Engine removal steps.

[Martiny]

Hi All

Having just been through the taks of removing and replacing an the Engine on the FD, I thought I would post the checklist that I used, her it is:


Remove:
undertray
Air box top half
battery and tray
air intake pipe (the one that goes to the upper intake manifold)
Intercooler top mounting brackets
AST, pipes and brackets
Intercooler pipes
Bottom half of air box
Intercooler
Cross member (the intercooler and air box are bolted to this)

Split the oil cooler lines

Remove:
Water pump hoses (from radiator)
Accessory belt (the one that goes around the PS and Aircon pumps)
Power steering pulley
Power steering pump
Loom-Fuse box wiring + 2 grey connectors on the passenger side inner wing
Air con pump wiring
top air con pump bolts
Fuel lines (x3)
Heater- block water hose
Vac line to boost sensor (on bulkhead)
Throttle cable
Brake servo line and ground strap

Unplug ECU
Pull wiring through bulkhead into engine bay

remove transmission splash pan
Unbolt engine mounts
Raise engine a couple of inches and remove the engine mounts completely
lower the engine onto the subframe
remove starter motor
Unbolt downpipe from cat/midbox
undo transmission wiring and pull up into engine bay
remove cat air pipe from engine

open transmission inspection hatch (2 bolts underneath)
undo the 6 bolts holding the clutch pressure plate to the flywheel (requires someone to turn the engine over via the front pulley with a spanner/socket of some description)
Pry pressure plate off flywheel (you can see the lugs it needs to come off)
Remove the 5 bellhousing bolts
Raise the engine
Remove the remaining 2 Aircon pump bolts and pull the pump to the side.
Support the gearbox with a jack
Wiggle, swear at and pull engine until it\'s free, then lift and remove.

Assembly is a reversal of the above process  

I found that I had to remove the downpipe when the engine was half out as it was catching under the car.

Also, bag EVERYTHING you take off and label it. I\'ve just put mine back in and it\'s amazing the number of little things I didn\'t mark up from near the very beginning of the removal.

Make your own checklist for swapping over the anciliaries! I found that there wasnt much i could just take off one engine and put it on the new Engine. Nearly everything has to come off, then you have to refit everything again! Make diagrams, draw pictures, do everything you can to ensure a diligent re fitting.

best of luck!

[RemarkLima]

Superb, very good to see this! Added to my favorites

[efiniste]

You missed my name off the bottom Martin

Glad it was of use to you.

Steve

[Laeeq]

Well done... you forgot to add cuts and bruses...:Laugh

iv\'e just installed a new engine in the red car...forgot to put the clutch plate right way round so she wouldn\'t go in gears so on Sunday had to drop the gearbox (what fun job it was) down to replace the plate.  All is in very good order and seeing and running her makes you forget about the troubles you have gone through:3gears-lh

The hrdest part was for me to put down pipe back on as i didn\'t know that it could make life easier if had removed steering rack..:2Mad :rolleyes:  but did it in the end:driving

[nikp]

Don\'t forget engine earth straps. That got me for a while.

[RobbieRX-7]

Sounds about right. I would just like to add that there is another connector by the ecu which has to be unplugged. This connector is further up the loom from the ecu and it must be unplugged so you can pull the loom through to the engine bay. It\'s right up behind the glovebox area so a bit fiddly and it\'s used to control the instruments i think.

[Martiny]

Sounds about right. I would just like to add that there is another connector by the ecu which has to be unplugged. This connector is further up the loom from the ecu and it must be unplugged so you can pull the loom through to the engine bay. It\'s right up behind the glovebox area so a bit fiddly and it\'s used to control the instruments i think.

Yeah, that was a bit of a surprise.

Another addition to make is map sensor.

[Martiny]

You missed my name off the bottom Martin

Glad it was of use to you.

Steve

Thanks Steve, yes it is your list, and helped me tons !

[rx7boy]

What changes are there if you are lifting Engine with tranmission box out of the car ??

[SmbFD3S]

What changes are there if you are lifting Engine with tranmission box out of the car ??

You have to remove the PPF and everything in this pic basically...

[rx7boy]

thanks i will get on it on wednesday !!