Contents: Removal ⇓ Installation ⇓
Removal
1. Remove the battery.
2. Remove the air filter.
3. Disconnect the electrical connectors from the reverse light switch and engine wiring harnesses.
4. On a vehicle with a manual five-speed transmission, disconnect the electrical connector from the selector control valve.
5. Disconnect the electrical connectors from the generator and oil pressure sensor.
6. Drain the coolant.
7. On a vehicle with an automatic transmission, disconnect the transmission oil cooler hoses.
Warning: Label the hoses before disconnecting them to avoid confusion when reconnecting them.
Warning! Be careful not to let transmission fluid leak out of the hoses. Plug the ends of the hoses to prevent dirt from getting in.
8. Disconnect the upper and lower hoses from the radiator and remove the radiator.
9. Disconnect the ground wire from the engine.
10. Disconnect the brake booster vacuum hose.
11. Disconnect the fuel supply and return hoses from the engine.
Warning! Gasoline is extremely flammable. When working with fuel system components, it is prohibited to use fire, sparking devices, open fire-hazardous lighting devices, and smoking. Avoid sparking when handling wires and electrical devices.
12. Disconnect the cooling system hoses leading to the heater.
13. Disconnect the accelerator cable from the engine.
14. On a vehicle with a manual five-speed transmission, disconnect the clutch cable from the transmission housing.
15. On a vehicle with an automatic transmission, disconnect the transmission control cable.
16. Disconnect the speedometer drive cable from the gearbox.
17. Remove the air conditioning compressor from the bracket.
18. Raise the car.
19. Drain the oil from the gearbox.
20. Disconnect the front exhaust pipe from the exhaust manifold.
Warning: Use soft wire to secure the exhaust pipe to the underbody of the vehicle.
21. On a vehicle with a manual five-speed transmission, disconnect the gear selection and shift rods.
22. Remove the bolts securing the lower arm ball joint and the anti-roll bar to the lower arm.
23. Use a crowbar to pry the inner drive shaft joints out of the gearbox.
Warning: To prevent dirt from entering, plug the holes in the gearbox.
Caution: When reinstalling the drive shafts, install new snap rings.
24. Secure the lower arms and drive shafts to the body using soft wire.
25. Attach the lifting gear clamps to the engine lugs and lift so that the engine weight is supported by the lifting gear.
26. Remove the front engine mount.
27. Remove the rear engine mount.
28. On a vehicle with a manual five-speed transmission, remove the transmission support.
29. Remove the engine mount bracket mounting bolts.
30. Remove the engine support brackets from the engine.
31. Slowly lift the engine off the mounts and hold it in this position temporarily.
Warning: Make sure all electrical connectors, hoses, tubes and wiring harnesses are disconnected from the engine.
32. Remove the bolts securing the gearbox bracket to the right wing.
33. Remove the left support mounting bolt.
34. Tilt the gearbox downwards to lift and remove the engine and gearbox from the vehicle.
Installation
1. Install the engine and transmission into the vehicle, making sure not to damage or pinch any hoses, wire harnesses, tubes or electrical connectors.
2. After installing the engine, temporarily secure the front mount.
3. After installing the engine with the gearbox on all supports, tighten the support mounting bolts to the required torques.
4. Reconnect all previously disconnected components, taking extra care to ensure they are connected correctly and securely.
5. Reconnect all previously disconnected components, taking extra care to ensure they are connected correctly and securely.
6. Check levels and top up all fluids if necessary.
7. Check the operation of the gear shift rods and accelerator cable.
8. Check the operation of all indicators.