R500 k-series engine removal.
Discussion
Just after Christmas I have my engine booked in for a refresh, I know it's early but I will probably need the next 5 months to remove the engine,( not being very machanicly minded) that is of cause unless somebody on this forum has a removal procedure typed up that they could post, any donations of expertise would be greatfully received. Many thanks.
(as i posted on Tour7 a while ago)
The taking it all apart is far more worrying mostly than the putting it back together if I've got my list right.....
The list I've sat and worked up is:
1) Disconnect / remove battery and top earthing wire
2) Remove silencer, disconnect exhaust manifold
3) Disconnect accelerator and clutch cables
4) Disconnect starter feeds
5) Disconnect Apollo reservoir
6) Disconnect ECU
7) Disconnect O2 sensor, unplug
8) Unplug injector loom connector
9) Disconnect Oil Pressure sender wire
10) Disconnect speedo sender cable
11) Remove circlips, disconnect Drive shaft @ transmission end
12) Disconnect Water Temp sender on water rail
13) Disconnect earthing wire below throttle bodies
14) Disconnect radiator, drain from front of engine
15) Disconnect heater hoses, drain
16) Disconnect PCV lead
17) Drain radiator expansion tank and disconnect hoses
18) Disconnect metal pipe to bottom of expansion tank (that goes to hose @ top of radiator)
19) unclip loom cable ties anywhere attached to frame
?? 20) disconnect steering knuckle @ steering box in front
?? 21) disconnect steering shaft @ pedal box, remove shaft
22) Attach crane to engine to support weight
23) Disconnect engine & transmission mounts
24) hoist (via "dipping maneuver") engine / transmission out of car, put onto stand
Once I've got the combined engine and transmission out of the car and on the bench the rest is pretty straightforward
1) remove bell housing
2) remove clutch cover
3) remove clutch centre plate, throwout bearing
4) replace 1-3
Voila, put it all in reverse order and put it back together.... ;-)
The taking it all apart is far more worrying mostly than the putting it back together if I've got my list right.....
The list I've sat and worked up is:
1) Disconnect / remove battery and top earthing wire
2) Remove silencer, disconnect exhaust manifold
3) Disconnect accelerator and clutch cables
4) Disconnect starter feeds
5) Disconnect Apollo reservoir
6) Disconnect ECU
7) Disconnect O2 sensor, unplug
8) Unplug injector loom connector
9) Disconnect Oil Pressure sender wire
10) Disconnect speedo sender cable
11) Remove circlips, disconnect Drive shaft @ transmission end
12) Disconnect Water Temp sender on water rail
13) Disconnect earthing wire below throttle bodies
14) Disconnect radiator, drain from front of engine
15) Disconnect heater hoses, drain
16) Disconnect PCV lead
17) Drain radiator expansion tank and disconnect hoses
18) Disconnect metal pipe to bottom of expansion tank (that goes to hose @ top of radiator)
19) unclip loom cable ties anywhere attached to frame
?? 20) disconnect steering knuckle @ steering box in front
?? 21) disconnect steering shaft @ pedal box, remove shaft
22) Attach crane to engine to support weight
23) Disconnect engine & transmission mounts
24) hoist (via "dipping maneuver") engine / transmission out of car, put onto stand
Once I've got the combined engine and transmission out of the car and on the bench the rest is pretty straightforward
1) remove bell housing
2) remove clutch cover
3) remove clutch centre plate, throwout bearing
4) replace 1-3
Voila, put it all in reverse order and put it back together.... ;-)
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