Since some connections are also required to be removed under the vehicle, the vehicle must be lifted and placed on secure stands. Before assembly work in the engine compartment, the front fenders must be covered.
Electric wires, as well as vacuum and water hoses, can be laid in different ways in the engine compartment, depending on the year of manufacture and the composition of the equipment. Since it is not possible to provide a detailed description of each of the routing options, it is recommended that wires and hoses be marked when they are disconnected.
Attention: The description of the removal of the M20 engine is given. Special instructions for M30 engines (with a working volume of 3.0 and 3.5 l) and M21 diesel engines are given at the end of the section.
Withdrawal
Remove the engine compartment hood.
Disconnect the wires from the battery.
Raise the car.
Remove the pan under the power unit.
Remove gearbox.
Vehicles with power steering: Remove the V-belt, unscrew the power steering pump and lay it aside with the hoses connected.
Caution: If the hydraulic system opens, it will need to be vented after installation.
Vehicles equipped with air conditioning: Unscrew the air conditioning compressor and lay it aside with the hoses connected.
Attention: Do not open the air conditioning circuit under any circumstances, as the release of freon can cause frostbite.
Drain coolant.
Disconnect the oil pressure switch connector. The figure shows the oil pressure switch on the M20 engine (under the right engine beam, on other models it is located on the cylinder head or on the oil filter housing).
Lower the car.
Remove air filter.
Attention: If the water hoses are fastened with clamping clamps, cut the clamps with side cutters and install screw clamps during installation.
Disconnect the throttle cable 1 from the throttle lever. To do this, open the throttle valve, disconnect the nipple 3 with a narrow screwdriver. Compress the tabs 3 of the clip and pull it out of the throttle lever. Pull the throttle cable down from the slot in the throttle lever.
If equipped, disconnect the automatic transmission cable.
Unscrew bracket -arrows-.
Loosen clamp 1, detach air hose from retainer -arrow- on air filter housing and pull out.
Cut off the loops of the water hose 2 on the air filter housing.
Disconnect connector 3.
Loosen clamp 1 and remove hose.
Pull out the air cleaner filter by loosening nuts 2.
Detach water hose 1 after releasing and pulling back the clamp.
Detach fuel hoses 2/3, having previously marked them with adhesive tape so as not to confuse the hoses when installing them: release the hose clamps.
Disconnect connector 1 for idle speed control.
Release the electrical cable from the holder 2.
Disconnect vacuum hose 3 from brake booster.
Mark with adhesive tape and remove heater hoses 1/2.
Disconnect vacuum hose 3.
Unscrew and remove the water tube.
Disconnect the ignition wires from the ignition coil.
If equipped, unscrew the hoses from the oil cooler and close them with plugs.
Lever out the cable duct under the distributor with a screwdriver and lead the wires to the left side of the engine.
Disconnect wires from starter.
Unscrew the cover from the back of the generator and disconnect the wires.
Disconnect the connector behind the generator.
Disconnect the TDC sensor connector in the cable harness under the intake pipe.
If equipped, disconnect the cylinder identifier connector.
Disconnect all plug connections in the cable harness under the intake pipe. If equipped, disconnect the vacuum hose.
Unbolt wiring harness under intake manifold on left -arrow- and right, remove wiring harness from intake manifold and lay aside.
Unscrew the earth jumper.
Unbolt engine mounts at top left and bottom right.
Hook up the engine with a rope. To do this, attach a rope or chain to the lifting eyes -arrow- of the engine. Raise the engine slightly with a crane.
Check that all hoses and wires connecting the engine to the body. disconnected, and then pull out the motor.
Attention: To avoid damage to the bodywork, drive the engine carefully.
Installation
Check engine mounts, water, oil and fuel hoses for ruptures and cracks and replace if necessary.
Check the ease of rotation of the crankshaft bearing and clutch release bearing and the ease of movement of the clutch release fork.
Check the thickness and condition of the clutch disc friction lining.
Carefully guide the engine into the engine compartment. To avoid damage to the drive shaft, clutch and body, use the engine very carefully when lowering.
Insert the guide pin into the hole in the axle beam and screw, without tightening, the nuts of the engine mounts.
Raise the car.
Install gearbox.
Lower the car.
Pulling on the engine, align it. Then tighten the engine mounts to 45 Nm.
Install and tighten the engine wiring harness.
Reconnect all removed connectors and hoses. Secure hoses with clamps.
Screw the electrical wires to the generator.
Screw on the generator cover.
Fasten the cable duct under the distributor.
Screw on the water pipe.
Check the air filter element, knock it out or replace if necessary. Install the air filter.
Connect the throttle cable and, if present, the automatic transmission cable, screw on the bracket.
Install the radiator.
Install fan.
If removed, install A/C compressor.
Screw on the power steering pump.
Install the pallet under the power unit.
Connect all electrical wires, vacuum, water and fuel hoses in accordance with the marking made during removal. Secure hoses with clamps. Secure the wires with cable ties.
Check the oil level in the engine and gearbox and top up if necessary.
Check the frost protection properties of the coolant and, if necessary, add a concentrate.
Connect the wires to the battery.
Start the engine and warm up to operating temperature, check the coolant level and the tightness of all hose connections.
Check valve clearances.
Install the engine compartment hood.
M30 engine
Withdrawal
Remove the pan under the power unit.
Remove the expansion tank of the cooling system.
Disconnect the gearbox oil pipes from the oil sump by unscrewing the coupling nuts.
Pull the idle air regulator out of the intake port. First disconnect the connector and unscrew the coupling nut.
Disconnect the air mass meter connector.
Loosen the air intake hose clamps. Remove the 3 mounting brackets from the back of the air mass meter. Pull out the air hose with the air mass meter, while disconnecting the crankcase ventilation hose.
Disconnect the oil level limit switch connector near the back of the generator.
Disconnect the connector from the fuel tank vent valve.
Disconnect the hose from the activated charcoal filter.
Disconnect the water hose from the back of the generator, after releasing the clamp.
Disconnect the temperature sensor connectors on the cable harness side from the throttle switch and from the oil pressure switch.
Unscrew the cable block, having previously removed the cover by prying it with a screwdriver.
Installation
Installation is carried out in the reverse order.
M21 engine
Withdrawal
Remove the expansion tank of the cooling system.
Remove the oil pipes, for which unscrew the bolt 1. Close the holes in the housing and in the hoses with plugs.
Unscrew 2 bolts securing 2 oil filter housing to the body.
Fasten the filter housing to the engine with wire.
Unscrew fuel hoses 1 and 2.
Unscrew nut 3 and remove cable.