Engine / Gearbox Removal

[ATinOf]

Now its really important you dont forget this bit on reassembly, or she wont start.
Disconnect the earth cable for the engine under the o/s chassis stub


That's installment 1, I will try and find some time this evening to continue this.

[ATinOf]

Disconnect the o/s charge pressure sender


And unscrew the Air charge tube from the air filter box


Unclip the hard to get to hose beneath the tube


I unclipped the oil breather hose from the oil tank to aid access, as you will see next up whilst this improved the access the pipe was so brittle it snapped as soon as I tried to move it out the way


Remove the charge tube from the throttle body and remove, unscrew the air box lid, remove the air filter; remove the side screw securing the air box (not shown) [oh and I forgot to mention the vac pipe behind the air box to remove]


With some elbow grease pull the air box free of its lower grommets and you can access the vacuum pipe and remove it from the recirc valve


And lift the air box off; Top tip - put something in that exposed turbo hose, you dont want anything falling down there! I find 10p shopping bags ideal but a smelly old sock works just as well.

[ATinOf]

The above process is much the same for the n/s air box and charge tube; ;


with the added complication there are 2 hard to reach hoses under the charge tube to disconnect



and also 2 hoses to disconnect at the back of the air box;


Plus this side you have the secondary air pump supply take-off to disconnect






Dont forget to plug that turbo hose, even if you are about to take it off, play safe

[ATinOf]

Dont under-estimate the storage space you will need for all this gear your removing


We are making progress

[ATinOf]

Now you will need to take off those top turbo hoses you stuffed up, they will foul on the chassis stubs when the engine comes out the front (because we need to drop the engine a bit to do that)



But again stuff up the turbos

[ATinOf]

Now we've just got a few more hoses before we turn our attention to electrics

We need to unclip the secondary air outlet from the pump, conveniently marked 'P'


Its not very easy to reach in there!


I tied this back out the way

[ATinOf]

Again to protect the A/C pipes from damage I disconnected these from the outlets near the A/C pump

[ATinOf]

Remove the trim seal and trim from the bulkhead


And unclip the V10, RS6 covers off the inlet manifold

[ATinOf]

Remove the seal cover and seal over the battery charger connection cables where they pass over the bulkhead



Disconnect the brake servo vac hose under the fuel pipe


Expose the fuel pipe and pop the quick disconnect; be prepared for a little fuel spillage,


Now disconnect the vac hose from the activated carbon filter solenoid


Remove the cover and disconnect the battery charge terminals to split the wiring - Its pretty important you have disconnected the battery before doing this if you haven't already!!

[ATinOf]

Take a note of every securing tie you cut off and ensure you refit them on reassembly; I'm not showing every instance here (I doubt I have every original one fitted on the gal given what Ive noted to date)

[ATinOf]

Nows time to remove the coolant filler; disconnect the small hose at the side


And the one on the outlet at the bottom;


Unclip the breather hose to get to the bulkhead nut


And remove

[ATinOf]

Unclip the small breather hose at the back of the oil tank


If you are conscientious like me and your cars out in the weather, the garage being delegated to engine and gearbox rework space, bag the tank outlet


This breather hose comes integrated with a coolant pipe (heatshrink sleeved together), disconnect the other hose (coolant);

[ATinOf]

To remove the cabling routed by the oil tank as its part of the engine loom; disconnect the oil level sender at the front of the oil tank


And the (coolant level switch I think) connector under the o/s wing


I also noted a clip fell off for the bonnet catch cable; noted for later


Now this bit of cabling can be pulled back ready

[ATinOf]

Now disconnect the activated carbon filter solenoid connector


The solenoid is on a rubber mount and can be unclipped to expose the bolts for the top bulkhead cross member n/s


Undo the 2 nuts holding the fuel hose support bracket to remove the bracket from the bulkhead cross member


There's also a lone nut on a bracket adjacent


Unclip the 2 connector pairs clipped to this bulkhead member


And remove the cross member exposing the engine loom pass throughs

[ATinOf]

Next up its time to start on the disconnection of the engine loom, hold that thought for a mo,I'll be back with the third installment