Contents: Removal ⬇ Installation ⬇
The manufacturer recommends removing the power unit (engine with clutch and gearbox) down. To do this, you need a lift to raise the front of the car higher. In a garage, if you don't have a lift, you will need a jack, as well as strong and high enough supports to install the raised front of the car on them, this will make it possible to remove the engine from under it, lowered to the garage floor.
Note: The engine is very heavy, so we recommend removing it with an assistant and using special equipment (lift, hoist, etc.).
Attention! When removing and installing the assembled power unit, which has a large mass, use only fully functional lifting mechanisms designed for the corresponding load, and especially carefully monitor the correctness and reliability of the connection of cables, crossbars, etc. to the engine transport eyes.
You will need: keys "10", "13", "18", socket heads "10", "13", "15", TORX E10, E14, E18, extension, ratchet, TORX T30 key, flat and Phillips-head screwdrivers, sliding-grip pliers.
Removal
1. Remove the battery (see Removal and installation the battery).
2. Remove the battery mounting shelf (see Removal and installation the battery mounting shelf).
3. Drain the oil from the engine (see Changing engine oil and oil filter).
4. Remove the air filter (see Removal and installation the air filter, air duct and intake noise muffler).
5. Remove the mudguards and engine crankcase protection (see Removal and installation mudguards and engine crankcase protection).
6. Drain the cooling system (see Replacing the coolant).
7. Press the lock…
8. …and disconnect the wiring harness connector from the electro-hydraulic valve of the exhaust camshaft.
9. In a similar manner, disconnect the wiring harness connector from the electro-hydraulic valve of the intake camshaft.
10. Press the lock…
11. …and disconnect the wiring harness connector from the coolant temperature sensor.
12. Loosen the engine compartment wiring harness bracket mounting nut…
13. …remove the bracket from the stud and move the wiring harness to the side.
14. Disconnect the wiring harness connector from the intake camshaft position sensor.
15. Similarly, disconnect the wiring harness connector from the exhaust camshaft position sensor.
16. Disconnect the wiring harness connectors from the fuel injectors.
17. Unscrew the bolt securing the negative wire tip to the cylinder head and move the tip to the side.
18. Press the lock and disconnect the wiring harness connector from the coolant temperature sensor.
19. Disconnect the wiring harness connector from the knock sensor.
20. Loosen the clamp securing the coolant outlet hose from the branch pipe by squeezing its bent tabs with pliers. Slide the clamp along the hose…
21. …and disconnect the hose from the branch pipe.
22. Similarly, loosen the clamp securing the hose to the thermostat pipe..
23. …and disconnect the hose from the branch pipe.
24. Press the retainer and disconnect the vacuum hose from the intake pipe branch.
25. Remove the catalytic converter (see Removal and installation the catalytic converter, replacing its gasket).
26. Loosen the clamp securing the coolant outlet hose from the branch pipe by squeezing its bent tabs with pliers. Slide the clamp along the hose…
27. …and disconnect the hose.
28. Remove the two bolts securing the water distribution pipe to the water pump…
29. …bolt for fastening the water distribution pipe to the cylinder block…
30. …two screws securing the water distribution pipe to the thermostat module…
Note: One of the screws that secures the pipe to the thermostat module is not visible in the photo because it is covered by the pipe.
31. …and remove the water distribution pipe.
Caution! The flanges of the water distribution pipe are sealed with a rubber ring. Replace the ring each time the connection is disassembled.
32. Slide the heat shield along the wire harness…
33. …move the wiring harness connector retainer to the side…
34. …and disconnect the wiring harness connector from the oil pressure sensor.
35. Disconnect the plastic holders of the engine wiring harness from the engine brackets by cutting them with pliers.
36. Remove the wiring harness from the engine compartment.
37. Squeeze the bent ears of the clamp securing the radiator outlet hose to the water pump pipe, slide the clamp along the hose…
38. …and remove the hose from the branch pipe.
39. Squeeze the steam hose tip retainer…
40. …and disconnect the tip from the purge valve nipple of the adsorber.
41. Press the lock of the wiring harness block…
42. …and disconnect the connector from the air conditioning compressor electromagnetic clutch connector.
43. Remove the accessory drive belt (see Replacement of auxiliary drive belt).
44. Remove the three air conditioning compressor mounting bolts, move the compressor to the side without disconnecting the hoses from it, and secure the compressor with wire, preventing the hoses from twisting or being pulled.
45. Unscrew the nut securing the power cable tip and disconnect the cable from the generator terminal.
46. Squeeze the voltage regulator wiring harness connector retainer…
47. …and disconnect the block from the regulator.
48. Unscrew the power cable fastening nut…
49. …and remove the wire from the contact bolt of the traction relay.
50. Unscrew the nut securing the control wire of the traction relay
51. Remove the control wire from the contact bolt of the traction relay and move the removed wires to the side.
52. Unscrew the nut securing the ground wire.
53. Remove the ground wire from the lower starter mounting stud and move it to the side.
54. Pry with a screwdriver…
55. …and remove the gear shift cable end from the gear shift lever shaft.
56. Remove the gear selection cable end in the same way
57. Remove the cable sheath ends from the slot in the bracket on the gearbox housing (see Replacing gearbox control cables).
58. Remove the wire harness retainer from the hole on the transmission bracket.
59. Squeeze the lock…
60. …and remove the wiring harness connector from the reverse light switch connector.
61. Pry with a screwdriver…
62. …pull the retainer out of the clutch release line adapter…
63. …and remove the hose tip from the adapter.
64. Remove the exhaust pipe (see Replacing the inlet pipe).
65. Attach the engine to the special lugs and tighten the sling (for example, a crane, a hoist or other lifting mechanism).
Attention! Make sure that the sling is securely fastened to the mounting eyes.
66. Remove the front suspension subframe (see Removal and installation the front suspension subframe).
67. Remove the front wheel drives (see Removal and installation front wheel drives).
68. Place reliable supports under the power unit (it is best to use a trolley with a lifting capacity of at least 300 kg).
69. Lower the front of the vehicle so that the power unit rests on a support or dolly.
70. Check that all wires attached to the body are disconnected from the power unit. Check that hoses, tubes and body components do not interfere with the removal of the power unit downwards.
71. Remove the right powertrain suspension support (see Replacing the right powertrain suspension support).
72. Remove the three bolts securing the left support of the powertrain suspension to the gearbox bracket.
73. Raise the front of the car (raise the car on a lift) to a height sufficient to remove the power unit from under the vehicle, and install reliable supports under the body.
74. Remove the power unit from under the vehicle.
75. Install the power unit, as well as all removed components and parts, in the reverse order of removal, taking into account the following:
- before installing the power unit, use a tap to clean the threaded holes for mounting its supports from rust;
- when connecting wires and pipelines, carefully ensure that they are correctly positioned in the engine compartment, avoiding contact with heating and moving elements of the power unit.
Installation
After installing the engine, do the following.
1. Fill the engine with oil (see Changing engine oil and oil filter).
2. Fill with coolant (see Replacing the coolant).
3. Remove air from the clutch release hydraulic drive (see Bleeding the clutch release hydraulic drive).
4. Start the engine and check for fuel, oil and coolant leaks. Check the oil pressure. Listen to the engine: it should run smoothly, without any extraneous noise or knocking.
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