Putting the Engine Back and Gearbox back in

[Simon_P]

Time to put the engine and gearbox back in - The question is which order ? Gearbox /Block /Head?

It came out in more or less one piece but I can't help thinking there is an easier way!

[dapinky]

Simon,

I have only ever removed/replaced it as a complete assembly.

If you decide to do it in bits, then I *think* the engine needs to go in before the gearbox, as I'm not sure that there is enough space to fit the block to the gearbox spline without the chassis getting in the way (laterally) - but you can remove the gearbox to change the clutch, so there is enough room to fit that with the engine in.

Obviously, apart from the weight/bulk issue, the engine lifting hooks are needed to attach to the crane, so with the head off it may be awkward????

I've done it with the inlet manifolds fitted and removed, and find it easy enough with it all together - apart from making sure the knock sensor wiring is plugged in before finally lowering it into place (awkward to get at when it's in situ - i got the scrapes and grazes to prove it).

To give maximum room for manoeverability, keep the exhaust manifold/turbo assembly off until it's all in (but ensure that the studs aint in the head or you wont get it on before the clamshell gets in the way - they are easy to fit once the manifold is roughly in the right place.

[Simon_P]

Thanks Dave,

I recall the rear engine mounting leg being of unknown parentage - pretty certain I took the plenum off because of that, and things like the the air filter bracket got in the way and took an age to remove (3 screws) - I just remember thinking "it must be easier than this"

[Simon_P]

A quick suspension rebuild has slowed things down a bit.

The manual says that it is easier to do with the topshell removed - So far I have ignored that bit, but with the suspension off, oil cooler out, new radiator required, A/C maintenance etc it may be easier to remove it.

question is..

To give maximum room for manoeverability, keep the exhaust manifold/turbo assembly off until it's all in (but ensure that the studs aint in the head or you wont get it on before the clamshell gets in the way - they are easy to fit once the manifold is roughly in the right place.
Putting the Engine Back and Gearbox back in

If I remove the topshell can I put the engine in with Exhaust, turbo, pipework etc already attached to the engine?

does removing the topshell have any other advantages?

[dapinky]

Simon,

It is the clamshell which makes my post above relevant - if it is removed, then the whole assembly will drop in complete without risk of damage (unless you're really clumsy/unlucky, anyway!).

Also, as you have A/C, I don't know if those bits get in the way at all - I don't have that level of luxury in my poverty-spec car.

If you are considering removal of clamshell, then it can only make the engine replacement easier, and the time taken to remove and replace will be easily saved with the ease of access to the other bits and pieces.

[Simon_P]

Just when I thought I could start putting bits back on!

Project creep from engine rebuild to front end rebuild.

A/C was retro-fitted by me so taking the topshell and bumper off will allow me to tidy a couple of issues... and replace the vac hoses and the foam on the fresh air duct and, and , and,

[cliff]

Hi Simon,

i would fit the engine and gearbox together, it is also easier to fit the cambelt with the engine out of the car. I don´t know about the clam shell but removing the prongeron makes it much easier to fit the rear engine mount and connect the starter and alternator.

The AC compressor has to come off before engine removal, it is quite easy to fit it with the engine in place.

It is worth taking off and checking the upper engine mount, only held in with 3 bolts, mine was very corroded underneath.