Attention. The following is a description of removing the engine without the gearbox.
Withdrawal
On engines with a fuel injection system, depressurize the fuel system.
Remove the ground wire from the battery Drain the coolant and engine oil Reinstall the oil drain plug. Remove the hood.
Remove the air filter housing and elements of the air supply system to the engine. Release the clamps and disconnect the following coolant hoses (see fig. 4D.1, 4D.2):
- all hoses in thermostat housing
- hose from the base of the radiator going to the water pump
- heater hoses
- intake manifold hose
Disconnect the canister vacuum fuel hose from the intake manifold.
Disconnect the brake booster vacuum hose from the intake manifold by pressing the hose retainer against the manifold while pulling the hose towards you (see fig. 4D.3).
Remove the accelerator cable. Disconnect the quick couplings and remove the fuel supply and return hoses to the fuel pump. Plug the ends of the removed hoses with plugs (see fig. 4D.4).
Tag and disconnect the electrical connectors from the following items (see fig. 4D.5, 4D.6):
- coolant temperature sensor
- oil pressure sensor
- ground bus from the radio
- fan thermal switch
- ignition coils
- speed sensor and crankshaft position
- engine temperature sensor
- shut-off valve
Disconnect the remaining multi-pin connectors from the engine sensors in the intake manifold and from the oxygen sensor in the exhaust manifold or exhaust pipe. On Endura-E engines, release both wiring harnesses and disconnect the 4 fuel injector multi-pin connectors.
Raise the front of the car and secure it on stands. Unscrew nuts and disconnect a reception exhaust pipe from a final collector. Remove the gasket. Remove the starter.
Unscrew the two mounting bolts and remove the lower clutch plate. Unscrew the mounting bolt and separate the stabilizer from the gearbox. Unscrew the gearbox mounting bolts, as well as the ground bus mounting bolt.
Unscrew one bolt securing the unit suspension to the beam. Check that all connections are disconnected and lower the vehicle to the ground.
Unscrew the bolt and remove the exhaust manifold heat shield. Place a hoist over the engine and tie the engine diagonally with slings. Raise the engine until the weight of the engine is fully supported by the hoist, then remove the nuts and bolts from the engine mount. Place a jack under the gearbox and raise it just enough so that the weight of the gearbox is supported by the jack.
Unscrew the top bolts of fastening of a transmission to the engine.
Check that all connections to the motor are disconnected. Move the engine away from the transmission and lift it out of the engine compartment. Do not let the engine hang on the transmission input shaft while the engine is being removed. After removing the engine, check its mounts. If they are worn out, they must be replaced. Check up a condition of hoses of system of cooling, vacuum hoses and tubes. Also check the condition of the clutch and if the clutch disc lining is worn, replace the clutch disc.
Installation
Installation is made in sequence, return to removal.
Lubricate the input shaft with a high melting point grease before installing the clutch on the transmission input shaft. If the leading part of the clutch was removed, then it is necessary to center the clutch disc.
Tighten all fastening bolts and nuts to the required torque.
Check that the mating surfaces of the exhaust manifold and exhaust pipe are clean, install a new gasket and bolt the exhaust pipe.
Check that all electrical connectors are connected as previously marked. Remove the plugs from the fuel lines and connect the fuel lines. Connect the accelerator cable and reinstall the air filter housing.
If necessary, replace the cooling system hoses Install the clutch cable. Check the connection of all hoses to the engine, fill in coolant and engine oil.
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