oil FIAT PUNTO 1998 176 / 1.G Repair Manual

11.15 Left-hand engine mounting viewed from below 9 lower the engine sufficiently to remove the mounting from the engine bracket. 10 Locate the new mounting in the engine bracket, refit the nut and washers and tighten securely. 11 Raise the engine and refit and tighten the mounting-to-body bolts. 12 Remove the trolley jack and lower the vehicle to the ground. Left-hand mounting 13 If not already done, firmly apply the handbrake, then jack up the front of the car and support It securely on axle stands (see
Jacking
and vehicle support). 14 Place a trolley jack beneath the trans-mission. with a block of wood on the jack head. Raise the jack until it is supporting the weight of the engine/transmission. 15 Unscrew the bolts securing the left-hand mounting to the body (see Illustration). 16 Unscrew the nut securing the mounting to the transmission bracket and recover the washers. 17 Lower the transmission sufficiently to remove the mounting from the transmission bracket. 18 Locate the new mounting in the transmission bracket, refit the nut and washers and tighten securely. 19 Raise the engine and refil and tighten the mounting-to-body bolts. 20 Remove the trolley jack and lower the vehicle to the ground. Rear mounting 21 If not already done, firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see
Jacking
and vehicle support). 22 Working beneath the vehicle, unscrew the bolts securing the rear engine mounting to the underbody (see illustration). 23 Temporarily support the weight of the engine/transmission using a trolley jack. 24 Unbolt the rear mounting assembly from the transmission and withdraw from under the vehicle. 25 Unscrew the bolt and separate the bracket from the mounting. 28 Fitting the new mounting is a reversal of tha removal procedure.
Diesel engine in-car repair procedures 2C*11
11.22 Rear engine mounting viewed from below
12 Sump -removal and refitting
Removal 1 Disconnect the battery negativo terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 Firmly apply the handbrake, then jack up the front of the car and support it securely on axie stands (see Jacking and vehicle support). 3 Drain the engine oil as described in Chap-ter 1B. Where applicable, remove the screws and lower the engine undertray away from the vehicle. 4 On turbo models disconnect the turbo-charger oil drain hose from the sump (see illustration). 5 Working around the outside of the sump, progressively loosen and withdraw the sump retaining bolts. 6 Break the joint by striking the sump with the palm of your hand, then lower the sump and withdraw it from underneath the vehicle. Recover and discard the sump gasket. 7 While the sump Is removed, take the opportunity to check the oil pump pick-up/strainer for signs of clogging. If necessary, clean or renew the strainer.
Refitting 8 Thoroughly clean the sump inside and out ensuring that all traces of gasket are removed from the mating surfaces of both the sump and the cylinder block/crankcase.
12.4 Turbocharger-to-sump oil drain hose
9 Ensure that the mating surfaces are clean and dry, then apply a little grease to the surface of the sump. This will retain the gasket in position while refitting the sump. 10 Lay the new sump gasket In position on the sump mating surface, then offer up the sump and refit the retaining bolts. Tighten the bolts evenly and progressively lo the specified torque. 11 On turbo models reconnect the turbo-charger oil drain hose. 12 Lower the vehicle to the ground then refer to Chapter 1B and refill the engine with the specified grade and quantity of oil. 13 Reconnect the battery negative terminal.
13 Oil pump and pick-up tube -removal, inspection and refitting
Removal 1 The oil pump Is mounted on the timing belt end of the cylinder block and is driven by flats on the crankshaft nose. Incorporated In the oil pump body is the crankshaft oil seal. 2 Remove the timing belt as described in Section 4, and the crankshaft sprocket as described in Section 5. 3 Remove the sump as described in Section 12. 4 Unscrew the bolts securing Ihe pick-up tube to the bottom of the oil pump. Also unscrew the bolt securing the tube to the No 2 main bearing cap. Withdraw the tube from the oil pump and crankcase. Recover the gasket (see illustrations).
13.4a Removing the oil pump pick-up tube... 13.4b ... and gasket

2014 Diesel engine in-car repair procedures
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13.5 Note the location of the bracket on the oil pump 13.6 Prising the oil seal from the oil pump housing 13.7 Using an impact drivor to loosen the oil pump cover screws
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13.6a Removing the inner rotor... 13.8b ... and outer rotor 13.9a Depress tho relief valve collar and remove the retaining plate...
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1MU55U
13.9b ... then remove the seat... 13.9c ... spring ... 13.9d ... and valve
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9 ; I 1 13.9e Oil pump housing and components 13.10a Checking the outer rotor-to-casing clearance 13.10b Checking the rotor endplay

Diesel engine in-car repair procedures 2C*11
X
a 13.14 Fitting the new oil seal to the oil pump casing
S Unscrew the bolts securing the oil pump to Ihe front of the cylinder block and withdraw it over the nose of the crankshaft. Note the location of the bracket (see Illustration). Recover the gasket.
Inspection 8 Prise the oil seal from the front of the oil pump using a screwdriver (see Illustration). 7 Unscrew the crosshead screws and lift off the cover. The screws are tight and are best loosened using an impact driver (see illustration). S Lift out the two rotors keeping them identified for position in relation to each other (see illustrations). 9 Depress the relief valve collar, then extract the retaining plate and withdraw the seat, spring and valve (see illustrations). 10 Clean the pump thoroughly, and Inspect the rotors for signs of damage or wear. Using a feeler blade, check the wear between the outer rotor and oil pump casing. Using the feeler blade and a straight-edge, check the endptay of Ihe rotors. If the rotors are worn in excess of the specified amount given in Specifications, the oil pump should be renewed as a complete unit (see Illustrations). 11 Check the condition of the relief valve and seating - If worn excessively the pump must be renewed. 12 If the components are In good condition, reassemble the pump using a reversal of the dismantling procedure. Before fitting the cover the rotors should be oiled and the cavity
13.15 Engine oil dipstick rubber grommet in the oil pump casing between them filled with clean engine oil. Make sure the cover screws are fully tightened. 13 Thoroughly clean the mating surfaces of the oil pump and cylinder block. 14 Dip the new oil seal in engine oil then locate it on the front of the oil pump with the sealing lips facing Inwards. Use a suitable tubular drift (or socket) to drive the seal into the oil pump casing (see illustration). 16 Examine the dipstick tube rubber grommet in the oil pump and renew il If necessary (see illustration).
Refitting 16 Smear a little engine oil on both sides of the new gasket then locate it on the cylinder block (see illustration), 17 To prevent damage to the new oil seal as it is passed over the nose of the crankshaft, wrap some adhesive tape around it and lightly oil it. 18 Carefully locate the oil pump over the crankshaft taking care not to damage the oil seal then Insert the bolts loosely. Remove the adhesive tape (see Illustration). 19 Using a straight-edge, position the oil pump so that the sump mating surface Is level with the surface of the crankcase (see illustration). With the pump correctly positioned, securely tighten the bolts in an even and progressive sequence. 20 Refit the oil pick-up tube together with a new gasket, and securely tighten the mounting bolts. 21 Refit the sump with reference to Section 12.
13.16 Positioning the oil pump gasket on the cylinder block 22 Refit the crankshaft sprocket with reference to Section 5 and the timing belt with reference to Section 4. 23 When starling the engine, let it Idle until the oil pressure warning light goes out.
14 Oil cooler -removal and refitting I I
Removal 1 The oil cooler is located on the right-hand side of the engine compartment. First remove the front bumper as described In Chapter 11. 2 Unbolt the support bar for the radiator and oil cooler. 3 Support the oil cooler then unscrew the upper mounting boll. Lower the cooler to the extent of the hoses. 4 Position a container beneath the cooler then unscrew the Inlet and outlet union nuts and disconnect the hoses from the oil filter. Note the fitted positions of the hoses for correct refitting. Allow the oil to drain into the container. 5 Fully unscrew the union nuts and disconnect the hoses from the oil cooler.
Refitting 6 Refitting is a reversal of removal, but top-up the engine oil level as necessary. Run the engine and check for leaks.
13.18 Locating the oil pump over the end of the crankshaft 13.19 Checking that the oil pump and sump mating surfaces are correctly aligned with a straight-edge

2D*10 Engine removal and overhaul procedures
Cylinder block Bore diameter: Petrol engines: 1106 cc engine 70.000 to 70.030 mm 1242 cc engine 70.800 to 70.630 mm Diesel engine 82.600 to 82.650 mm Underslzes * Increments of 0.010 mm
Pistons and piston rings Piston diameter: Petrol engines: Grade A; 1108 cc engine 69.960 to 69.970 mm 1242 cc engine 70.760 to 70.770 mm Grade 8: 1108 cc engine 69.970 to 69.980 mm 1242 cc engine 70.770 to 70.780 mm Grade C; 1108 cc engine 69.980 to 69;990 mm 1242 cc engine 70.780 to 70.790 mm Diesel engine: Grade A 82.530 to 82.640 mm GradeB GradeC , 82.550 to 62.560 mm Grade E ; 82.570 to 82.580 mm Piston projection above top of bore: Diesel engine 0.637 to 1.162 mm Piston to bore clearance: Petrol engines 0.030 to 0.050 mm Diesel engine 0.060 to 0.080 mm Maximum difference in weight between pistons x 5g Gudgeon pin diameter 17.970 fo 17.974 mm Gudgeon pin-to-plston clearance: Petrol engines 0.008 to 0.016 mm Diesel engine 0.003 to 0.009 mm Piston ring-to-groove clearance: Petrol engines: Top compression ring: 1108 cc engine 0.040 to 0.075 mm 1242 cc (8-valve) engine 0,040 lo 0,080 mm 1242 cc (16-valve) engine 0 to 0.06 mm 2nd compression ring: 1108 cc and 1242 cc (8-valve) engines 0.020 to 0.055 mm 1242 cc
(1
B-valve) engine 0 to 0.055 mm Oil scraper ring: 1108 cc and 1242 cc (8-valve) engines 0.020 to 0.055 mm 1242 cc (16-valve) engine 0 to 0.055 mm Diesel engine: Top compression ring 0.080 to 0.130 mm 2nd compression ring 0.020 to 0.052 mm Oil scraper ring 0.030 to 0.065 mm Piston ring end gap: Petrol engines: Top compression ring: 1108 cc engine 0.25 to 0.45 mm 1242ccengine : 0.20to0.40mm 2nd compression ring 0.25 to 0.45 mm Oil scraper ring 0.20 to 0.45 mm Diesel engine: Top compression ring 0.020 to 0.350 mm 2nd compression ring 0.300 to 0.500 mm Oil scraper ring 0.250 lo 0.500 mm
Connecting rods Gudgeon pin-to-small end clearance: Petrol engines Interference fit Diesel engine 0.014 to 0.020 mm

2D*10 Engine removal and overhaul procedures
1 General information
Included In (his Part of Chapter 2 are details of removing the engine/transmission from the car and general overhaul procedures for tho cylinder head, cylinder block/crankca9e and all other engine internal components. The information given ranges from advice concerning preparation for an overhaul and the purchase of replacement parts, to detailed step-by-step procedures covering removal, inspection, renovation and refitting of engine Internal components. After Section 5, all instructions are based on the assumption that the engine has been removed from the car. For Information concerning in-car engine repair, as well as the removal and refitting of those external components necessary for full overhaul, refer to Part A, 8 or C of this Chapter (as applicable) and to Section 5. Ignore any preliminary dismantling operations described in Part A. B or C that are no longer relevant onca the engine has been removed from ihe car.
2 Engine overhaul -general information
1 It Is not always easy to determine when, or if, an engine should be completely overhauled, as a number of lectors must be considered. 2 High mileage Is not necessarily an Indication that an overhaul Is needed, while low mileage does not preclude the need for an overhaul. Frequency of servicing Is probably the most important consideration. An engine which has had regular and frequent oil and filter changes, as well as other required maintenance, should give many thousands of miles of reliable service. Conversely, a neglected engine may require an overhaul very early In its life. 3 Excessive oil consumption Is an Indication that piston rings, vaivo seals and/or valve guides are in need of attention. Make sure that oil leaks are not responsible before deciding that the rings and/or guides are worn Perform a compression test, as described In Parts A or B (petrol engines) or C (diesel engines) of this Chapter, to determine the likely cause of the problem. 4 Check the oil pressure with a gauge fitted In place of the oil pressure switch. If it Is extremely low. the main and big-end bearings, and/or the oil pump, are probably worn out. 5 Loss of power, rough running, knocking or metallic engine noises, excessive valve gear noise, and high fuel consumption may also point to Ihe need for an overhaul, especially if
they are all present at the same time. If a complete service does not remedy the situation, major mechanical work is the only solution. 6 An engine overhaul involves restoring ell Internal parts to the specification of a new engine. During an overhaul, the cylinders are rebored (where applicable), the pistons and the piston rings are renewed. New main and big-end bearings are generally fitted; If necessary, the crankshaft may be reground. to restore the journals. 7 The valves are also servrced as well, since they are usually In less-than-perfect condition at this point. While the engine is being overhauled, other components, such as the starter and alternator, can be overhauled as well. The end result should be an as-new engine that will give many trouble-free miles. Note: Critical cooling system components such as the hoses, thermostat and coolant pump should be renewed when an engine is overhauled. The radiator should be checked carefully, to ensure that it is not clogged or leaking. A/so. it Is a good Idea to renew the ofI pump whenever the engine i$ overhauled.
8 Before beginning the engine overhaul, read through tho entire procedure, to familiarise yourself with the scope and requirements of the job. Overhauling an engine is not difficult If you follow carefully all of the instructions, have the necessary tools and equipment, and pay close attention to all specifications. It can, however, be time-consuming. Plan on the car being off the road for a minimum of two weeks, especially If pans must be taken to an engineering wo'kd for repair or reconditioning.
9 Check on the availability of parts and make sure that any necessary special tools and equipment are obtained in advance. Most work can be done with typical hand lools, although a number of precision measuring tools are required (or Inspecting parts to determine if they must be renewed. Often the engineering works will handle the inspection of parts and offer advice concerning reconditioning and renewal, Note: Always wait unt'l the engine has been completely dismantled, and until all components (especially the cylinder block/crankcase and the crankshaft) have been inspected, before deciding what service and repair operations must be performed by an engineering works. The condition of these components will be the major factor to consider when determining whether to overhaul the original engine, or to buy a reconditioned unit. Do not. fh ere tore, purchase parts or have overhaul work done on other components until they have been thoroughly Inspected. As a general rule, time is the primary cost of an overhaul, so it does not pay to fit worn or sub-standard parts.
10 As a final note, to ensure maximum life and minimum trouble from a reconditioned engine, everything must be assembled wilh care, in a spotlessly-clean environment.
3 Engine and transmission removal -methods
and
precautions
1 If you have decided that the engine must be removed for overhaul or major repair work, several preliminary steps should be taken. 2 Locating a suitable place to work is extremely important. Adequate work space, along with storage space for the car, will be needed. If a workshop or garage Is not available, at the very least, a flat, level, clean work surface Is required. 3 Cleaning the engine compartment and engine/transmission before beginning the removal procedure wilt help keep tools clean and organised. 4 An engine hoist or A-frame will also be necessary. Make sure the equipment is rated In excess of the combined weight of the engine and transmission, Safety Ib of primary Importance, considering the potential hazards involved in lifting the engine/transmission out of the car. 5 If this is Ihe first time you have removed
an
engine, an assistant Bhould Ideally be available. Advice and aid from someone more experienced would also be helpful. There are many instances when one person cannot simultaneously perform all of the operations required when lifting the engine out of Ihe vehicle. 6 Plan the operation ahead of time. Before starting work, arrange for the hire of or obtain all of the tools and equipment you will need. Some of the equipment necessary to perform engine/transmission removal and Installation safely and wilh relative ease On addition to an engine hoist) Is as follows: a heavy duly trolley jack, complete sets of spanners and sockets as described in the reference section of this manual, wooden blocks, and plenty of rags and cleaning solvent for mopping up spitted oil, coolant and fuel. If the hoist must be hired, make sure that you arrange for it In advance, and perform all of the operations possible without it beforehand. This will save you money and time.
7 Plan for the car to be out of use for quite a while. An engineering works will be required to perform some of the work which the do-it-yourselfer cannot accomplish without special equipment. These places often have a busy schedule, so it would be a good idea to consul! them before removing the engine, in order to accurately estimate the amount of time required to rebuild or repair components that may need work, 9 Always be extremely careful when removing and refitting the engine/transmission. Serious injury can result from careless actions. Plan ahead and take your time, and a job of this nature, although major, can be accomplished successfully.

2D*10 Engine removal and overhaul procedures
Engine and transmission -removal, separation, connection and refitting
Note: The engine Is lowered from the engine compartment as a complete unit with the transmission; tho two are then separated for overhaul.
Removal 1 Remove the bonnet and disconnect the washer tubing as described in Chapter 11 (see illustrations). 2 Apply the handbrake, then jack up the front of the vehicle and support on axle stands (see Jacking and vehicle support). Remove both front wheels. In order to remove tne engine/transmission assembly in an upright position from under the vehicle, there must be a minimum clearance of 660 mm between the floor and the front crossmember. Additional height Is necessary if the assembly is to be lowered onto a trolley. 3 Where fitted, unbolt and remove the engine compartment lower cover. 4 Remove the auxiliary drivebelt(s) with reference to Chapter 1A or 1B. 5 Dram the engine oil. transmission oil/fluid and coolant with reference to Chapter 1A or 1B. 6 Remove the battery (see Chapter 5A). 7 On manual transmission models with a cable dutch, disconnect the clutch cable from the transmission (refer to Chapter 6). On manual transmission models with a hydraulic clutch unbolt the clutch slave cylinder from the top of the transmission then fit a cable-tie around it to prevent the piston coming out (see Illustration). Position the cylinder to one side. 8 Unscrew the nut and disconnect the earth lead from the transmission (see illustration). Petrol engines 9 Unbolt and remove the battery tray. 10 Disconnect the wiring from the reversing light switch. 11 On manual transmission models disconnect the reverse Inhibition cable from the transmission then disconnect the gear selector rod from the lever on the transmission. 12 Remove the air cleaner and ducting as descnbed In Chapter 4A or 4B. 13 On automatic transmission models disconnect the kickdown cable and gear selector cable as described in Chapter 7B. Also disconnect the wiring for the electro-magnetic clutch. 14 Unbolt and remove the cover from the bulkhead then disconnect the oxygen sensor wiring. 15 Disconnect the remaining wiring at the bulkhead and release the fuse holders at the mounting. 16 Disconnect the vacuum pipe from the inlet manifold, and also disconnect the wiring connector located next to it.
4.1a Unscrewing the bonnet hinge bolts
17 Unscrewthenutsandseparatetheengine wiring harness lead from the battery positive cable terminal. 18 Disconnect the accelerator cable from the engine as described in Chapter 4A or 4B, 19 Loosen the clip and disconnect the radiator top hose from the elbow on the left-hand end of the cylinder head. Similarly disconnect the bottom hose. On 16-valve models, remove the radiator electric cooling fan as described in Chapter 3. 20 Identify the hoses connected to the throttle housing, then disconnect them. 21 Identify the coolant heater hoses on the bulkhead for position, then loosen the clips and disconnect the hoses. 22 Loosen the clip and disconnect the brake servo vacuum hose from the Inlet manifold. Where applicable, disconnect the remaining emission control system vacuum hoses from the Inlet manifold after Identifying their locations to aid refitting. 23 Disconnect tho fuel supply and return hoses from the throttle housing. 24 Release the connector from the ignition/fuel ECU located on the right-hand side of the engine compartment. 25 Unscrew the nut and detach the earth cable from its location near the ECU. 26 Disconnect the diagnostic connector located near the ECU. 27 On models fitted with power steering, refer to Chapter 10 and unbolt the power steering pump from the front of the engine without disconnecting the hydraulic fluid lines then tie It to one side so that it will not obstruct the removal of the engine. On
4.1b Disconnecting the washer tubing
models with air conditioning, similarly unbolt the air conditioning compressor and position it clear of the engine. Do not disconnect the air conditioning refngerant pipes/hoses. 26 On manual transmission models pull out the retaining plate and disconnect the gear selector cable from the lever on the transmission. 29 Unscrew the nuts retaining the track rod ends on the swivel hubs and use a balljoint separator tool to disconnect them. 30 Release the flexible brake fluid hoses and ABS system sensor wrring from the front suspension struts. 31 On manual transmission models, unscrew the nuts from the outer ends of each driveshaft. To prevent the hubs from turning either have an assistant depress the brake pedal, or temporarily Insert two wheel bolts and use a lever to hold the hub. 32 On automatic transmission models use a suitable drift to drive out Ihe roll pins securing 2D the inner ends of the drlveshafts to tho trans-mission output stubs. Turn the driveshalts as necossary to access the roll pins . 33 Unscrew the two bolts securing the right-hand swivel hub assembly to the front suspension strut, then move the hub assembly outwards. On manual transmission models release the outer end of the driveshaft from the hub assembly - on automatic transmission models slide the inner end of the driveshaft off the final drive output stub. Take care not to strain the flexible brake hose while doing this. Move the driveshaft to one side thon temporanly refit the hub assembly to the strut. On manual transmission models, make
^ - / //
4.7 Fit a cable tie around the dutch slave cylinder to prevent the piston coming out 4.8 Disconnecting the earth lead from the transmission

2D*10 Engine removal and overhaul procedures
4.50b ... and expansion tank 4.S2 Disconnecting the radiator coolant temperature sensor wiring plug
4.53b One of tho wheel arch liner retaining screws is hidden in a recess 52 On the radiator cooling fan housing, disconnect the wiring plug for tho coolant temperature sensor (see illustration). 53 Unscrew the four front screws on each side retaining the wheel arch liners in order to
4.53c Bolt securing the front bumper to the valance access the front bumper mounting bolts • one of lite screws is hidden in a recess. Pull back the liners and use an extension and socket to unscrew the bolts securing the front bumper to tho valance (see illustrations).
4.55 Releasing the retaining clips from the rear of tho indicator lights 4.56a Side bumper retaining screw
4.56b Centre bumper retaining screw 4.57a Radiator lower mounting bracket bolt
4.54 One of the front bumper lower retaining screws 54 Unscrew and remove the front bumper lower retaining screws (see Illustration). 55 From inside the engine compartment, disconnect the wiring from the rear of the Indicator lights and release the retaining clips (see illustration). 56 Unscrew the upper retaining screws and withdraw the front bumper from the body (see Illustrations). 57 Unscrew the bolts socunng the radiator lower mounting bracket to the body then prise the bracket from the rubbers on the bottom ol the radiator (see Illustrations). 58 Unscrew the upper mounting bolt securing the engine oil cooler then lower the cooler and support on an axle stand (see illustrotion). Take care not to damage the hoses. 59 Support the radiator then unscrew the radiator upper mounting bolts, and remove the radiator from the vehicle (see illustrations).
4.57b Removing the bracket from the rubbers on the bottom of the radiator

2D*10 Engine removal and overhaul procedures
60 At the otl filter, unscrew the union nuts and disconnect the oil cooler lines/hoses then remove the oil cooler from the vehicle (see Illustration). Be prepared for some oil leakage. Note the fitted position of the hoses before disconnecting them so that they can be refitted correctly. 61 Disconnect the reversing light wiring from Ihe switch on the front of the transmission (see illustration) 82 Using an Allen key, unscrew the bolts securing the inner ends of the driveshafts to the flanges on the transmission. The right-hand driveshaft is disconnected from the Intermediate shaft flange on the rear of the engine. Recover the plates beneath the heads ol the driveshaft bolls (see illustrations). 63 Unscrew the bolts securing the front sv/lvel hub assemblies to the struts. Also
4.59c Removing the radiator from the vehicle
4.62a Use an Allen key to unscrew the inner driveshaft bolts
release the flexible brake hoses from the struts. 64 Move the swivel hub assemblies outwards and support the inner ends of the dnveshafts on axle stands (see Jacking and vehicle support). Take care not to strain the flexible brake hoses. 65 Remove the exhaust front pipe with reference to Chaptor 4D. If difficulty is expenenced in separating Ihe front pipe from the intermediate pipe, it may prove easier to remove the complete exhaust system. Ail models 66 Attach a suitable hoist to the engine and transmission lifting eyes (see illustration). The left-hand eye is located on the transmission and the right-hand one on the right-hand side of the engine, Take the weight of the engine/transmission.
4.60 Loosening the union nuts securing the oil cooler lines to the oil filter housing
4.62b Removing the driveshaft bolts and plates
67 Working boneath the vehicle, unscrew the bolts securing tne rear engine mounting to the underbody and transmission, and withdraw the mounting. 68 In the engine compartment, unscrew the bolts securing the right-hand engine mounting to the body and engine. For additional working room completely remove the mounting. 69 Unscrew the boils securing the left-hand engine/transmission mounting to the body. For additional working room completely remove Ihe mounting. 70 With the help of an assistant lower the engine/transmission from the engino compartment taking care not to damage the surrounding components (see illustration). Ideally lower the unit onto a low trolley so that it may be withdrawn from under the vehicle. Disconnect the hoist from ihe assembly.
4.61 Disconnecting the reversing light wiring
4.66 Attaching a hoist to tho ongine and transmission assembly

2D*10 Engine removal and overhaul procedures
05 Remove the brush holder assembly from the automatic transmission as described in Chapter 7B, Section 4. The brushes bear on the slip rings at the rear of the electro-magnetic clutch housing and they may be damaged when the transmission is removed. 86 Unscrew and remove the transmission-to-engine bolts then carefully draw the transmission away from the engine, resting It securely on wooden blocks. Collect the locating dowels If they are loose enough to be extracted, 87 If the oil pump driveshaft remains engaged with the crankshaft, remove it and reert Into the transmission to protect It from damage.
Connection 86 If the engine and transmission have not been separated, go to paragraph 104. Manual transmission models 89 Smear a little high-melting-point grease
on
the splines of the transmission input shaft. Do not use an excessive amount as there Is the risk of contaminating the clutch friction plate. 90 Carefully offer up the transmission to the engine cylinder block, guiding the input shaft through the clutch friction plate. 91 Refit the transmission-to-engine bolts and
the
single nut. hand^jghtenlng 1hem to secure the transmission in position. Note: Do not hghten them to force the engine and transmission together. Ensure that the beilhousing and cylinder block mating faces will butt together evenly without obstruction, before finally tightening the bolts and nut securely. Automatic transmission models 92 Check that the oil pump driveshaft is correctly engaged with the oil pump in the transmission. 93 Carefully offer up the transmission to Ihe rear of the engine and insert the oil pump driveshaft In the centre of the electro-magnetic clutch housing. Locate the transmission on the locating dowels then Insert the bolts and tighten them securely. 94 Refit the brush holder assembly to the automatic transmission with reference to Chapter 7B, Section 4. Petrol engines 96 Refit the transmission lower cover and tighten the bolts. 96 Locate the support bracket on the lower cover, then insert the bolts hand-tight. Also Insert the bolts securing the bracket lo the rear of Ihe cylinder block. With all the bolts Inserted, tighten them securely. 97 Refit the earth leads and tighten the bolts. Diesel engines 98 Refit the rpm sensor and tighten the bolts. 99 Insert the Intermediate shaft through the bracket then locate the dust boot on it and insert the Inner end in the transmission.
100 Refit and tighten the bolts securing the Intermediate shaft to the bracket on the rear of the cylinder block. 101 Refit the transmission lower cover and tighten the bolts. Ail models 102 Refit the starter motor (see Chapter 5A). 103 Refit the wiring harness to the components on the engine/transmission assembly making sure it is routed correctly.
Refitting 104 Locate the engine/transmission assembly beneath the engine compartment and attach the hoist to the lifting eyes. 105 Carefully lift the assembly up into the engine compartment taking care not to damage the surrounding components. 106 Reconnect the left-hand engine/trans-mission mounting to the body and tighten the bolts. 107 Reconnect Ihe right-hand engine mounting to the body and tighten the bolts. 108 Working beneath the vehicle, refit the rear engine mounting and tighten the bolts. 109 Disconnect the hoist from the engine and transmission lifting eyes and remove the hoist from under the vehicle. 110 The remainder of the refitting procedure is the direct reverse of the removal procedure, noting the following points:
a) Ensure that alf sections of the wiring harness follow their original routing; use new cable-ties to secure the harness In position, keeping it away from sources
of
heat and abrasion. b) On vehicles with manual transmission check and if necessary adjust the gearchenge cable and rod with reference to Chapter 7A. c) On vehicles with automatic transmission use new ro//p/ns fo secure the driveshafts to the transmission output stubs. Also check and if necessary adjust the kickdown end selector cables with reference to Chapter 78. d) Ensure that afi hoses are correctly routed and are secured with the correct hose clips, where applicable. If the hose clips cannot be used again; proprietary worm drive clips should be fitted
In
their place. e) Refill the cooling system as described in Chapter 1A or 18. f) Refill the engine with appropriate grades and quantities of oil (Chapter
1A
or 1B). g) Refit and adjust the auxiliary drivebelt(s) wfth reference fo Chapter 1A or 1B. h) Check and If necessary adjust the accelerator cable with reference to Chapter
AA,
48 or
AC.
i) When the engine is started for the first time, check for
air,
coolant, lubricant and fuel leaks from manifolds, hoses etc. If
the
engine has been overhauled, read
the
notes In Section 13 before attempting to starlit.
5 Engine overhaul • dismantling sequence
1 It is much easier to dismantle and work on the engine if it is mounted on a portable engine stand. These stands can often be hired from a tool hire shop. Before the engine is mounted on a stand, the flywheel should be removed, so that the stand bolts can be tightened Into the end of the cylinder block/crankcase. 2 If a stand Is not available, it Is possible to dismantle the engine with it blocked up on a sturdy workbench, or on the floor, Be very careful not to tip or drop the engine when working without a stand. 3 If you intend to obtain a reconditioned engine, all anclllarles must be removed first, to be transferred to the replacement engine (just as they will If you are doing a complete engine overhaul yourself). These components Include the following:
Petroi engines a) Power steering pump if removed with the engine (Chapter
10).
b) Alternator fmcluding mounting brackets) and starter motor (Chapter
SA).
c) The Ignition system and HT components including ail sensors, HT leads and
spark
plugs (Chapters 1A and
SB).
d) The fuel injection system components (Chapters A A and
AB).
e) All electrical switches, actuators and sensors, and the engine wiring harness (Chapters 4A, AB, SB). f) Inlet and exhaust manifolds (Chapters 4A, AB end
AD).
g) Engine oil dipstick and tube. h) Engine mountings (Chapter
2A).
i) Flywheef/driveptate (Chapter
2A).
j) Clutch components (Chapter
6)
- manual transmission. k) Electro-magnetic clutch components (Chapter 7B) - automatic transmission. I) Cooling system components (Chapter
3).

Diesei engines a) Power steering pump //removed with the engine (Chapter
10).
b) Alternator (Including mounting brackets) and starter motor (Chapter 5A). c) The glow plugfpre-heatlng system components (Chapter
SC).
d) Ait fuel system components, including the fuel injection pump, all sensors and actuators (Chapter
AC).
e) The vacuum pump. f) Ail electrical switches, actuators and sensors, and the engine wiring harness (Chapter 4C and 5C). g) Inlet and exhaust manifolds and, where applicable, the turbocharger (Chapter
AC
and 4D). h) The engine oil level dipstick and its tube. i) Engine mountings (Chapter
2C).

2D*10 Engine removal and overhaul procedures
6.5s Prising out the feed stub of the camshaft lubricating pipe J) Flywheel (Chapter 2C). k) Clutch components (Chapter
6).
I) Cooling system components (Chapter
3).
Note: When removing trie external components from the engine, pay close attention to details that may be helpful or important during refitting. Note the fitted position of gaskets, seals, spacers, pins, washers, bolts, and other small components. 4 If you are obtaining a short engine (the engine cylinder block/crankcase, crankshaft, pistons and connecting rods, all fully assembled), then the cylinder head, sump, oil pump, timing belt (together with its tensloner and covers), coolant pump, thermostat housing, coolant outlet elbows, oil filter housing and where applicable oil cooler will also have to be removed. 5 If you are planning a full overhaul, the engine can be dismantled in the order given below: $) Ftywhaoi/drivoplate.
6.5d When removing the camshaft bearing caps, note the position of the (ong and short locating dowels
bearing/banjo union bolt b) Timing belt, sprockets, and tensioner. c) Inlet and exhaust manifolds. d) Cylinder head. e) Sump. f) Oil pump. g) Pistons and crankshaft.
6 Cylinder head - % dismantling, cleaning, inspection and reassembly ^
Note: Now and reconditioned cylinder heads are available from the manufacturer or engine overhaul specialists. Be aware that some specialist tools are required for the dismantling and inspection procedures, and new com-ponents may not be readily available. It may therefore be mors practical and economical for the home mechanic to purchase a reconditioned head, rather than dismantle, inspect and recondition the original head.
Dismantling Note: On 8-valve petrol engines and diesel engines, the camshaft and cam followers are /oca fed In the cylinder head assembly and the relevant dismantling and reassembly procedures are contained in this Section. On 1$-valve petrol engines, the camshafts and cam followers are /oca fed In a separate housing (cylinder head extension) which is bo/fed fo the top of the cylinder head. All procedures relating to the camshafts and cam followers on 16-valve engines are therefore contained in Chapter 2B. Proceed fo paragraph 15 for cylinder head dismantling
6.8a Unscrew and remove the bolts from the thermostat housing, noting the location of the bracket
6.5c Removing the camshaft lubricating pipe procedures on /6-vafve engines, and ignore any references to camshafts, cam followers and oil seals in the paragraphs that follow. 1 Remove the cylinder head as described in Part A. B or C of this Chapter (as applicable). 2 If not already done, remove the inlet and exhaust manifolds with reference to the relevant Part of Chapter 4. Also remove the spark plugs, glow plugs and injectors as applicable. 3 Remove the camshaft sprocket with reference to Chapter 2A or 2C. Petrol engines 4 Mark the positions of the camshaft bearing caps, numbering them from the timing end. 5 Unbolt and remove the lubrication pipe (prise the oil feed stub out with a screwdriver). Unscrew the remaining bolts and take off the bearing caps (see illustrations). 6 Lift the camshaft carefully from the cylinder head, checking lhat the valve clearance shims and cam followers are not withdrawn by the adhesion of the oil (see Illustration). 7 Remove the shims and cam followers, but keep them In their originally fitted order. Diesel engines 8 Unbolt the thermostat housing and gasket, and vacuum pump from the left-hand end of the cylinder head. Also if necessary unbolt the coolant cover and gasket from the right-hand end of the head. Note the location of brackets (see illustrations) 9 Using a soft metal drift, carefully lap out the left-hand side mount and recover the gasket (soe illustrations). 10 At tho timing bait end of the cylinder head.
6.8b Removing the thermostat housing ... 6.6 Removing the camshaft