2. It should be noted right away that this procedure is quite complicated for an ordinary motorist and requires the use of fairly serious lifting and rigging and some other equipment. It is essential to have an appropriate work area with enough space to accommodate the vehicle, a sturdy workbench/mounting stand, and the necessary materials, equipment, and components to be removed from the engine. The best option is a large garage or indoor workshop, equipped with shelving with wide shelves. In extreme cases, just a flat area with an asphalt or concrete surface is suitable.
3. In the process of removing the unit from the car, there are many situations when the help of an assistant is required - arrange in advance with one of your friends or neighbors in the garage. If the engine is removed for the first time by an amateur mechanic, be sure to enlist the support of a specialist or someone who has already performed this procedure on the same vehicle. Some operations can only be performed in a service station (e.g. removal of refrigerant from the A/C system), therefore, part of the procedures that require highly qualified personnel and the use of special equipment will have to be entrusted to car service specialists.
4. Try to plan in advance the entire sequence of actions. Prepare the necessary tools and equipment. It is advisable to wash the engine and transmission. Prepare a set of wrenches and interchangeable sockets with a suitable (preferably ratchet) drive, a couple of sturdy wooden blocks, and enough rags and thinner to remove traces of fuel, oil, and coolant.
5. Due to the peculiarities of the layout and suspension of the engine, it is removed together with the gearbox on a subframe. The power unit is removed by lowering it down from the engine compartment, so equipment will be required to raise the car to a sufficiently high height and securely fix it in the raised position. When performing work on unfastening the engine mount, it must be held from above with a winch (hoist), or from below using a hydraulic jack and a special device for holding the unit on the jack.
Note: The jack must be able to lift the machine by at least 100 cm (1m).
Attention: Make sure that the hoist and rigging correspond in terms of their lifting characteristics to the total mass of the power unit (engine with transmission). Do not forget about the need to strictly comply with safety regulations! Do the work slowly, in an organized manner!
6. On diesel models, you must first discharge the air conditioning system (with appropriate equipment). This operation is performed using special equipment - contact the service station specialists. On petrol models, it is not necessary to discharge the system, but during work, be careful and careful not to accidentally damage the refrigeration lines, otherwise injury may result. Safety measures when working with the A/C system are given in Chapter 3.
7. Remove the front wheels of the car (see chapter «Introduction»), drain the coolant (see chapter 3) and remove the multirib belt (see Section 7).
8. Relieve the pressure in the fuel system through the service fitting using a special tool KM-J-34730-91 (see chapter 4 for details).
Attention: Do not forget that fuel is a highly flammable liquid! When working with the components of the power system, observe all fire safety measures taken! Do not smoke, do not approach the place of work with an open flame or an unprotected carrier! Fuel, like most other technical fluids, is one of the carcinogenic and toxic substances. Try to prevent fuel from getting into open areas of the body - use protective rubber gloves and goggles, in case of accidental unexpected contact, thoroughly wash your hands with warm water and soap. Clean up spilled fuel without delay, and do not place fuel-soaked rags near open flames. Keep a fire extinguisher handy at all times!
9. If the engine is removed for later disassembly or transport, remove the oil filter and drain the oil (see chapter 1). In this case, it is advisable to drain the oil from the gearbox as well.
10. Below is a list of the main operations to prepare the engine for removal, most of them are described in the relevant chapters of the Manual. Note: Depending on the layout of attachments on the engine and in the engine compartment, the number and procedure for removing attachments may vary.
- a) Remove the engine cover (with appropriate equipment) (see section 2). Remove the air cleaner assembly with air ducts (see chapter 4), disconnect all turbocharger air ducts (with appropriate equipment);
- b) Remove partially or completely the exhaust system (see chapter 4) and hoses of the crankcase ventilation system;
- c) Disconnect the fuel lines (see chapter 4);
- d) Disconnect the brake booster servo vacuum hose;
- e) Disconnect the hose from the vacuum pump and the EGR valve, - take the hose aside;
- f) Disconnect all feed lines from throttle/fuel rail assembly;
- g) If equipped, disconnect and move aside the shift cables and clutch hydraulic lines (see chapter6 or 7);
- h) Loosen the clamps and remove the upper and lower coolant hoses from the radiator. Disconnect all hoses of the cooling path from the engine, if necessary, remove the expansion tank;
- i) Remove the front bumper cover (see chapter 11);
- j) On models equipped with an air conditioning system, disconnect the A/C compressor and lines of the refrigeration path from the engine and take aside (see chapter 3), tie the compressor to the load-bearing elements of the body in the engine compartment. If the system is discharged, the compressor can be removed. In this case, you can also remove the refrigeration lines that interfere with the dismantling of the engine;
- k) Tie the radiator to the load-bearing elements of the front end;
- l) Disconnect the electrical wiring of the engine control systems and electrical equipment. On models with AT, disconnect the electrical wiring from the transmission;
- m) Release the wiring harnesses from all intermediate clamps and place them on top of the engine, if necessary, remove the fuse box.
11. Disconnect the intermediate shaft of the steering column, disconnect the steering rods from the steering knuckles and the anti-roll bar (see chapter 10). Remove both drive shafts (see chapter 8).
12. Install the right/left support remover (see Section 5). Remove the right and left engine mounts (see Section 18).
13. Once again make sure that all communication lines are disconnected and nothing prevents the removal of the power unit from the engine compartment.
14. Place a trolley jack under the engine. Lift and install the KM-904 and KM-6168 devices on the front subframe (see resist. illustration) - the devices must enter the corresponding holes of the subframe with their guide pins and firmly, without play, fix on the subframe. Install the centering pins and center the fixtures on the subframe (indicated by an arrow in the illustration).
19.14. Installation of devices KM-904 (1) and KM-6168 (2) on the front subframe: 3. Centering axles
15. Having unscrewed 4 fixing bolts, disconnect the front subframe from the car body (see chapter 10).
16. Lower the power unit on the front subframe, being careful not to pinch the hoses or wiring or damage the radiator/fan. Seek help from an assistant if necessary.
17. Roll out the jack with the power unit attached to it from under the car. Hang the power unit and remove the subframe by disconnecting the front and rear supports. Turn out bolts of fastening of a dome of coupling and separate a transmission from the engine.
18. Installation of all units and removed components is carried out in the reverse order of removal.
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