Removing And Installing Engine

Rem ov ing

1. Use fender and bumper protective covers.

2. Disconnect battery ground cable at spare wheel well.

5, Detach windshield washer hoses and engine compartment light wires.

6. Disconnect engine hood supports at top, loosen engine hood bolts and remove engine hood.

7. Remove cap from coolant expansion tank.

8. Remove air intake hoses and entire air cleaner assembly.

9. Raise car. Place piece of wood (locally manufactured) on central tube and rear tunnel brace.

3. Loosen and remove engine compartment

cross brace.

cross brace.

4. Set up hoist and align with specified pick-up points on car, but do not raise car.

13. Remove lower body brace.

10. Detach splash shield at bottom.

13. Remove lower body brace.

11. Drain coolant from radiator. 14. Detach exhaust pipes at exhaust manifolds and heat shields on left and right sides.

15, Detach ground cable at body.

11. Drain coolant from radiator. 14. Detach exhaust pipes at exhaust manifolds and heat shields on left and right sides.

12. Drain engine oil.

Remove water drain plugs on left and right side of ciankcase.

15, Detach ground cable at body.

16. Install and tighten oil drain plug to specified torque.

17. Install and tighten coolant drain plugs to specified torque.

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18. Unscrew clutch slave cylinder at clutch housing and remove with line connected.

Note

Do not operate clutch pedal.

19. Remove mounting strap for pressure line to slave cylinder.

20. Disconnect wires on starter.

21. Remove clutch housing cover with starter.

Disconnect release lever at ball pin by pressing release lever down in direction of clutch.

22. Open clamps for starter wires on steering cross member.

23. Remove socket head bolts and slide back clamping sleeve on drive shaft.

24. Unscrew throwout bearing sleeve mounting bolts and push sleeve in direction of clutch.

25. Disconnect left and right engine shock absorbers at control arms.

26. Detach engine shock absorbers with left and right mounts.

27. Cars with air conditioning: Detach temperature switch wires on radiator.

Disconnect plug leading to compressor (on right drive belt cover).

28. Loosen compressor, remove from console and suspend it with the hoses connected.

29. Loosen and remove air pump filter housing.

30. Detach alternator cooling hose.

Place engine on front cross member carefully. Remove second mount accordingly.

32. Detach all coolant hoses at radiator.

33. Detach bottom oil hose at radiator.

35. Remove clutch/engine mounting bolts.

34. Remove engine mounts separately by applying a lifting force from one side to engine with a hydraulic jack, locally manufactured pad and an appropriate piece of wood on the oil pan, loosening the bolts, lifting the engine and removing the engine mounts.

Place engine on front cross member carefully. Remove second mount accordingly.

32. Detach all coolant hoses at radiator.

33. Detach bottom oil hose at radiator.

31. Loosen lower fan shroud at radiator and remove.

35. Remove clutch/engine mounting bolts.

36. Lower car.

37, Loosen and detach vent hose at T-adaptor for radiator and thermostat housing.

38. Loosen and detach coolant hoses at thermostat housing.

39. Detach upper oil hose at radiator while counterholding.

42. Disconnect B + wire, plug of transmitter wire to distributor and plug for engine wire harness.

40. Loosen top radiator mountings and lift out radiator carefully.

41. Open hose clamp and remove hose between heater valve and neck.

43. Remove control unit.

44. Detach ignition coil and place aside.

45. Detach fuel feed and return lines while counterholding.

46. Detach hydraulic line at power steering pump.

47, Detach oil hoses at supply tank of power steering pump, drain oil and remove tank.

48, Detach brake booster vacuum hose at manifold.

49. Disconnect operating cable for accelerator pedal and cruise control, remove holder and clamp, and place cables outside.

50. Be sure to cover condenser on cars with air conditioning to prevent damage when removing and installing (e.g. with a wood board).

51. Engage adapter 9137 (in conjunction with floor hoist) in the eyelets provided for this purpose. Raise adapter until tight on engine.

Note

This requires that car stands on its wheels

52, Unscrew top engine block/clutch housing mounting bolts.

Note the following for installation.

1, Tighten nuts and bolts to specified torques.

2. Add coolant until level is at edge of filler opening (position-heater lever at "warm").

3. Run engine to operating temperature and check coolant level, adding more coolant if necessary.

Coolant level must reach center of expansion tank.

53. Pull engine forward carefully and remove central shaft I with guide tube.

54, Lift out engine.

ENGINE; REMOVING AND INSTALLING (32-VALVE ENGINES) TOOLS

No.

Designation

Special Tool

Remarks

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