Remove/Install Engine
Removal and Installation of Engine AssemblyNOTE:
^ Numbers in parentheses ( ) indicate a component or tool in the associated illustration.
^ In the case of engine damage involving damage to the pistons, valves etc., parts may have got in as far as the catalytic converter, or pre-catalytic converter.
^ When replacing the engine, it is essential to remove such parts otherwise they will be pulsed back into the cylinders as a result of the gas vibrations in the exhaust system and may once again cause engine damage. In addition, these parts may cause mechanical damage to the catalytic converter.
^ It is therefore essential to remove any foreign bodies in the exhaust system when dealing with such types of engine damage. Catalytic converters which have been damaged must be replaced.
Technician Safety Information
1. Remove bottom engine compartment panel.
2. Remove air cleaner.
3. Remove viscous fan and radiator.
4. Remove hot film air mass filter.
5. Remove air cleaner.
6. If A/C fitted: attach guard plate to condenser.
- Guard plate for radiator and condenser (approximate size): 400 x 680 x 1 mm
7. Disconnect engine wiring harness.
8. Disconnect vacuum pipes (arrows) at switchover valves.
9. Disconnect pipe (B) at purge control valve (Y58/1).
10. Unbolt vacuum pipe to brake servo unit at intake manifold.
11. Open fuel filler cap to release pressure in fuel tank.
12. Disconnect fuel pipes (17/2) and (17/3) at engine compartment partition.
13. Seal fuel pipes (17/2) and (17/3) with pipe union (01) (shop-made).
14. Detach accelerator control Bowden cable.
15. Extract hydraulic fluid from power steering pump reservoir with priming pump.
NOTE: Refer to Steering and Suspension for filling and bleeding of power steering pump.
16. Unbolt suction and pressure oil pipes (arrows) at power steering pump (5).
17. Disconnect coolant hose (4).
18. Remove poly V-belt (37).
19. Unbolt A/C compressor (7) with pipes connected, attach to side of engine compartment.
20. Disconnect rear coolant hose (6).
21. Remove exhaust system (2).
22. Drain coolant at crankcase.
23. Unbolt front propeller shaft (8) at transmission.
24. Push propeller shaft (8) to the rear.
25. Remove rear engine support (9).
26. Detach shift rod of automatic transmission.
27. Unbolt engine mount (12) at front suspension support.
28. Remove front cover (13).
29. Attach engine hoist to both lifting lugs of engine; use engine supporting bar if necessary.
30. Tilt engine together with transmission.
31. Remove engine.
32. Examine front engine mounts (12) and rear engine mounts (10).
33. Reverse procedure to install, noting the following:
- Adjust Bowden cable for control pressure.
- Check tightening torque of oil drain plugs.
- Adjust engine and transmision oil to correct level.
- Pour in anti-corrosion/anti-freeze coolant and adjust to correct level and ratio.
- Check for leaks.
- Read and erase fault memory. Refer to Powertrain Management.
NOTE: Stored faults which may be caused by disconnecting or by simulation during removal/ installation or test work. must be erased in the fault memories after completing operations.