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PostPosted: Mon 13 Jun 2005, 3:12 pm 
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Joined: Fri 03 Oct 2003, 7:28 pm
Posts: 929
Location: Victoria
Hi Guys

I just want to writte this FAQ so others can benefit from it.Tom i know you want to pull your engine out yourself and hopefully this will help you!

1.First remove the bonnet so its easier to take stuff off.Two 12 mm bolts on each side

http://img215.echo.cx/my.php?image=bonnetbolts1oa.jpg

2.Yake your fron bumber off and disconnect indicators 12 mm bolts

http://img153.echo.cx/my.php?image=bumberbolts25si.jpg

3.Take off your intercooler piping if you have any,Tom you ll have to do this


4.Take out your radiator off two 14 mm bolts on each side,also make sure you disconnect that fan plug

http://img153.echo.cx/my.php?image=radiatorbolt3bf.jpg

Than take off the water hoses upper one going to a thermostart housing and the one at the bottom going to the pipe that connected to your water pump.

http://img147.echo.cx/my.php?image=waterhose3pk.jpg

5.Next thing i would to is take out your battery and disconnect + and - terminals.

While you are there take out the airbox,airbox turbo rubber pipe and disconnect plug from the back and the vacume line.

In your case Tom you just have to take off your Pod wich is connected to your turbo.

Rubber pipe

http://img153.echo.cx/my.php?image=airb ... ipe0br.jpg

Plug at the back

http://img147.echo.cx/my.php?image=airb ... ion0df.jpg


6. Take off your fuel lines. two 8 mm bolts on one side of the throtlle body

http://img147.echo.cx/my.php?image=fuellines2de.jpg


While you are there take of the plugs that are connected to injectors and the ones next to your tps and isc

http://img247.echo.cx/my.php?image=unplugtit5pj.jpg

http://img247.echo.cx/my.php?image=unplugit24es.jpg

Take off the injector clips, just push them up with a screwdriver and unplug them from injectors.

http://img247.echo.cx/my.php?image=injectorclips7oj.jpg

Also on the inlet manifold take off the temp sensor, and this vacume line which goes to your brake system.

http://img147.echo.cx/my.php?image=vacumeline8lx.jpg

8.If you are not sure where everything goes back i would suggest that you mark it or writte it down, it will help

Next take of these two water lines that are connect to your manifold and to that water pipe which goes along your block to your water pump

These two

http://img270.echo.cx/my.php?image=waterlines9iq.jpg

Underneath these you ll also have to take off two wires which are connected to the back of your manifold 12 mm

http://img270.echo.cx/my.php?image=conn ... old0xh.jpg

9.Accelerator cable , one 14 mm spanner would take it off but you also have to take out that ball out of there too, simple

http://img270.echo.cx/my.php?image=acce ... ble0du.jpg

http://img11.echo.cx/my.php?image=balla ... ble7vk.jpg

On your Vr4 engine just make sure you take off connections to your computer and mark where everything goes.It's all the same just a different setup.

10.Now its time to take off your dump pipe.You have two options you can take it off the turbo or underneath where its connected to the rest of your exhaust.At the top you ll have 3 bolts 17 mm.Underneath you ll have two and they could be 14 mm or 17 mm

http://img11.echo.cx/my.php?image=dumppipebolts4wn.jpg

http://img11.echo.cx/my.php?image=dumpp ... der1fg.jpg

11.Take off connections of your alternator.It will stay one when engine is pulled out so you don't have to touch it

http://img207.echo.cx/my.php?image=alte ... ons4ne.jpg

Also connections to your coil must be taken off .

http://img207.echo.cx/my.php?image=coil ... ons6ud.jpg


12.I would not disconnect vacume lines at the back off the manifold i would disconnect it at this vacume plug ,its underneath the airbox

http://img207.echo.cx/my.php?image=vacu ... ect9se.jpg


13 .At this point most things should be disconnected but its always good to check everything twice.Next thing you should do is take out your driveshafts and clutch/gearbox connections underneath the car and inside the enginebay

Therefor this is from section on how to remove a gearbox.Just remember once you pull your driveshafts out you must put back your hub/disk back to your shocker so you can put wheels back once the engine comes out.

14.Jack your car up and put all safety things underneath

15 Take your wheels off

16 Take your brake calipers off.Two bolts are holding it 17 mm, once you take them off i usually tie them to a shocker so i have more room

http://img224.echo.cx/my.php?image=shoc ... lts0pb.jpg

17Than take 2 boltsoff that are holding brake disc and shocker together 17 mm again.With these two bolts you must hold another side of the bolt with 17 mm too / opposite direction

http://img224.echo.cx/my.php?image=oppo ... ion7ve.jpg

18.
Than, you must take off the bearing/at the end of your driveshafts
which is located right in the midlle of the brake disc

with this bolt you must take off that wire thingy first ,the one which is there as a safety thing so if it get loose it doesn't come off

This bolt is 24 mm and you won't be able to just turn it anti-
clockwise to take it off.You must use a some pole to lock your all disc from moving around when turning

If you can't do it by hand than step on it it works every time

So once that bolt is off behind it there is one bearing take it off too

Or you can do this if there is somone to help you lock the brakes!

" take out pin, undo 24mm centre bolt while having someone push on the brake pedal to stop the disc and driveshaft spinning.

then take off brake calipers and tie them too the spring or strut.

.then take out the 2 17mm bolts holding the hub assembly to the strut.

hope you dont mind, just learnt from experience that 24mm bolt is a pain to get loose if i couldnt keep the disc and driveshaft from turning"

http://img231.echo.cx/my.php?image=bear ... pin0lz.jpg

19.

The next thing
i do is i take of the safety wire thingy off the tierod ends and unsrew the bolt off them which 14 mm , but i don't take off the tierod of the disc

Its just to make your disc move abit more,easier

remember all this you have to do on both sides

http://img231.echo.cx/my.php?image=tierodpin9kj.jpg

20.

Drain your gearbox oil out.When you underneath your car its the bolt in the midlle section of the gearbox 24 mm

21
.Now your whole disc/hub is loose and off the shocker so pull it to yourself and push out your driveshaft end out of it

Once its free gently keep turning your drive shaft and with quick pull try to pop it out of the gearbox

Pull both drive shafts out

22.
Take off your airfilter box, battery all the stuff that will get you easier to gearbox bolts/you can do this before everything

23.
Than take off your clutch cable at the clutch cylinder.Bolt size 17 mm i think , don't loose 2 washers put them back

http://img231.echo.cx/my.php?image=clut ... olt3kh.jpg

24.

Take off your Clutch slave cylinder bolt that connects it to the clutch cable, bolt size 14 or 17 mm i think

http://img231.echo.cx/my.php?image=slav ... olt5lp.jpg

25.

.take off your 5th gear actuator two 12 mm bolts

http://img142.echo.cx/my.php?image=5thgearbolts5xx.jpg

26.

Unscrew speedo cable from the back of the gearbox

http://img142.echo.cx/my.php?image=speedocable6ec.jpg

27.

Than, take of the metal plate thats holding the side engine mount to the gearbox .This metal plate is underneath the engine mount two 14 mm bolts

Take it off


28.

Go underneath your car and disconnect gear shifters from the gearbox.Two bolts one i s 14 mm and the other one 12 mm i think.Take it off/see the pic.Each bolt holds one shifter, and with the smaller one that has that wire around it, you must pull out the shifter out of that rubber insulator.

http://img190.echo.cx/my.php?image=gear ... ors5fr.jpg

29.

Some Cordias will have a metal holder between the rear engine mount and your gearbox.My car cordia doesn't have this because someone took it off so if your has has this you must take it off. Its that black thing next to your speedo cable.

http://img190.echo.cx/my.php?image=gear ... tion1w.jpg


At this point
everything in your engine bay should be disconnected and your driveshafts pulled out.Now, the only thing holding engine in are 4 engine mounts.Front rear and two on the side.

All 4 have 17 mm bolts holding them. I usually first take of the one that's holding the gearbox but if you did everything i said this one is already out.Next one i take off is the on the side and the one at the front and rear i leave there until i secure engine.

rear engine mount

http://img266.echo.cx/my.php?image=rear ... unt0du.jpg

Side engine mount , two pics from both sides

http://img266.echo.cx/my.php?image=side ... unt5eh.jpg

http://img266.echo.cx/my.php?image=side ... olt0ir.jpg

30.To pull your engine out i usually have a chain across the engine from one of the bolts holding the gearbox to the one next to the side engine mount ,and a pulley above.It should come out with no probs If your engine mounts are stuck use your hammer and if still they don't come out pull your engine up a bit this would help

Bolt at the engine mount that i use to connect the chain to

http://img270.echo.cx/my.php?image=bolttopullout3tc.jpg

I know its long but i hope it helps somebody.Tom hopefully this will give you a good start and if you have any questions just ask bro

Cheers guys




:D

Additions:
AB wrote:
The only recommendation I have is to undo your dump pipe bolts when they are still hot and expanded, they will come off a lot easier then when they are cold and tightend up. Just be careful not to burn yourself!


CORDI4 wrote:
the only thing i would change is to disconnect the battery first. it never hurts and it guarantees that nothing can short out.



Have you got something you would like to add to this FAQ? PM a moderator to have it included.


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