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Originally posted by carnoisseurcraig
here is a quick list of what and how to do it.

ok... it IS very easy but here you go:
to remove the current engine:
Disconnect and remove the battery
jack up front end, and put car on axel stands.
Remove wheels.
remove hub nuts (30mm deep reach socket required)
remove brake disks and calipers
remove hub carriers from the strut, track rod end and tie bars
remove drive shafts from gear box - you will need a bucket underneeth to catch the gear box oil.
remove exhaust mainfold.
loosen and free the gear linkage
disconnect PAS (and AC) pipes (again bucket required)
remove drivers side kick panel and disconnect ecu from loom and unplug engine loom from car loom.
in the engine bay - pull the engine loom through from the car
remove airbox and induction tubing
depressurise and disconnect fuel lines from fuel rail.
un plug the grey plug near the gear box (connects aux loom to car loom) - disconnect the car loom from the positive battery terminal
remove water pipes, rad and header tank
remove vacume hose from brake servo
- check there is nothing else connected the engine -
support the engine (and gear box) with engine hoist
remove the rear gear box mount and disconnect the gear linkage at the top of the gear box
remove the NS engine mount
finally remove the OS engine mount, the enging should now be "loose" in the engine bay
raise the engine out of the engine bay, looking out for any pipes / wires that may not have been disconnected.

prep -
clean the engine bay and make sure all pipes / wires are out of the way
transfer aux loom from old engine to new
remove exhaust mainfold from new engine if it has it fitted
fit new engine loom to engine, (preferably from a cav / cally)
transfer water pipes (heater matrix ones etc) to new engine
remove any engine mounts currently on the new engine
mate new gear box and new engine

Fitting -
lower the engine into the engine bay (gearbox end first - so it needs to be at an angle)
line up and bolt up gear box side mount
continue lowering untill the drivers side mount lines up - when it does, bolt this up.
bolt rear engine mount to gear box and bottom of car - you may need to jack up the back of the engine to do this
connect water pipes to heater matrix
plug grey plug into car loom
connect fuel lines
re instate exhaust mainfold
fit rad, header tank and other water pipes
fit pas pump and connect hoses
connect gear linkage to the top of the gear box
feed engine loom into car - connect to car loom (colour for colour) and plug in ecu
put 4mm drill bit into alignment hole
loosly connect gear linkage to car linkage
select nutral in the car
tighten gear linkage
remove drill bit
comfirm you can get gears
fit vacume hose for brake servo
connect car loom to battery terminal, along with +ve wire from new engine loom
make up exhaust system from mainfold back
fit drive shafts and hubs / hub carriers
fit and bleed brakes
fit wheels
lower onto ground
fit battery
fit induction pipes and air box
fill up water / oil / pas
shut bonnet
turn key
enjoy

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quote:

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Originally posted by Gsi_Ire
what happened to having to grind drive shafts and the like? (or so i was told?)

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quote:

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Originally posted by Siberia

quote:

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Originally posted by Gsi_Ire
what happened to having to grind drive shafts and the like? (or so i was told?)

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who told you?

[Edited on 16-03-2005 by Siberia]

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quote:

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Originally posted by carnoisseurcraig
without a doubt put it thru the bottom... far easier. easiest method for shafts is use the corsa shafts with cavvy mk 2 inner cv joints.. will cost ya 60-70 quid from a factors. buy a mount from a guy on migweb called andy16vturbo. that will cost ya 30 sheets, buy an ecotec pipe for vauxhall, 12 sheets, an adapter for the throttle housing, 25 sheets from the migweb guy, ditch ur anti roll bar so ur manifold clears it and ur away.. thats all the parts u need apart from the engine and box.

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quote:

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Originally posted by broster
ditch ti and get some coilovers set it up right and you wont need it!

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quote:

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Originally posted by carnoisseurcraig
yup, thats what im running just now... slot straight onto the corsa shaft and right into the box.... thats it job done...

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quote:

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Originally posted by broster
ditch ti and get some coilovers set it up right and you wont need it!

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quote:

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Originally posted by Gsi_Ire
go on, u want to do urs now, cause then you can do mine

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