Dismantling
Attention! The engine is removed from the vehicle as part of the power unit (together with transmission).
The power unit is lowered and removed from under the car. In order to freely remove the engine in this way, the front of the car must be raised to a sufficient height and placed on supports.
1. Place the car on a firm, level surface. Remove the hood and decompress the fuel system.
2. Block the rear wheels, set the handbrake. Raise the front of the car and place it on stands. Remove the front wheels. On some cars, remove the lower protective cover by unscrewing the screws.
3. Drain the coolant and oil from the engine, remove the oil filter.
4. Do the following.
- 1) Remove the air filter.
- 2) Disconnect the exhaust pipe from the manifold.
- 3) Disconnect the throttle and cruise control cables and set them aside.
- 4) Mark and disconnect all hoses from the intake manifold.
- 5) Disconnect the fuel tank vent hose from the throttle body.
5. Identify and disconnect all cooling and heating system hoses from the engine (to disconnect the heater hose, press the latch and pull the coupling). Remove the hoses from the brackets and clamps, move them away from the engine. Secure the air conditioner radiator/condenser by inserting the bolts into the bracket holes (see photo).
6. Disconnect all wiring harnesses from the engine (see photo), disconnect all buses to ground.
7. On models with manual transmission, do the following:.
- 1) Drain the oil from the gearbox.
- 2) Disconnect the reverse switch wire.
- 3) Disconnect the gear shift rod from the gearbox (see photo).
- 4) Clamp the hose immediately behind the fitting, use a screwdriver to pry up and remove the hose fitting mounting bracket on the clutch housing and disconnect the hose.
8. On models with automatic transmission, drain the fluid, mark and disconnect hoses, wires and cables from the transmission (the wiring connector is disconnected after tightening the lock).
9. Hang the engine on a hoist, securing it to the eyes on the engine and gearbox.
10. Remove the axle shafts (Chapter 8).
11. Remove the front bulkhead (Chapter 10).
12. Loosen the bolts securing the right engine support to the body and cylinder block. Loosen the bolts securing the left support to the gearbox bracket (see photo). On models with air conditioning, disconnect the wires from the compressor and move them away from the engine.
13. Place a pallet dolly under the vehicle. Carefully lower the engine, being careful not to hit the radiator or fans. Remove the engine from under the vehicle.
Removal the gearbox (transmissions)
Manual transmission
14. On models with a stamped steel pan, unscrew the bolts and remove the lower clutch housing cover.
15. Loosen the bolts and remove the starter.
16. Install reliable supports under the engine and gearbox, unscrew the mounting bolts and carefully separate the gearbox from the engine, preventing the gearbox from sagging on the input shaft. The gearbox mounting bolts should be screwed in place. Mark the position and orientation of the clamps and brackets to be removed.
17. If the guide pins are loose, remove them so that they can be reinstalled during assembly.
Automatic transmission
18. Loosen the bolts and remove the starter.
19. Remove the rubber plugs on the cylinder block/oil pan flange that cover the access holes for the torque converter mounting bolts. Unscrew the accessible torque converter mounting bolt(s). While turning the crankshaft, unscrew the remaining bolts (on all engines except the 2.0 L, the torque converter is secured with 3 bolts; on the 2.0 L engine, it is secured with 6 bolts). Replace the bolts during assembly
20. Move the torque converter into the transmission housing. Unscrew the bolts and remove the transmission.
Installation
21. Installation of the power unit is carried out in the reverse order, taking into account the following.
- a. Install the gearbox on the pins, preventing the gearbox housing from sagging on the input shaft (see photo).
- b. Align the power unit with the holes for the right support, install the support and tighten the bolts. Then tighten the bolts of the left support and install the air conditioning compressor. Install the subframe, then finally tighten the engine mount mounting bolts.
- c. On models with automatic transmission, replace the torque converter mounting bolts. Tighten the bolts by hand first, then tighten them finally in a diagonal pattern.
- g. Replace the axle shaft seals, clutch hose sealing ring and fitting gaskets on the automatic transmission.
- d. Securely fasten the heater hoses (see photo).
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