Advertisement
8-38
GROUP
8-
ENGINE
EJ
ENGINE REMOVAL AND INSTALLATION
REMOVAL
1.
Remove
the
bonnet.
l. Drain the cooling system and
the
crankcase.
3. Remove the air cleaner. Dis-
connect the battery ground cable at
the cylinder head, and at the battery.
Disconnect the radiator upper hose
at the water outlet housing and the
radiator lower hose at the water
pump.
On a car with automatic
transmission disconnect the transmis-
sion oil cooler lines from the radi-
ator.
4. Remove the radiator. Remove
the drive belt, fan, and pulley.
5. On
a
car
equipped
with air
conditioning remove
the compressor,
leaving hoses attached. Place
a suit-
ably
sized sheet
of hardboard or
similar
material between the air con-
ditioning heat
exchanger and
the
engine to prevent
accidental
damage
occurring to the
exchanger.
6. Disconnect
the
heater hoses
from the water pump. Disconnect
the alternator wires
from
the
al-
ternator, the starter cable from the
starter, the accelerator rod and the
choke control cable from the car-
burettt>r.
A2017-A
FIG. 43
-Engine Lifting
Hook
7. Disconnect
the
flexible fuel
line
at
the
fuel tank line and
plug
the
fuel
tank line.
8. Disconnect the
coil
primary
wire at the coil. Disconnect the oil
pressure and the water temperature
sending unit wires at the sending
units.
9. On
250-2V engines
remove the
inlet and
exhaust
manifolds
as
des·
cribed on
page
8-27.
10. Remove the starter.
On a car with a manual-shift
transmission, disconnect the clutch
retracting spring. Disconnect the
slave cylinder from the clutch hous-
ing and suitably support it clear of
the transmission.
11. Raise the car. Remove the fly-
wheel or converter housing upper re-
taining bolts through the access
holes
in
the
underbody.
12
..
Disconnect the muffler inlet
pipe at the exhaust manifold. Loosen
the inlet pipe clamp and slide it off
the support bracket on the engine.
Disconnect the engine right and left
mount at the underbody bracket. Re-
move the flywheel or converter hous-
ing cover.
On a car with a manual-shift
transmission, remove the flywheel
housing lower retaining bolts.
On a car with automatic transmis·
sion, disconnect the converter from
the flywheel. Remove the converter
housing lower retaining bolts.
Lower the car. Support the
transmission and flywheel or con-
verter housing with a jack.
13. Attach the engine lifting hook
(Fig. 43). Carefully lift the engine
out of rne engine compartment. In-
stall the engme on a work stand.
INSTALLATION
1. Install guide pins in the fly·
wheel or converter housing bolt holes
in the rear of the engine. Place a
new gasket over the studs of the ex-
haust manifold.
l. Carefully lower the engine into
the engine compartment.
3. Make sure the studs on the ex·
haust manifold are aligned with the
boles in the muffler inlet pipe and
the guide pins in the block engage
the holes in the flywheel housing.
On a car with automatic transmis-
sion, start the converter pilot into
the crankshaft.
On a car with a manual-shift
transmission, start the transmission
main drive gear into the clutch disc.
It may be necessary to adjust the
position of the transmission in rela-
tion to the engine if the input shaft
will not enter the clutch
disc.
U the
eDgine
lump
up after tbe
shaft
enten, tum the Cl'llllksWt slowly
(tnmsmisslon la
lear)
undl the sWt
spUnes mesh with the clutch disc
5pUnes.
4. Remove
the
engine
lifting
hooks. Install the flywheel or con·
verter housing upper retaining bolts.
5. On
250-2V engines install the
starter
motor
and the exhaust and
inlet manifolds as described on page
8·27
6. Remove the jack from the
transmission.
Raise the car.
7. Remove the guide pin and in-
stall the flywheel or converter hous-
ing lower retaining bolts.
On a car with automatic trans-
mission, attach
the
converter to the
flywheel and
torque
the retaining
nuts to specifications.
8.
Install the flywheel orconverter
housing dust cover.
On a car with a manual-shift
transmission, install the clutch equal-
izer shaft and arm bracket. Connect
the clutch retracting spring.
9. Install the engine left and right
mount to the underbody bracket. In-
stall the sediment bowl on
the
fuel
pump.
10. Remove the plug
from
the fuel
tank line and connect the flexible
fuel line to the fuel tank line. Install
the exhaust manifold to muffler inlet
pi~
retaining lock washers and nuts.
Torque the nuts to
specifications.
Position the inlet pipe clamp on the
support bracket on the engine and
tighten the
clamp.
11
.
Lower the car. Connect the
oil pressure and the engine temper-
ature sending unit wires. Connect
the coil primary wire. Connect the
accelerator rod. Connect and adjust
the choke control cable.
12. Install the starter motor. Con-
nect the starter cable. Connect the
alternator wires. Connect the battery
ground cable.
13.
Remove the hardboard
and
install
the
air conditioning com-
pressor.
Install the
pulley, fan,
and
drive belt.
Adjust the drive
belt
tension.
Install
the
radiator. Con-
nect
the
radiator
upper and
lower
hoses.
Fill and bleed the cooling
system. Fill the
crankcase
with the
proper grade and quantity of engine
oil.
14. Install and adjust
the
bonnet.
15. Operate the
engine
at fast
idle
and check all
gaskets
and hose con-
nections for
leaks.
On a car
with
automatic trans-
mission, check the transmission con-
trol
linkage (Group
7).
16. Install the air cleaner.
Advertisement
