Removal
NOTE:- Remove the engine in a forward direction (together with the transmission).
- First obtain the radio anti-theft code from the customer before disconnecting the battery.
- All tie wraps which are opened or cut to remove the engine, must be replaced in the same position and location when installing the engine.
PROCEDURE
1. Switch off the ignition and disconnect the battery ground wire.
2. Remove ribbed drive belt.
3. Remove intake hose.
4. Remove spark plug connectors with ignition wires.
5. Remove ignition wire guides -1- and -2-.
6. Remove cover for intake manifold upper section -3-.
7. Disconnect accelerator cable at throttle valve housing and support bracket (do not remove locating clip at support bracket).
8. Loosen power steering reservoir hose clamp.
9. Unbolt power steering hydraulic line retainers from engine mount and transmission.
10. Remove power steering pump and lay to side; hoses remain connected.
11. Remove lock carrier with attachments.
12. Drain coolant.
13. Disconnect 42-pin connector (near ignition coil).
14. Disconnect all wiring from transmission, alternator and starter and move clear.
15. Disconnect all coolant, vacuum and breather hoses from engine.
16. Disconnect fuel supply and return lines from fuel rail and unclip from retainers on cylinder head cover.
WARNING: For protection against fuel spray cover connections with a cloth.
17. Separate 4-pin connector to Oxygen sensor probe and 2-pin connector to knock sensor 1 on rear right assembly mounting.
18. Unbolt drive shafts and tie up.
19. Remove balance weight and front exhaust pipe from exhaust manifold.
20. Pull off vacuum hose between intake manifold upper section and fuel pressure regulator.
21. Remove intake manifold absolute pressure sensor from intake manifold upper section.
22. Remove radiator with fan and air ducting.
23. On models with A/C, proceed as follows:
NOTE:
- The A/C refrigerant circuit must not be opened.
- Only open up the A/C refrigerant circuit in workshops, having trained personnel and the necessary range of tools and equipment to complete the work
a. Unbolt A/C fluid reservoir and allow to hang free.
b. Remove retaining clamp(s) from refrigerant lines.
c. Remove A/C compressor.
d. Remove A/C compressor with radiator and condenser and lay to one side so that the refrigerant hoses arrows are not stressed.
24. On models with manual transmission, proceed as follows:
a. Remove hydraulic clutch slave cylinder.
b. Remove transmission operating cables with support bracket from transmission.
c. Attach lifting tackle tool No. 2024 A, or equivalent, as follows and lift engine/trans assembly slightly using workshop crane:
- Vibration damper end: 4th hole in hook at position 1
- Flywheel end: 4th hole in hook at position 6
NOTE:
- Hooks and locating pins must be secured with locking pins.
- The positions marked 1 through 4 on the bar must be toward the vibration damper.
- The holes in the hooks are counted up from the hook.
25. On models with automatic transmission, proceed as follows:
a. Remove selector lever cable from transmission.
b. Attach lifting tackle tool No. 2024 A with extension tool No. 2024 A/1, or equivalents, as follows and lift power train slightly using workshop crane:
- Vibration damper end: 1st hole in extension at position 1
- Flywheel end: 3rd hole in extension at position 6
NOTE:
- Hooks and locating pins must be secured with locking pins.
- The positions marked 1 through 4 on the bar must be toward the vibration damper.
- The holes in the hooks are counted up from the hook.
26. On all models, release transmission from rear left assembly mounting and engine from rear right assembly mounting.
27. Release engine at front assembly mounting.
28. Disconnect engine carrier and on one side pry the spacer bracket out of the rubber mountings.
29. Take power steering hydraulic lines out of disconnected engine carrier.
30. Pry out assembly forwards.
NOTE: When lifting out, carefully guide the assembly to prevent damage to the bodywork.