Removal
Warning! The engine can only be removed from the vehicle with the gearbox. The engine is removed from underneath the vehicle.
1. Remove the hood.
2. Depressurize the fuel system. Remove the battery and battery support.
3. Block the rear wheels, raise the front of the car and secure 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 cleaner housing, 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 cylinder head and 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 hoses from the mounting brackets and move them to the side of the engine, disconnect the wires from the starter, alternator, pressure and oil level sensor, unscrew the ground bus from the transmission.
6. Remove 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, do the following: drain the transmission fluid, 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 automatic transmission, perform the following steps: drain the transmission fluid, disconnect the gear selector cable, disconnect the electrical connectors from the transmission, disconnect the heat exchanger hoses from the transmission.
9. Attach the lifting mechanism to the power unit and lift until the weight of the power unit is supported by the lifting mechanism.
10. Remove the lower front frame.
11. Remove the inner drive shaft joints from the transmission. Using soft wire, suspend the inner ends of the drive shafts from the body.
12. Ensure that any items that may prevent engine removal are removed or disabled.
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13. Remove the bolts securing the torque compensator rod to the right end of the cylinder head.
14. Place a trolley under the power unit to facilitate removal of the power unit from under the vehicle. Lower the power unit down to the bottom of the vehicle.
15. Remove the lifting gear clamps from the power unit and remove the power unit from under the vehicle.
Separating the gearbox from the engine
Manual transmission
1. Mount the power unit on the appropriate bars.
2. On models with a stamped steel pan, remove the bolts and lower flywheel guard.
3. Unscrew the bolts and remove the starter.
4. Check that the engine and gearbox are securely fastened. Then unscrew the remaining bolts securing the gearbox housing to the engine.
5. Carefully separate the transmission from the engine so that the weight of the transmission does not press on the input shaft.
6. Remove the guide pins.
Automatic transmission
7. Mount the power unit on the appropriate bars.
8. Unscrew the bolts and remove the starter.
9. Remove the rubber cover from the oil pan lip to access the torque converter mounting bolts. Remove the torque converter mounting bolt and, while turning the crankshaft, remove the remaining torque converter mounting bolts. There are three torque converter mounting bolts on 1.6L engines, and six bolts on 1.8L and 2.0L engines.
10. To prevent the torque converter from falling when removing the gearbox, move the torque converter along the shaft toward the gearbox.
11. Mount the power unit on the appropriate bars.
12. On models with a stamped steel pan, remove the bolts and lower flywheel guard.
13. Unscrew the bolts and remove the starter.
14. Check that the engine and gearbox are securely fastened. Then unscrew the remaining bolts securing the gearbox housing to the engine.
15. Carefully separate the transmission from the engine so that the weight of the transmission does not press on the input shaft.
16. Remove the 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 specified torque.
3. Install the starter.
4. On models with a stamped steel oil pan, install the lower flywheel skid plate to the transmission 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 unit, tilt and rotate it as necessary so that it fits into place without causing damage.
7. Align the engine with the mount on the right side of the engine compartment and install the torque compensator rod and tighten the mounting bolts by hand.
8. Replace the drive shaft oil seals and install the drive shafts into the gearboxes.
9. Install the front suspension lower frame.
10. After installing the lower frame, tighten the torque compensator rod mounting bolts.
11. Further installation is performed in the reverse order of removal. Fill the gearbox with oil. Fill the engine with oil. Fill the cooling system with coolant.
Automatic transmission
12. Clean the threads of the torque converter mounting bolts.
13. Check that the dowel pins are installed in the engine or transmission. Lubricate the torque converter dowel pin and the bushing in the end of the crankshaft with molybdenum disulphide grease.
14. Install the gearbox to the engine on the guide pins. Install and tighten the gearbox to engine mounting bolts to the specified torque.
15. Screw in the first torque converter mounting bolt. Turn the crankshaft and screw in the remaining torque converter mounting bolts.
16. Install the starter and tighten the bolts.
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 unit, tilt and rotate it as necessary so that it fits into place without causing damage.
19. Align the engine with the mount on the right side of the engine compartment and install the torque compensator rod and tighten the mounting bolts by hand.
20. Replace the drive shaft oil seals and install the drive shafts into the transmission.
21. Install the front suspension lower frame.
22. After installing the lower frame, tighten the torque compensator rod mounting bolts.
23. Further installation is performed in the reverse order of removal. Fill the gearbox with oil. Fill the engine with oil. Fill the cooling system with coolant.
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