Engine and transmission - removal, separation and refitting

Engine removal and overhaul procedures / Engine and transmission - removal, separation and refitting

Removal
1 Select a solid, level surface to park the vehicle upon. Give yourself enough space to move around it easily.

2 Refer to Chapter 11 and remove the bonnet from its hinges.

3 Disconnect the battery negative cable and position it away from the terminal. Note: If the vehicle has a security coded radio, check that you have a copy of the code number before disconnecting the battery cable; refer to Chapter 12 for details.

4 Refer to Chapter 1 and carry out the following:
a) Drain the cooling system.

b) If the engine is to be dismantled, drain the engine oil.

5 Refer to Chapter 3 and carry out the following:
a) Remove the auxiliary cooling fan and its cowling.

b) Remove the radiator.

c) Loosen the clips and disconnect the radiator top and bottom hoses, expansion tank hose and cabin heater hoses from the thermos tat housing.

6 With reference to Chapter 4C, unplug the Lambda sensor cabling from the main harness at the multiway connector (where applicable).

7 Disconnect the ignition HT king lead from the centre terminal of the distributor cap and tie it back away from the engine.

8 Refer to Chapter 9 and disconnect the brake servo vacuum hose from the port on the inlet manifold.

9 On vehicles fitted with an activated charcoal canister emission control system, refer to Chapter 4C and disconnect the vacuum hose from the port on the throttle body. Make a careful note of the point of connection to ensure correct refitting.

Single point injection models 10 With reference to Chapter 4A, carry out the following operations: a) Depressurise fuel system b) Remove the exhaust manifold- to-air cleaner and throttle body air box-to-air cleaner ducting from the engine bay.

c) Remove the air cleaner assembly from the top of the throttle body; make a note of the vacuum hose connections to ensure correct refitting later.

d) Disconnect the accelerator cable from the throttle spindle lever.

e) Disconnect the fuel supply and return hoses from the throttle body - observe the safety precautions detailed at the beginning of Chapter 4A.

Multi point injection models 11 With reference to Chapter 4B, carry out the following operations: a) Depressurise fuel system.

b) Slacken the clips and remove the exhaust manifold-to-air cleaner and throttle bodyto- air flow meter ducting from the engine bay.

c) Disconnect the accelerator cable from the throttle spindle lever.

d) Disconnect the fuel supply and return hoses from the throttle body - observe the safety precautions detailed at the beginning of Chapter 4B.

e) G40 models: slacken the clips and disconnect the supercharger-toin tercooler and intercooler- to- thro ttle body ducting.

Caution: On G40 models, when dismantling any part of the air inlet system, take care to ensure that no foreign material can get into the G-charger air inlet port; cover the opening with a sheet of plastic, secured with an elastic band. When the engine is running, the Gcharger compressor vanes rotate at very high speeds could be severely damaged if debris has been allowed to enter.

12 Refer to Chapter 5A and disconnect the wiring from the alternator, starter motor and solenoid.

13 With reference to Chapter 5B and Chapter 4A or B as applicable, identify any sections of the ignition and fuelling system electrical harness that remain connected to sensors and actuators on the engine and disconnect them. Label each connector carefully to ensure correct refitting.

14 Refer to Chapter 7 and carry out the following:
a) At the top of the transmission casing, disconnect the wiring from the speedometer drive transducer and reversing light switch.

b) Disconnect the gear selection mechanism from the transmission.

15 Refer to Chapter 6 and disconnect the clutch cable from the release mechanism at the front of the transmission casing.

16 Refer to Chapter 8 and separate the driveshafts from the transmission differential output shafts.

17 With reference to Chapter 4C, unbolt the exhaust down pipe from the exhaust manifold. Recover and discard the gasket.

Unbolt the front exhaust mounting and lower the exhaust to the floor.

18 Unbolt the engine and transmission earthing straps from the bodywork (see illustration).

2.18 Unbolting the engine earthing strap

19 Attach the jib of an engine lifting hoist to the lifting eyelets at the cylinder head. Raise the jib until it just takes the weight of the engine and transmission.

20 With reference to Chapter 2A, slacken and withdraw the through-bolts from all three engine mountings (see illustration).

2.20 Front engine mounting through-bolt

21 Carry out a final check to ensure that nothing else remains connected to the engine, then slowly raise the hoist and manoeuvre the engine and transmission out through the top of the engine bay. Guide the auxiliary belt drive pulleys past the inner wing to avoid damaging the paintwork.

Separation
22 Rest the engine and transmission assembly on a firm, flat surface and use wooden -blocks as wedges to keep the unit steady.

23 The transmission is secured to the engine by a combination of machine screws and studs, threaded into the cylinder block and bellhousing - the total number of fixings depends on the type of transmission and vehicle specification. Note that some of these fixings also serve as mountings for the rear engine mounting.

24 Starting at the bottom, remove all the screws and nuts then carefully draw the transmission away from the engine, resting it securely on wooden blocks (see illustration).

Collect the locating dowels if they are loose enough to be extracted.

2.24 Separating the engine and transmission

Caution: Take care to prevent the transmission from tilting, until the input shaft is fully disengaged from the clutch friction plate.

25 With reference to Chapter 6, remove the clutch release mechanism, pressure plate and friction plate.

Refitting
26 If the engine and transmission have not been separated, proceed from paragraph 29 onwards.

27 Smear a quantity of high-melting-point grease on the splines of the transmission input shaft. Do not use an excessive amount as there is the risk of contaminating the clutch friction plate. Carefully offer up the transmission to the cylinder block, guiding the dowels into the mounting holes in cylinder block.

28 Refit the bellhousing bolts and nuts, hand tightening them to secure the transmission in position. Note: Do not tighten them to force the engine and transmission together. Ensure that the bellhousing and cylinder block mating faces will butt together evenly without obstruction, before tightening the bolts and nuts to their specified torque.

All models
29 With reference to Chapter 2A, refit the rear engine mounting bracket and tighten the retaining bolts to the specified torque.

30 Attach the jib of an engine hoist to the lifting eyelets on the cylinder head and raise the engine and transmission from the ground.

31 Wheel the hoist up to the front of the vehicle and with the help of an assistant, guide the engine and transmission in through the top of the engine bay. Tilt the assembly slightly so that the transmission casing enters first, then guide the auxiliary belt drive pulleys past the bodywork.

32 Align the engine mounting brackets with the mounting points on the body - refer to Chapter 2A for details. Insert the engine mounting through-bolts, tightening them by hand initially.

33 Detach the engine hoist jib from the lifting eyelets.

34 Settle the engine and transmission assembly on its mountings by rocking it backwards and forwards, then tighten the mounting through-bolts to the specified torque.

35 Refer to Chapter 8 and reconnect the driveshafts to the transmission.

36 The remainder of the refitting sequence is the direct reverse of the removal procedure, noting the following points: a) Ensure that all sections of the wiring harness follow their original routing; use new cable-ties to secure the harness in position, keeping it away from sources of heat and abrasion.

b) Refer to Chapter 7 and reconnect the gear shift mechanism to the transmission, then check the overall operation of the gear shift mechanism, adjusting it if necessary.

c) Refer to Chapter 6 and reconnect the clutch cable to the transmission, then check the operation of the automatic adjustment mechanism (where applicable).

d) Ensure that all hoses are correctly routed and are secured with the correct hose clips, where applicable. If the hose clips originally fitted were of the crimp variety, they cannot be used again; proprietary worm drive clips must be fitted in their place, unless otherwise specified.

e) Refill the cooling system as described in Chapter 1.

f) Refill the engine with appropriate grades and quantities of oil, as detailed in Chapter 1.

g) With reference to Chapter 4A or B as applicable, reconnect the throttle cable and adjust it as necessary.

h) With reference to Chapter 5B, check and adjust the engine idle speed and where applicable, the ignition timing.

37 When the engine is stat-ted for the first time , check for air, coolant, lubricant and fuel leaks from manifolds, hoses etc. If the engine has been overhauled, read the cautionary notes in Section 13 before attempting to start it.