Step 1 – Engine & drivetrain removal

Remove the internal combustion engine, fuel system, exhaust and all associated components. Drain all fluids first and ensure the vehicle is safely supported on rated axle stands throughout.

Procedure

1. Drain all fluids: engine oil, coolant, fuel tank
2. Disconnect negative battery terminal first, then positive
3. Remove air intake, exhaust manifold and downpipe
4. Disconnect and label all wiring harnesses connected to engine
5. Remove and cap fuel lines; remove fuel tank
6. Disconnect driveshaft from transmission or differential
7. Support engine and transmission with crane and jack
8. remove all engine and transmission mounting bolts
9. lift engine and transmission clear of the bay
10. remove clutch pedal assembly and hydraulic lines
11. clean engine bay thoroughly for inspection and measurements

Safety warnings

1. Never work under a vehicle supported only by a jack
2. Fuel vapours are explosive – no sparks or open flames
3. Wear eye protection when disconnecting fuel lines
4. Engine hoist must be rated above the engine weight

Pro tip

Photograph all wiring connections before removal. Label every connector with tape. You may need to retain certain sensors (coolant temp, TPS) for the EV controller.