Punto (Mk2/2b) Punto JTD engine removal and refitting

THE FOLLOWING ASSUMES YOUR DONOR ENGINE HAS BEEN SUPPLIED WITHOUT STARTER MOTOR, ALTERNATOR AND STILL INCLUDES THE INJECTION SYSTEM, INLET / EXHAUST MANIFOLD / DIESEL PUMP ETC AS MOST 2ND HAND ENGINES ARE SUPPLIED THIS WAY.


BEFORE PERFORMING THE FOLLOWING TAKE SEVERAL PHOTOS ALL AROUND THE ENGINE / GEARBOX TO ASSIST IN PUTTING THE PARTS ON THE NEW ENGINE.

1. Pull each of the 4 plugs from the injectors before unclipping and feeding the wiring down the space between the engine and throttle body.

2. Uclip the wiring for the MAF sensor plug and the adjacent plug which connects the small box where the turbo vacuum pipes go.

3. remove the red live cables and associated smaller wire from both the starter and alternator.

4. Pull the remaining plugs from the sensor on the inlet manifold / fuel rail sensor / sensor to the rear of the mechanical fuel pump / crankshaft position sensor / cam position sensor.

5. Remove the separate loom from the glow plugs which are right at the bottom rear of the inlet manifold.

6. Remove the loom from the engine by removing the 2 x 10mm nuts on the plastic housing under the fuel pump on the rear of the engine. Keep the housing with the loom as it helps keep the shape of the wiring to assist transferring onto the new engine.

7. the ECU seems only to prefer its own fuel pump sensor and fuel rail pressure sensor so remove these and transfer to the new engine. All other sensors / injectors / fuel pump etc will work anywhere so you can run the ones which came with the donor engine without issue. The fuel pump sensor is a cylindrical object secured by 2 x torx screws. The fuel rail pressure sensor is secured by a large nut . It is initially tight but will loosen easily after that.

8. Remove the alternator by cracking the bottom bolt then loosening the top bolt. Push the alternator towards the engine and remove the auxiliary drive belt before removing the alternator.
NOTE:- If your car has air con, the alternator is in a fixed position. Instead, belt tension is taken up by a tensioner pulley which is secured by 13mm bolt. Slacken this off and withdraw the belt before removing the alternator.

9. Remove the starter motor by removing the 3 x 13mm bolts from the gearbox.

10. remove the bolts securing the carrier shaft to the engine block ans slide the splined rod out of the inboard side of the gearbox. Plug the hole to prevent spillage of gearbox oil and the ingress of dirt.

11. Ensure the engine is hanging level and withdraw fully the engine to gearbox mounting bolts. The gearbox will now sit nicely on the thread on the back and the input shaft. Now slide the gearbox off the engine keeping it straight until the input shaft has fully cleared the clutch plate.

12. Unless your engine comes without exhaust manifold and turbo then you can now drop the old engine and prepare to attach the new one. Remember to recover all worthwhile parts as spares / sell etc.