Removing
Warning! The engine can only be removed from a vehicle with a gearbox. Removal of the engine is carried out from under the car.
1. Remove the hood.
2. Depressurize the fuel system. Remove the battery and battery stand.
3. Block the rear wheels, raise the front of the vehicle and support it on stands.
4. If the engine is to be disassembled, drain the engine oil and remove the oil filter. Drain the coolant from the cooling system.
5. Remove the air filter cover, remove the front exhaust pipe, disconnect the fuel supply and return hoses from the fuel line, disconnect the accelerator cable, disconnect the vacuum hose from the brake booster and the hoses from the intake and exhaust manifolds, disconnect the electrical connectors from the electrical components of the intake manifold, loosen the clamps and disconnect the coolant supply hoses from the engine head and cylinder block, on models with air conditioning, unscrew the compressor mounting bolt and move the compressor to the side without disconnecting the hoses from it, release the air conditioning system hoses from the mounting brackets and move them away from the engine, disconnect the wires from the starter, generator, pressure and oil level sensor, unscrew the ground bus from the gearbox.
6. Unscrew the power steering pump mounting bolt and move it away from the engine without disconnecting the hoses from it.
7. On models with a manual transmission, perform the following steps: drain the oil from the transmission, disconnect the electrical connector from the reverse light switch, disconnect the shift rods from the transmission, disconnect the clutch cable from the transmission housing.
8. On models with an automatic transmission, do the following: drain the transmission fluid from the transmission, disconnect the gear selection cable, disconnect the electrical connectors from the transmission, disconnect the heat exchanger hoses from the transmission.
9. Hook the load handler to the power unit and lift until the weight of the power unit is supported by the load handler.
10. Remove the lower front frame.
11. Remove the inner drive shaft joints from the gearbox. Using a soft wire, hang the inner ends of the drive shafts from the body.
12. Check that any elements preventing removal of the engine are removed or disabled.
13. Unscrew bolts of fastening of draft of the compensator of a torque to the right end of a head of the block of cylinders.
14. Install a trolley under the power unit in order to facilitate the removal of the power unit from under the vehicle. Lower the power unit down the vehicle.
15. Remove the lifting gear from the power unit and remove the power unit from under the vehicle.
Separation of the gearbox from the engine
Manual Transmission
1. Install the power unit on the appropriate bars.
2. On stamped steel pan models, unscrew the bolts and remove the lower flywheel skid plate.
3. Unscrew bolts and remove a starter.
4. Check that the engine and gearbox are securely fixed. Then unscrew the remaining bolts securing the gearbox housing to the engine.
5. Being careful, separate the gearbox from the engine so that the weight of the gearbox does not press on the input shaft.
6. Remove guide pins.
Automatic transmission
7. Install the power unit on the appropriate bars.
8. Unscrew bolts and remove a starter.
9. Remove the rubber sheath from the protrusion of the oil pan to access the torque converter mounting bolts. Unscrew the torque converter mounting bolt and, turning the crankshaft, unscrew the remaining torque converter mounting bolts. On 1.6 liter engines there are three transformer mounting bolts, and on 1.8 and 2.0 liter engines there are 6 bolts.
10. To prevent the torque converter from falling when the gearbox is removed, move the torque converter along the shaft towards the gearbox.
11. Install the power unit on the appropriate bars.
12. On stamped steel pan models, unscrew the bolts and remove the lower flywheel skid plate.
13. Unscrew bolts and remove a starter.
14. Check that the engine and gearbox are securely fixed. Then unscrew the remaining bolts securing the gearbox housing to the engine.
15. Being careful, separate the gearbox from the engine so that the weight of the gearbox does not press on the input shaft.
16. Remove guide pins.
Installation
Manual Transmission
1. Check that the guide pins are installed in the engine or gearbox.
2. Install the gearbox to the engine on the guide pins. Tighten the gearbox mounting bolts to the required torque.
3. Install starter.
4. On stamped steel pan models, install lower flywheel skid plate to transaxle case and secure with bolts.
5. Position the power unit under the engine compartment of the vehicle, hook the power unit with a lifting device and install it in the engine compartment.
6. When installing the power package, if necessary, tilt and rotate it so that it is installed in place without causing harm.
7. Align the engine with the mount on the right side of the engine compartment and install the torque compensator link and hand-tighten the mounting bolts.
8. Replace the driveshaft oil seals and install the driveshafts to the gearboxes.
9. Install the lower front suspension frame.
10. After installing the lower frame, tighten the bolts securing the torque compensator rod.
11. Further installation is carried out in the reverse order of removal. Pour oil into the gearbox. Fill the engine with oil. Pour coolant into the cooling system.
Automatic transmission
12. Clean the threads of the torque converter mounting bolts.
13. Check that the guide pins are installed in the engine or gearbox. Lubricate the torque converter locating pin and bushing at the end of the crankshaft with molybdenum disulphide grease.
14. Install the gearbox to the engine on the guide pins. Establish and tighten bolts of fastening of a transmission to the engine by the demanded moment.
15. Screw in the first torque converter mounting bolt. Turn the crankshaft and screw in the remaining torque converter mounting bolts.
16. Install starter and bolt on.
17. Position the power unit under the engine compartment of the vehicle, hook the power unit with a lifting device and install it in the engine compartment.
18. When installing the power package, if necessary, tilt and rotate it so that it is installed in place without causing harm.
19. Align the engine with the mount on the right side of the engine compartment and install the torque compensator link and hand-tighten the mounting bolts.
20. Replace the driveshaft oil seals and install the driveshafts to the gearbox.
21. Install the lower front suspension frame.
22. After installing the lower frame, tighten the bolts securing the torque compensator rod.
23. Further installation is carried out in the reverse order of removal. Pour oil into the gearbox. Fill the engine with oil. Pour coolant into the cooling system.
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