Ford 2.0 litre DOHC engine.pdf

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

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

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°

Crankshaft pulley bolt:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 to 58

33 to 43

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten further 90°

Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten further 90°

M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 to 39

27 to 29

Camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 to 8

4 to 6

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.

Removal of the crankshaft main bearings.

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) .

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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