Removal
1. Place the vehicle on a two-post lift.
2. Disconnect the battery, starting with the negative cable.
3. Remove the battery, front wheels, engine guard and side guard.
4. Remove the refrigerant from the air conditioning system, drain the coolant, oil from the engine, if necessary.
5. Disconnect the wiring connector from the air flow meter.
6. Remove the air filter and engine cover.
7. Remove the license plate, turn signals and radiator grille (figure 4.1).
Figure 4.1. Remove the license plate, turn signals and radiator grille.
8. Unscrew the headlight mounting bolts and disconnect the wiring connectors from the headlights (figure 4.2).
Figure 4.2. Unscrew the headlight mounting bolts and disconnect the wiring connectors from the headlights.
9. Remove the bumper (figure 4.3a, b).
Figure 4.3a. Remove the bumper.
Figure 4.3b. Remove the bumper.
10. Remove the power steering fluid reservoir.
11. Remove the hood locking mechanism (figure 4.4).
Figure 4.4. Remove the hood locking mechanism.
12. Disconnect the air ducts from the charge air cooling radiator, two tubes from the condenser, the upper hose of the cooling system radiator, and the wiring connectors from the fan motor.
13. Remove the expansion tank.
14. Remove the boost pressure control solenoid valve.
15. Disconnect the wiring connector from the pre-heating and post-heating control unit.
16. Remove the engine control unit cover and unscrew its mounting bolts. Disconnect the wiring connectors from the engine control unit.
17. Disconnect the fuse box from the junction box.
18. Disconnect the wire harness from the connector.
19. Disconnect the fuel shut-off sensor wiring connector.
20. Disconnect the hydraulic transmission control on the master cylinder, transmission rods (figure 4.5).
Figure 4.5. Disconnect the hydraulic transmission control on the master cylinder, transmission rod.
21. Unscrew bolt 1 securing the hydraulic power steering tube to the cross beam, remove the lower cross beam 2, unscrew the bracket mounting nuts and remove the engine suspension rod (figure 4.6).
Figure 4.6. Unscrew bolt 1 securing the hydraulic steering tube to the cross member, remove the lower cross member 2.
Right side of the car
22. Remove the brake caliper and attach it to the suspension spring, ABS sensor, stabilizer link, unscrew the lower ball joint nut (use a socket wrench at X = 22 mm if necessary to lock the ball joint), unscrew both bolts securing the gearbox flange to the bracket, remove the tie rod end using the T.Av. 476 tool and two shock absorber support bolts (figure 4.7).
Figure 4.7. Socket wrench for X = 22 mm.
23. Disconnect the axle shaft.
24. Remove the hub together with the axle shaft.
Left side of the car
25. Remove the brake caliper and attach it to the suspension spring, ABS sensor, unscrew the lower ball joint nut (use a socket wrench with X = 22 mm if necessary to lock the ball joint), remove the tie rod end using the T.Av. 476 tool, unscrew the three axle boot bolts and the two shock absorber support bolts.
26. Disconnect the axle shaft.
27. Remove the hub together with the axle shaft.
28. Remove the fuel tank filler cap.
29. Loosen the fuel tank mounting bolts to gain access to the fuel level sensor.
30. Disconnect the fuel level sensor wiring connector 3 (figure 4.8).
Figure 4.8. Disconnect wiring connector 3 from the fuel level sensor.
31. Disconnect the wiring harness from the battery support.
32. Disconnect the air duct from the turbocharger, the hydraulic power steering tubes from the steering gear.
33. Disconnect the pipe from the heater radiator using tool Mot. 1448 (figure 4.9).
34. Disconnect the wiring connector from the fuel heater, the fuel intake line from the high-pressure fuel pump, and the fuel drain line from the fuel temperature sensor.
Figure 4.9. Disconnect the pipe from the heater radiator using tool Mot. 1448.
35. Unscrew the bolts securing the crossbar 4 and remove it (figure 4.10). Disconnect the ground wire from the transmission.
Figure 4.10. Unscrew the bolts securing the crossbar 4 and remove it.
36. Place the Mot. 1390 hoist under the engine (figure 4.11).
Figure 4.11. Position the Mot. 1390 hoist under the engine.
37. Remove the right engine mount (figure 4.12).
Caution: Before completely loosening the engine mount bolts, make sure that the engine is securely fastened to the lift.
Figure 4.12. Remove the right engine mount.
38. Unscrew the nut and knock out bolt 5 with a hammer (figure 4.13).
Figure 4.13. Unscrew the nut and knock out bolt 5 with a hammer.
39. Remove the engine together with the gearbox.
Installation
40. Installation is carried out in the reverse order of removal.
Tightening torques
- Shock absorber mounting bolt - 180 Nm.
- Brake caliper mounting bolt - 35 Nm.
- Tie rod end mounting nut - 37 Nm.
- Lower ball joint nut - 105 Nm.
- Axle shaft boot mounting bolt - 105 Nm.
- Engine mount rod mounting bolt: to subframe - 105 Nm, to engine - 280 Nm.
- Upper engine mount arm mounting bolt - 105 Nm.
- Engine mount travel limiter mounting bolt to the body - 44 Nm.
- Engine mount cover mounting bolt to engine - 65 Nm.
- Travel limiter mounting nut - 44 Nm.
- Wheel mounting bolts - 142 Nm.
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