Engine Removal and Disassembly



The removal of the engine should be pretty straight forward. Since the car is lifted on the jack stands, the engine will just barely clear through under the front slam bar.

Support the engine with an engine hoist (alternatively, have a friend hold the engine straight and support it from underneath with a hydraulic jack and block of wood).

Undo the gearbox lower mount from the gearbox and chassis. Then undo the engine side mount, and the gearbox side mount, and lower the engine to the ground. If you're doing this with the jack, lower one side at a time and check for clearance on both sides. Like I said, I don't recommend this method, a hoist will definitely save you time and trouble.

When lowering the engine, drop it onto something soft so it isn't damaged. I used an old tire.

Tilt the engine slightly, and have a friend help you pull it towards the front of the car. Your old engine and gearbox are finally out.

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Now, at this point, you'll have to collect a few parts from your old engine, depending on how you chose to do the swap. Here's a short list of the things you'll grab from your old engine:

For a block-only swap:

  • Remove the complete SMPI head off your engine (it's the same as the 1.2 SMPI).
  • There should be two dowel pins locating the head on the block. Save these.

Whether you have an additional head or not:

  • Remove the oil pressure switchm, elbow, and banjo bolt.
  • Remove the alternator, bolts and bracket.
  • Remove the engine mount.
  • Remove the starter motor (assuming you're re-using it).
  • Separate the old engine from the gearbox. Keep all parts with the gearbox.
  • Remove the coilpack bracket and coilpacks.
  • Remove the water pump collector pipe.

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If you're using a P75 head (again, won't reccommend this):

  • Remove the camshaft timing pulley from the Sei head.
  • Remove the cam cover and camshaft position sensor from the Sei head.

For a gearbox swap:

  • Remove the upper bracket (black part) where the gearbox bolts to the engine. You'll need this for the new one.
  • Remove the earthing cable (this is a true PITA to remove).
  • If you're swapping the C526 with a C514, renew your transmission gaiters and joints if needed. It's best done while they're out.