| Engine Replacement, Part 2 -- Engine Disassembly, Top |
From "Weekend Mechanic"
episode WKM-205 |
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Top-Side Engine Disassembly With parts labeled, engine disassembly gets fully underway with the engine accessories on the top side of the engine. Later, work will begin on disassembly steps beneath the vehicle. As engine accessories are removed, carefully inspect each one to determine which ones might need to be replaced for installation on the new engine. Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts. Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools and when working beneath a vehicle. - Remove the distributor cover, and disconnect the distributor cap (figure A ).
- Unbolt and remove the cooling fan (figure B) to provide easier access to the engine, and to prevent the fan from getting damaged during the engine replacement.
- Disconnect the electrical harnesses, checking as you go to make sure they are in good shape and weather-tight.
- Unclamp and disconnect the fuel lines (figure C). There's likely to be fuel remaining in the lines, so be sure to capture the fuel and dispose of it properly. Inspect the lines for any cracks or damage.
Safety Alert: If you have a gas heater in your garage, turn it off before disconnecting fuel lines from the vehicle to minimize fire hazard. - Disconnect all wiring harnesses (figure D) and other small accessories that might impede removal of the engine.
- Disconnect the electrical ground-wire from the firewall.
- Disconnect the throttle linkage using needle-nose pliers. The cables are held on with small clips. Place the clips on a piece of tape to avoid losing them (figure E), and set them aside.
- Disconnect and remove the bracket that holds the cables onto the throttle body (figure F).
- Tip: Wherever possible, replace bolts as you go so you won't lose track of their proper locations. Where that's not feasible, place them in ziplock bags and label them accordingly with making tape and a marker.
- With the coolant drained from the vehicle, remove the upper radiator hose (figure G) and heater hoses. Make note of any hoses that are worn, and will need to be replaced on the new engine.
- Loosen the belt-adjuster pulley on the air-conditioning system, and remove the a/c compressor and line assembly from the engine and set it aside (figure H). You may want to use shop-rags to protect the painted areas of your car.
Important: If the lines need to be removed from the compressor for removal, make sure that the refrigerant has been removed and recovered properly from the a/c system. Releasing a/c refrigerant can be dangerous and harmful to the environment. - Next, remove the alternator bolts and belt, then tilt the alternator (figure I) so that you can access the wiring harness.
- Disconnect the battery supply-line to the alternator, and any other connections. Set the alternator aside with other re-usable parts.
- Remove the adjusting pulley for the a/c belt (figure J) if your car is equipped with one.
- You can now access the power-steering pump. As with the a/c unit, the power-steering pump can be left attached, but unbolted and lowered out of the way (figure K).
In the segment that follows, work continues the following morning with engine disassembly on parts beneath the vehicle.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
How Cars Work
Author: Tom Newton
ISBN: 0966862309
Publisher: Black Apple Press
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
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