Mazda Rotary Club

Ok folks, my engine block should be here any day now (supposed to be tomorrow!), so I thought it was about time I started doing some preperation for it! (with help from a friend).

Ok.... so far the oil and coolant\'s been emptied.
The FMIC and incuction kits have been removed.
The Air Con pipes have been disconnected
The ECU plugs have been pulled through.
The loom has been disconnected from the engine, all the little plugs etc.
The downpipe has been disconnected from the mid pipe.
Disconnected the oil cooler pipes.
Removed the cross bar thing

So, what\'s still to be done?

I\'m thinking...

Engine mounts
Gearbox

Have I missed anything?

The engine mounts should be easy, no? I\'m a little worried about the gearbox side of it? Is there a how to anywhere, or I\'m open to as much advice as you folks can give me please!!

Here\'s some piccys...

(http://i58.photobucket.com/albums/g279/weebockle/DSC00486.jpg)

(http://i58.photobucket.com/albums/g279/weebockle/DSC00490.jpg)

(http://i58.photobucket.com/albums/g279/weebockle/DSC00494.jpg)

Ecu plugs pulled through...
(http://i58.photobucket.com/albums/g279/weebockle/DSC00496.jpg)

(http://i58.photobucket.com/albums/g279/weebockle/DSC00495.jpg)

What\'s next??....
(http://i58.photobucket.com/albums/g279/weebockle/DSC00498.jpg)

belts power steering pump, air con pump disconnect exhaust from DP,
Good luck Bob

DP disconnected from exhaust.

Taken one belt off, the one that goes around the air con pump etc. (see last pic). I take it this is what you mean? Or do you mean remove the power steering and the air con pump?? Any hinters on how to?


Anything else??

I\'m looking for help especially about the gearbox side of things. Also if I\'ve missed anything obvious.

I would reccommend disconecting the clutch hydraulic line right by the map sensor. The gearbox is gonna drop and brake that right off. Remove starter motor, Remove the slave cylinder above the starter motor, Unbolt the little inspection plate from the bottom of gearbox, then use 2 long 12" screwdrivers to release the pull type clutch mechanism. Once released, unbolt engine/gearbox and it will come out. Get 2 mates to help you.

Oh yeah, unplug the connections on the bottom of the gearbox. you might need to remove the alu undertray to gain access. This video is gonna help out a ton. It shows hot to deal with the pull type clutch http://www.youtube.com/watch?v=uPCi4RpGQCU&mode=related&search=

Quote from: RobbieRX-7I would reccommend disconecting the clutch hydraulic line right by the map sensor. The gearbox is gonna drop and brake that right off. Remove starter motor, Remove the slave cylinder above the starter motor, Unbolt the little inspection plate from the bottom of gearbox, then use 2 long 12" screwdrivers to release the pull type clutch mechanism. Once released, unbolt engine/gearbox and it will come out. Get 2 mates to help you.

Ok...

I don\'t know my way around the engine bay of the fd3s too well tbh. I\'m quite suprised we\'ve got so far!

Any pics of where the clutch hydraulic line is? Where to disconnect it etc.

Also, the starter motor is near the ground on the passenger side am I right? When you say disconnect it, do you mean simply the electrics? If so, that\'s been done. If not, what do you mean?

Also, any pics of where the slave cylinder is or how to remove it?

Finally, once you do the screw driver thing, is that the clutch released? Then you just unbolt it all etc, or do you need to release it at the exact point you try to disconnect? Also, you said the gearbox will drop?? Alot, hit the deck style... or only a few inches??

Also, at what point do I need two mates to help, and why?


Sorry for all the questions!! Your help is appreciated.

Quote from: RobbieRX-7Oh yeah, unplug the connections on the bottom of the gearbox. you might need to remove the alu undertray to gain access. This video is gonna help out a ton. It shows hot to deal with the pull type clutch http://www.youtube.com/watch?v=uPCi4RpGQCU&mode=related&search=

Now I get why you need two screw drivers... that vid should help alot! Cheers.

How easy is it to do with the screw drivers? Is it advised to get a jack under the gearbox to stop it dropping?

Hello jim.

The clutch hydraulic line is in my picute circled yellow. A 10mm spanner will undo it. Once undun, pull the clip out with pliers.

you need to remove the starter motor to get to a bolt holding the engine/gearbox together. The gearbox might rest on the subframe, but put a jack or something to hols just incase. Dont forget to unplug the 5 connections on the gearbox


The clutch mechanism. You need 2 screwdrivers really to make it easier. One to push the collar forward to the front of the car and hold it whilst the other screwdriver to push the fork/bearing backwards to the rear of the car.

Get 2 mates to help lift the engine out the car. 1 mate to guide the downpipe out, you and the other 1 to pull/guide the engine out.

Cheers mate. That helps quite a bit.

Just thought... fuel lines. Where are these connected about? They\'ll need to be disconnected somewhere.


Anything simple I\'m missing? Oh, also you mentioned Power steering pump?

Fuel lines. There are 3 of these just below the yellow circle. Mark them up such as top, bottom left, bottom right

Do you mind marking them on the pic mate? Not exactly sure where they are.

Are these the fuel lines?? Circled with the arrow.

(http://img170.imageshack.us/img170/7338/emptyenginebaysn6.jpg)

Also, how far will the gearbox drop?

The fuel lines attach directly to the engine. If you look below the oil fliter, you will see 3 rubber hoses about 10mm wide. These are the fuel lines.

Dont forget to unplug the electrical connections from the gearbox. These are attached to the gearbox by metal bended over the wiring harness on the actual box. Simply bend the metal tabs and release the wiring loom,. Pull it through to the engine bay and out the way

Top, bottom, or side of the gearbox mate?

I think these might be disconnected already actually.

The gearbox wont drop much. Maybe 2 inches. Mine actually rested on the engine subframe.

Quote from: Jim_rx7Are these the fuel lines?? Circled with the arrow.

(http://img170.imageshack.us/img170/7338/emptyenginebaysn6.jpg)

Yes they are mate

Cheers mate. Making this alot easier with your wealth of knowlege!!

No doubt, there will be more questions once I get back outside tomorrow... lol. ;)

It\'s quite fiddly getting it back in. might take some head scratching and swearing lol

Quote from: RobbieRX-7The fuel lines attach directly to the engine. If you look below the oil fliter, you will see 3 rubber hoses about 10mm wide. These are the fuel lines.

Dont forget to unplug the electrical connections from the gearbox. These are attached to the gearbox by metal bended over the wiring harness on the actual box. Simply bend the metal tabs and release the wiring loom,. Pull it through to the engine bay and out the way

Are these plugs on the underside of the gearbox?

Passenger side mate, on the side of gearbox

Quote from: RobbieRX-7Passenger side mate, on the side of gearbox

Where do you live? What you doing tomorrow? ;)

gonna meet hotstepper1973 and grinder near lancashire for a local meet, then going to nurburg on my rebuild on thursday

i disconnected your engine from the gearbox by removing the 6 bolts that hold the clutch housing onto the flywheel.  with a bit of jiggling the engine came loose, that way you dont need to mess around with the clutch slave cylinder, etc.

Will have a chat when I see you....

ok mate... any hinters appreciated!

Quote from: dazsiri disconnected your engine from the gearbox by removing the 6 bolts that hold the clutch housing onto the flywheel.  with a bit of jiggling the engine came loose, that way you dont need to mess around with the clutch slave cylinder, etc.

Will have a chat when I see you....

You can do it this way, BUT you still need to take the pressure plate off the gearbox anyway by using the 2 screwdriver method through the peephole, so you might as well do it like i said earlier. just remember to do this BEFORE removing any bolts that hold the engine/gearbox together, otherwise it\'s gonna make it 10 times harder to push the release collar forward!! You dont need to remove the clutch slave cylinder. I know i said earlier that you need to, but actually you dont. It is definitly worth putting new brake fluid in the resevoir and bleeding the clutch. makes for a smoother gear change

hows i going mate?

me? ... not done anything today.

Gonna go pick up the engine tomorrow.

Should paint your engine bay black when the engine is out!

Quote from: RobbieRX-7

If you want some advice, Remove the Map sensor (the Little Black box fastened to the Bulk head just above your top Circle) then keep it safe and dry some where. They have a Tendency to play silly buggers if they get Knocked or sit for some time.

Quote from: koolanceShould paint your engine bay black when the engine is out!

Yip... that\'s the plan. It has been done. Just some bits still red for some reason.


Well I\'ve got the engine.. (thanks dazir). There\'s more attached to it than what I expected. SHould make life a little easier.


Will be attempting to get the old one out tomorrow hopefully.

Not had a chance to get much done due to the weather!

But today I\'ve ...

Removed the map sensor
Disconnected the Clutch hydraulic line
Disconnected the power steering lines
Disconnected the fuel lines

I also found a coolant hose near the rear of the engine I had forgot about and also another near the front. I also removed the hose which goes to the black thing at the top left of the engine bay (it connects to the UIM) and I also removed the throttle cables.

So.....

Am I now right in thinking I need to :

Undo the mounts
Unclip the harness on the gearbox
Remove starter motor
Undo the gearbox/clutch

Then it should lift out?? Or have I missed anything here?

thanks in advance people... your help certainly makes it easier!

Aircon?

You should nearly be there, basically take your time and put things in different margarine pots to keep things methodical!

P.s. Argos sell quite good gazebos for £15-20, which would keep you reasonably dry under it...

Quote from: dazsirAircon?
 
You should nearly be there, basically take your time and put things in different margarine pots to keep things methodical!
 
P.s. Argos sell quite good gazebos for £15-20, which would keep you reasonably dry under it...

Also mark the lids with whats in them and from what area they came from cos after a while u have many many little pots lol

Quote from: dazsirAircon?

You should nearly be there, basically take your time and put things in different margarine pots to keep things methodical!

P.s. Argos sell quite good gazebos for £15-20, which would keep you reasonably dry under it...

Air-Con is disconnected and the starter motor\'s off now too.
One mount is also undone.

I think all that\'s left is the gearbox and some plugs on the box to be disconnected.

Not much at all. Just trying to get hold of a bluddy hoist!!