It is necessary to remove the engine mounts from the body, having previously raised the car using a lift. Before starting work in the engine compartment, protect the fenders from damage.
Depending on the model and year of manufacture of the vehicle, electrical wires, vacuum hoses and cooling system hoses may be routed differently. Without going into details of the laying schemes, we recommend that all wires and hoses be marked with adhesive tape before disconnection.
Removing
Remove battery.
Remove the hood (see chapter "Body").
Drain coolant.
Disconnect the coolant hose at the upper radiator hose, after fully releasing the clamp and sliding it back.
Remove air filter. Close the carburetor with a rag.
If there is a suction hose and pre-chamber, remove them.
Mark with adhesive tape and disconnect the oss wires, hoses and cables going to the engine (wires from the generator and starter, coolant temperature sensor, oil pressure sensor, injection system pipe, high voltage wires).
Remove the accelerator link.
Remove the alternator drive V-belt. If a V-ribbed belt is installed, remove the pulley from the coolant pump. Remove the pump from the cylinder block. The illustration shows the E16NZ engine.
If the vehicle is equipped with power steering and air conditioning, remove the power steering pump and air conditioning compressor from the engine by removing the bolts securing them to the cylinder block.
Loosen the upper bolts securing the clutch housing to the cylinder block.
Hang the engine on the lifting device KM-263 (see fig.).
If there is no such device, put a suitable piece of pipe over the engine compartment, resting it on the wings and placing wooden blocks under the contact points. Fasten the cable or hooks to the engine and connect them to the pipe. Pull the rope.
Raise the vehicle and place it on stands.
Remove the front exhaust pipe.
If the vehicle is equipped with power steering and air conditioning, remove their drive belts.
Loosen the lower mounting bolts for the power steering pump and A/C compressor.
Attention! Push the pump and compressor with hoses attached to them to the side or hang them on a wire. Never disconnect the hoses from the air conditioner! The refrigerant used in the air conditioner can cause frostbite if spilled. If brake lines are disconnected, air must be bled from the system during reassembly.
Loosen the gearbox cover bolts.
For 1.8 and 2.0 liter engines: remove the belt pulley from the crankshaft. Drain the oil and remove the oil filter.
Remove clutch.
Loosen the right engine mount bolts.
Loosen the remaining engine mounting bolts.
Loosen the lower gearbox-to-cylinder block bolts.
Lower the car.
Raise the gearbox with a jack, laying a wooden gasket.
Remove lifting device KM-263.
Attach the lifting hooks to the engine.
Separate the engine from the gearbox with a pry bar until the input shaft is completely free.
Check if all hoses and wires leading to the body are disconnected.
Lift the engine out of the engine compartment. Remove power steering pump (for vehicles with V-ribbed belts). Figure D0910 shows the E16NZ engine.
Attention! When lifting the engine, be careful not to hit the engine against the body.
Installation
Check engine mounts, coolant hoses, oil and fuel hoses for cracks or kinks. Replace damaged parts.
Check the thickness of the clutch drive plate and the quality of its surface. If severe wear is found, the clutch must be replaced completely. If the release bearing makes noise when you press the clutch pedal, it must also be replaced.
Clean and lubricate clutch release bearing and input shaft splines with M0S2 grease.
Carefully lower the engine into the engine compartment. When lowering, take care not to damage the input shaft, clutch and bodywork.
Vehicles with V-ribbed drive belt: Install and secure the power steering pump.
Tighten clutch housing bolts to 75 Nm.
Install lifting device KM-263 (remove the jack).
Tighten lower gearbox-to-engine block bolts to 75 Nm.
Tighten the engine mounts to 60 Nm.
Secure the right engine mount to the body with a torque of 65 Nm using new bolts.
Raise the car with a jack and place it on stands.
Install clutch.
If the crankshaft pulley was removed, install and secure it.
Attach the gearbox cover.
For 1.8 and 2.0 liter engines: Install an oil filter.
Install the front exhaust pipe.
If the power steering pump and air conditioning compressor were removed, install and tighten them with bolts to a torque of 40 Nm. Install and tighten the V-belt.
Vehicles with V-ribbed belt: Install the power steering pump and secure to the cylinder block with a torque of 30 Nm, and the belt pulley with a torque of 25 Nm. Install poly V-belt and tension it.
Lower the car.
Install and tighten the V-belt.
Connect all wires, hoses and cables going to the engine, in accordance with the marks on them.
Secure hoses with clamps and electrical wires with clamps.
Pour fresh oil into the engine.
Check oil level, top up if necessary.
Check coolant density and top up if necessary.
Clean the air filter housing and filter element. Replace element if necessary.
Install the air filter.
Install the hood.
Install the battery and connect the wires to it.
Check ignition timing setting.
Check engine idle speed.
Start the engine, warm up to operating temperature, check the coolant level, check all hose and pipe connections for leaks.
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