable from gearbox.
- Disconnect the two oil cooler hoses from the radiator using a victory clip tool.
11. Remove:
- clutch slave cylinder retaining ring
- slave cylinder, from gearbox
- battery negative lead from engine
- lower radiator hose from radiator
12. Undo and fold aside ACL filter bracket:
- Remove ACL rubber mounting from bracket.
- Pull clutch slave cylinder through the front hole in the bracket and place bracket and cylinder to one side.
13. Remove engine coolant fan:
- Disconnect both relays from fan shroud, disconnect connectors and place wiring to one side.
- Remove the two control module air cooling ducts.
- Undo four fan shroud bolts from radiator.
- Push shroud back and remove air intakes.
- Remove fan shroud with fan.
NOTE:
- Protect the radiator with a piece of hardboard/plywood etc.
- Or use shield 999 5474, or equivalent.
14. Remove two AC-compressor long mount bolts:
- Leave the compressor in position until lifting out engine.
15. Remove front engine mount upper nut:
- Remove upper engine mount nut and wiring conduit bracket bolts. Remove intake manifold support bracket.
- Remove starter motor support bracket.
16. Remove:
- upper radiator hose from thermostat housing
- radiator hose, expansion tank/thermostat housing cover
- lower expansion tank hose, from engine connector
- auxiliaries belt Remove six servo pump screws, (disconnect temperature sensor wiring from servo pump).
NOTE: Leave servo pump in position until later.
17. Remove:
- fuel distribution manifold cover
- fuel pipe clips (upper/lower)
- fuel distribution manifold screws
- ground strip from engine
18. Remove fuel distribution manifold:
- Secure injectors with holders tool No. 999 5533, or equivalent (5).
- Lift up and place fuel distribution manifold with injectors to one side.
NOTE: Ensure that injectors and needles are not damaged.
19. Remove engine wiring harness:
- Disconnect all connectors from engine.
NOTE: Note positions of all connection points on wiring harness shown in the illustration above using the Legend below.
1 Injectors
2 Temperature sensor (ECT)
3 Knock sensor (KS)
4 Generator (GEN)
5 A/C-compressor
6 Engine coolant fan (FC)
7 Starter motor
8 Oil pressure switch
9 Throttle Potentiometer (TP)
10 Automatics
11 Reversing lights
12 Vehicle speed sensor (VSS)
13 Heated Oxygen Sensor (HO2S)
14 Camshaft position (CMP) sensor
15 Mass air flow (MAF) sensor
16 Engine speed (RPM) sensor
17 Ground terminals
20. Lift out engine and gearbox
- Remove spark plug cover and install lifting eyelets tool No. 999 5459 and tool No. 999 5464, or equivalent.
- Lift servo pump and put to one side.
- Remove AC-compressor and place on sub-frame.
- Lift out engine, use lifting yokes tool No. 999 2810 and tool No. 999 5428, or equivalent.
- Correct lifting angle throughout entire lift.
NOTE: Carefully ensure that power train is clear of body and any extra equipment.