Ford 2.0 litre DOHC engine.pdf
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Pobierz
2B•1
Chapter 2 Part B:
2.0 litre DOHC engine
Unless otherwise stated, procedures are as described for the SOHC engines in Part A of this Chapter
Contents
Camshafts and cam followers - removal, inspection and refitting . .21
Compression test - description and interpretation . . . . . . . . . . . . .35
Crankcase ventilation system - general information . . . . . . . . . . . . .2
Crankshaft and bearings - examination and renovation . . . . . . . . .31
Crankshaft and main bearings - removal and refitting . . . . . . . . . . .30
Crankshaft front oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . .23
Crankshaft rear oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Cylinder head - dismantling and reassembly . . . . . . . . . . . . . . . . . .19
Cylinder head - inspection and renovation . . . . . . . . . . . . . . . . . . .20
Cylinder head - removal and refitting (engine in vehicle) . . . . . . . . .17
Cylinder head - removal and refitting (engine removed) . . . . . . . . .18
Engine/automatic transmission assembly - reconnection and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Engine/automatic transmission assembly - removal and separation .8
Engine dismantling - general information . . . . . . . . . . . . . . . . . . . . .14
Engine/manual gearbox assembly - reconnection and refitting . . . .11
Engine/manual gearbox assembly - removal and separation . . . . . .7
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Engine reassembly - general information . . . . . . . . . . . . . . . . . . . . .33
Engine - refitting (automatic transmission in vehicle) . . . . . . . . . . . .10
Engine - refitting (manual gearbox in vehicle) . . . . . . . . . . . . . . . . . .9
Engine - removal leaving automatic transmission in vehicle . . . . . . .6
Engine - removal leaving manual gearbox in vehicle . . . . . . . . . . . . .5
Examination and renovation - general information . . . . . . . . . . . . .32
Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . .22
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Initial start-up after overhaul or major repair . . . . . . . . . . . . . . . . . .34
Major operations possible with the engine in the vehicle . . . . . . . . .3
Major operations requiring engine removal . . . . . . . . . . . . . . . . . . . .4
Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . .27
Oil pump drive chain and sprockets - examination and renovation .28
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Pistons and connecting rods - removal and refitting . . . . . . . . . . . .29
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Timing chain and sprockets - removal and refitting . . . . . . . . . . . . .15
Timing chain, sprockets and tensioner - examination and
renovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2B
Degrees of difficulty
Easy,
suitable for
novice with little
experience
Fairly easy,
suitable
for beginner with
some experience
Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert
DIY or professional
Specifications
General
Manufacturer’s code:
Carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
N8B
Fuel-injection engine without catalyst . . . . . . . . . . . . . . . . . . . . . . . .
N9B
Fuel-injection engine with catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . .
N9D
Bore - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.00 (3.386)
Stroke - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.00 (3.386)
Cubic capacity - cc (cu in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1998 (121.9)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3:1
Compression pressure at cranking speed . . . . . . . . . . . . . . . . . . . . . . .
11 to 13 bar (160 to 189 lbf/in
2
)
Maximum power (DIN, kW @ rpm):
N8B engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80 @ 5600
N9B engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92 @ 5500
N9D engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88 @ 5500
Maximum torque (DIN, Nm @ rpm):
N8B engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
174 @ 3000
N9B engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
174 @ 2500
N9D engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
171 @ 2500
Lubrication system
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
See
“Lubricants and fluids”
Oil capacity:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 litres (7.92 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.0 litres (7.04 pints)
2B•2 DOHC engine
Cylinder block
Bore diameter:
Standard grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.000 to 86.010 mm
Standard grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.010 to 86.020 mm
Oversize 0.15 grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.150 to 86.160 mm
Oversize 0.15 grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.160 to 86.170 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.500 to 86.510 mm
Crankshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.090 to 0.300 mm
Main bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.011 to 0.048 mm
Main bearing journal diameter:
Standard (yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.980 to 54.990 mm
Standard (red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.990 to 55.000 mm
Undersize 0.25 (green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.730 to 54.750 mm
Main bearing thrustwasher thickness:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.301 to 2.351 mm
Oversize 0.38 (yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.491 to 2.541 mm
Big-end bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.006 to 0.060 mm
Big-end bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50.890 to 50.910 mm
Undersize 0.25 (green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50.640 to 50.660 mm
Pistons and piston rings
Piston diameter:
Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85.970 to 85.980 mm
Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85.980 to 85.990 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85.980 to 86.000 mm
Oversize 0.15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.130 to 86.150 mm
Oversize 0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86.470 to 86.490 mm
Piston ring end gap:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.300 to 0.600 mm
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.500 to 0.800 mm
Bottom (oil control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.400 to 1.500 mm
Cylinder head
Valve guide bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.063 to 7.094 mm
Camshaft bearing parent bore diameter . . . . . . . . . . . . . . . . . . . . . . . . .
26.000 to 26.030 mm
Camshafts
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.020 to 0.260 mm
Valves and valve springs - general
Valve timing:
Carburettor engine:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13°BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39°ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43°BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13°ATDC
Fuel-injection engines:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13°BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51°ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43°BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13°ATDC
Valve spring free length:
Inner spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48.200 mm
Outer spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46.800 mm
Inlet valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.025 to 7.043 mm
Oversize 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.225 to 7.243 mm
Oversize 0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.425 to 7.443 mm
Oversize 0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.625 to 7.643 mm
Oversize 0.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.825 to 7.843 mm
Exhaust valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.999 to 7.017 mm
Oversize 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.199 to 7.217 mm
Oversize 0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.399 to 7.417 mm
Oversize 0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.599 to 7.617 mm
Oversize 0.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.799 to 7.817 mm
DOHC engine 2B•3
Torque wrench settings
Nm
lbf ft
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90 to 104
66 to 77
Big-end bearing cap bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 to 8
4 to 6
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 to 17
11 to 13
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tighten further 85° to 95°
Tighten further 85° to 95°
Crankshaft pulley bolt:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 to 58
33 to 43
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tighten further 80° to 90°
Tighten further 80° to 90°
Camshaft sprocket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 to 63
41 to 46
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82 to 92
61 to 68
Oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 to 12
7 to 9
Oil pump sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 to 19
12 to 14
Oil pump chain tensioner bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 to 13
7 to 10
Sump bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 to 10
6 to 7
Sump studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 to 8
4 to 6
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 to 28
15 to 21
Sump front mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 to 28
17 to 21
Oil baffle nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 to 21
13 to 15
Oil pick-up pipe-to-cylinder block bolts . . . . . . . . . . . . . . . . . . . . . . . . .
9 to 13
7 to 10
Oil pressure warning lamp switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 to 22
13 to 16
Cylinder head bolts:
M11 bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
18
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
41
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tighten further 90°
Tighten further 90°
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tighten further 90°
Tighten further 90°
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 to 39
27 to 29
Camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 to 8
4 to 6
2B
Camshaft bearing cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 to 26
16 to 19
Lower timing chain guide:
Upper bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 to 13
7 to 10
Lower bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 to 28
18 to 21
Upper and lower timing chain cover bolts . . . . . . . . . . . . . . . . . . . . . . .
7 to 10
5 to 7
Crankshaft rear oil seal housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . .
8 to 11
6 to 8
Engine-to-gearbox/transmission bolts . . . . . . . . . . . . . . . . . . . . . . . . . .
29 to 41
21 to 30
with oil from drillings in the connecting rods.
The hydraulic cam followers are supplied with
oil from passages in the cylinder head. The
camshafts are lubricated by oil from spray
tubes mounted above the camshaft bearing
caps.
A closed crankcase ventilation system is
employed, whereby piston blow-by gases are
drawn from the crankcase, through a breather
pipe into the inlet manifold where they are
burnt with fresh air/fuel mixture.
2 Crankcase ventilation system
-
general information
1 General information
The 2.0 litre DOHC (Double OverHead
Camshaft) engine was introduced in June
1989 to replace the 2.0 litre SOHC engine
used previously in the Granada range, at the
same time a 2.0 litre version of the Scorpio
model was also introduced. The engine is of
four-cylinder, in-line type.
The crankshaft incorporates five main
bearings. Thrustwashers are fitted to the
centre main bearing in order to control
crankshaft endfloat.
The camshafts are driven by a chain from
the crankshaft and operate the angled valves
via hydraulic cam followers. One camshaft
operates the inlet valves, and the other
operates the exhaust valves.
The distributor is driven directly from the
front of the inlet camshaft, and the oil pump is
driven by a chain from the crankshaft. An
electric fuel pump is mounted in the fuel tank.
Lubrication is by means of a bi-rotor pump
which draws oil through a strainer located
inside the sump, and forces it through a full-
flow filter into the engine oil galleries, from
where it is distributed to the crankshaft and
camshafts. The big-end bearings are supplied
with oil via internal drillings in the crankshaft.
The undersides of the pistons are supplied
The crankcase ventilation system
(see
illustration)
consists of an oil separator and
vent valve fitted to the cylinder block on the
left-hand side of the engine. This is connected
by a pipe to the inlet manifold. The system
operates according to the vacuum in the inlet
2.1 Crankcase ventilation
system - fuel-injection engine
1 Inlet manifold connection
2 Inlet manifold
3 Breather pipe
4 Oil separator
5 Vent valve
6 Connecting hose
2B•4 DOHC engine
manifold. Piston blow-by gases are drawn
through the oil separator and the vent valve to
the inlet manifold. The blow-by gases are then
drawn into the engine together with the fuel/air
mixture. Refer to Chapter 1 for maintenance of
the system.
3 Major operations possible with
the engine in the vehicle
The following operations can be carried out
without removing the engine from the vehicle.
a) Removal of the camshafts.
b) Removal and servicing of the cylinder
head.
c) Removal of the timing chain and
sprockets.
d) Removal of the oil pump.
e) Removal of the sump.
f) Removal of the pistons and connecting
rods.
g) Removal of the big-end bearings.
h) Removal of the engine mountings.
i) Removal of the clutch and flywheel.
j) Removal of the crankshaft front and rear
oil seals.
5.5 Removing the hose support bracket
bolt from the cylinder head
5.8 Water pump coolant hoses (viewed
from above)
8
Disconnect the coolant hoses from the
water pump housing on the left-hand side of
the engine and the cylinder head
(see
illustration)
.
9
Disconnect the coolant hoses from the
thermostat housing.
10
Disconnect the heater coolant hose from
the inlet manifold.
11
Where applicable, release the coolant
hose from the bracket under the carburettor
automatic choke housing.
12
Disconnect the throttle cable and (where
necessary) speed control cable from the
throttle linkage.
13
On carburettor models, disconnect the
vacuum pipe from the engine management
module.
14
Disconnect the brake servo vacuum hose
(where necessary) from the inlet manifold.
15
On fuel-injection models, disconnect the
vacuum pipes from the MAP sensor (located
on the suspension turret on the right-hand
side of the engine compartment) and, where
applicable, the air conditioning system.
16
On carburettor models, disconnect the
fuel supply and return hoses at the
carburettor, and plug the ends of the hoses to
minimise petrol spillage. Take adequate fire
precautions.
17
On fuel-injection models, slowly loosen
the fuel feed union at the fuel rail to relieve the
pressure in the fuel system before
disconnecting the union. Be prepared for
petrol spillage and take adequate fire
precautions. Disconnect the fuel feed hose,
and disconnect the fuel return hose from the
fuel pressure regulator. Plug the ends of the
hoses to minimise petrol spillage.
18
Disconnect the HT lead from the ignition
coil, and unclip it from the timing chain cover.
19
Disconnect the wiring from the following
components as applicable, depending on
model. Then free the wiring loom from any
necessary retaining clips or ties and position it
clear of the engine.
a) Alternator.
b) Starter motor.
c) Oil pressure warning lamp switch.
d) Temperature gauge sender.
e) Cooling fan switch.
f) Anti-dieselling valve (carburettor models).
g) Automatic choke heater (carburettor
models).
h) Engine coolant temperature sensor.
i) Crankshaft speed/position sensor.
j) Air charge temperature sensor.
k) Throttle position sensor.
l) Fuel temperature sensor.
m) Fuel injectors.
20
Remove the water pump/alternator
drivebelt, then unbolt the power steering
pump from the mounting bracket and move it
clear of the engine. Note that there is no need
to disconnect the fluid hoses, but make sure
that the pump is adequately supported to
avoid straining them.
21
On models fitted with air conditioning,
unbolt the air conditioning compressor from the
mounting bracket, and move it clear of the
engine
(see illustration)
.
Do not
disconnect the
hoses, but make sure that the compressor is
adequately supported to avoid straining them.
22
Unscrew and remove the top engine-to-
gearbox bolts which are accessible from the
engine compartment. Note the location of the
bolts, and the positions of the earth strap and
any wiring clips attached to the bolts.
23
Unscrew the securing bolt, and
disconnect the earth lead from the rear left-
hand side of the cylinder head.
24
Unscrew the nuts securing the engine
mountings to the engine mounting brackets.
25
Apply the handbrake, jack up the front of
the vehicle and support it securely on axle
stands (see “
Jacking
”).
26
Drain the engine oil into a container.
4 Major operations requiring
engine removal
The following operations can only be carried
out after removing the engine from the vehicle.
a)
Removal of the crankshaft main bearings.
b)
Removal of the crankshaft.
5 Engine
- removal leaving manual
gearbox in vehicle
Warning: Vehicles equipped with
air conditioning: Components of
the air conditioning system may
obstruct work being undertaken
on the engine, and it is not always possible
to unbolt and move them aside sufficiently,
within the limits of their flexible pipes. In
such a case, the system should be
discharged by a Ford dealer or air
conditioning specialist. Refer also to the
precautions given in Chapter 3.
Note:
A hoist and lifting tackle will be required
to lift the engine out of the vehicle.
1
Disconnect the battery negative lead.
2
Remove the bonnet.
3
On carburettor models, remove the air cleaner.
4
On fuel-injection models, remove the air
inlet hose, plenum chamber and air cleaner lid
as an assembly.
5
Disconnect the breather hose from the
camshaft cover, and unscrew the bolt
securing the hose support bracket to the left-
hand side of the cylinder head
(see
illustration)
.
6
Drain the cooling system.
7
To provide additional working space,
remove the radiator.
5.21 Air conditioning compressor mounting
bolts (arrowed) (viewed from underneath)
DOHC engine 2B•5
5.29 Intermediate shaft lower clamp bolt
(arrowed)
5.33 Engine adaptor plate bolt (arrowed)
5.36 Remove the engine mounting brackets
to improve clearance
27
Remove the starter motor.
28
Remove the exhaust downpipe.
29
Ensure that the steering wheel is
positioned in the straight-ahead position then,
using a dab of paint or a suitable marker pen,
make alignment marks between the
intermediate shaft lower clamp and steering
gear pinion. Slacken and remove the lower
clamp bolt then disconnect the intermediate
shaft from the steering gear
(see illustration)
.
30
Working inside the vehicle, place a
wooden block under the clutch pedal to raise
it fully against the stop, so holding the
automatic adjuster pawl clear of the toothed
quadrant.
31
Disconnect the clutch cable from the
clutch release arm, and pass the cable
through the bellhousing.
32
Support the gearbox with a trolley jack,
using a block of wood between the jack and
the gearbox to spread the load.
33
Unscrew and remove the remaining
engine-to-gearbox bolts, and remove the bolt
from the engine adapter plate
(see
illustration)
. Recover any shims fitted
between the sump and the gearbox when
removing the lower engine-to-gearbox bolts.
34
Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected and positioned clear of the
engine to facilitate engine removal.
35
Attach a suitable hoist to the engine lifting
brackets located at the front and rear of the
cylinder head, and carefully take the weight of
the engine.
36
To improve clearance in the engine
compartment when lifting the engine, unbolt
the engine mounting brackets from the
cylinder block, and remove them
(see
illustration)
.
37
Detach the brake lines from the front
suspension crossmember
(see illustration)
.
38
Support the crossmember with a jack (do
not remove the jack from under the gearbox),
then loosen the bolts securing the
crossmember to the underbody. Remove the
bolts from one side, and carefully lower the
crossmember to allow sufficient room for the
sump to clear the steering rack and
crossmember when pulling the engine
forwards from the gearbox
(see illustration)
.
2B
5.37 Removing a brake line securing clip
from the suspension crossmember
5.38 Removing a suspension crossmember
securing bolt
4
Where applicable, remove the bolt securing
the transmission fluid dipstick tube to the left-
hand side of the cylinder block.
5
Working through the starter motor aperture,
unscrew the four torque converter-to-
driveplate nuts. It will be necessary to turn the
crankshaft, using a suitable spanner on the
crankshaft pulley bolt, in order to gain access
to each bolt in turn through the aperture.
6
Support the transmission with a trolley jack,
using a block of wood between the jack and
the transmission to spread the load.
7
Unscrew and remove the remaining engine-
to-transmission bolts, and remove the bolt
from the engine adapter plate. Recover any
shims fitted between the sump and the
transmission when removing the lower engine-
to-transmission bolts. Where applicable, pull
the blanking plug from the adapter plate.
8
Proceed as described in paragraphs 34 to 38
of Section 5.
9
Gently raise the engine, then pull the engine
forwards to disconnect it from the
transmission. Ensure that the torque converter
is held firmly in place in the transmission
housing, otherwise it could fall out resulting in
fluid spillage and possible damage. It may be
necessary to rock the engine a little to release
it from the transmission.
10
Once clear of the transmission, lift the
engine from the vehicle, taking care not to
damage the components in the engine
compartment.
39
Gently raise the engine, then pull it
forwards to disconnect it from the gearbox.
Ensure that the gearbox is adequately
supported, and take care not to strain the
gearbox input shaft.
It may be necessary to rock
the engine a little to release it
from the gearbox.
40
Once clear of the gearbox, lift the engine
from the vehicle, taking care not to damage
the components in the engine compartment.
6 Engine
- removal leaving
automatic transmission in vehicle
Note:
Refer to Part A, Section 4 of this
Chapter and to the warning that appears at the
start of Section 5 before proceeding. A
suitable hoist and lifting tackle will be required
for this operation.
1
Proceed as described in paragraphs 1 to 21
of Section 5.
2
Unscrew and remove the top engine-to-
transmission bolts which are accessible from
the engine compartment. Note the location of
the earth strap, vacuum pipe bracket, and
transmission dipstick tube bracket, as
applicable.
3
Proceed as described in paragraphs 23 to 29
of Section 5.
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