Engine/transmission - removal and separation (903 cc engine)

Engine / Engine/transmission - removal and separation (903 cc engine)

1 Open the bonnet, disconnect the windscreen washer tube.

2 Mark the hinge positions on the underside of the bonnet using masking tape and then with the help of an assistant to support its weight unbolt the bonnet and remove it to a safe place.

3 Disconnect the battery negative lead.

4 Drain the cooling system and engine oil.

5 Disconnect the leads from the rear of the alternator, the starter motor and the oil pressure switch also the coolant temperature switch.

6 Disconnect the HT lead from the ignition coil and the LT lead from the distributor.

Disconnect the transmission earth strap.

7 Remove the air cleaner.

8 Disconnect the clutch cable from the release lever at the transmission.

9 Disconnect the speedometer drive cable by unscrewing the knurled nut from the transmission.

10 Disconnect the leads from the reversing lamp switch.

11 Disconnect the coolant hoses from the cylinder head and coolant pump.

12 Disconnect the fuel inlet hose from the fuel pump. Plug the hose.

13 Disconnect the throttle and choke controls from the carburettor.

14 Disconnect the heater hoses from the engine.

15 Disconnect the fuel return hose from the carburettor.

16 Disconnect the exhaust downpipe from the manifold.

17 Raise the front end of the car and support it securely on axle stands. Remove the roadwheels.

18 Unscrew the driveshaft to hub nuts. These are very tight and a long knuckle bar will be required when unscrewing them. Have an assistant apply the brakes hard to prevent the hub turning.

19 Working under the car, remove the protective shields and disconnect the exhaust system mountings and withdraw it to the rear.

20 Disconnect the forward ends of the gearchange rods by prising their sockets from the ballstuds.

21 Unscrew the nuts on the steering tie-rod end balljoints and using a suitable “splitter” tool separate the balljoints from the steering arms. Unbolt the brake calipers and tie them up out of the way.

22 Unscrew and remove the bolts which secure the hub carriers to the U-clamps at the base of the suspension struts (photo).

13.22 Hub carrier strut clamp

23 Pull the tops of the hub carriers from the clamps and release the driveshafts from the hub carriers.

24 Tie the driveshafts in a horizontal plane with lengths of wire.

25 Support the engine on a hoist or use a trolley jack under the engine/transmission and remove the bottom mounting and then the upper left and right-hand ones (photo).

13.25 Right-hand engine mounting

26 Carefully lower the power unit to the floor and withdraw it from under the car.

27 External dirt and grease should now be removed using paraffin and a stiff brush or a water-soluble solvent.

28 Unbolt and remove the engine mounting brackets and the starter motor.

29 Unbolt and remove the cover plate and gearchange ball stud strut from the lower front face of the flywheel housing.

30 With the engine resting squarely on its sump pan unscrew the flywheel housing connecting bolts noting the location of any lifting lugs and hose and wiring brackets.

31 Support the weight of the transmission and withdraw it in a straight line from the engine.

Fig. 1.9 Coolant temperature switch (Sec 13)

Fig. 1.10 Clutch cable disconnected (Sec 13)

C Reversing switch cables

Fig. 1.11 Speedometer drive cable at transmission (Sec 13)

Fig. 1.12 Coolant hoses at thermostat housing (Sec 13)

Fig. 1.13 Coolant hose at rear of coolant pump (Sec 13)

Fig. 1.14 Fuel inlet hose disconnected from pump (Sec 13)

Fig. 1.15 Fuel return hose disconnected from carburettor (Sec 13)

Fig. 1.16 Gearchange rods disconnected (Sec 13)

Fig. 1.17 Tie-rod end balljoint disconnected (Sec 13)

Fig. 1.18 Hub carrier detached from strut clamp (Sec 13)

Fig. 1.19 Left-hand flexible mounting (Sec 13)

Fig. 1.20 Flywheel housing cover plate removed (Sec 13)