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. First of all, you need to discharge the air conditioning system (with appropriate equipment). This operation is performed using special equipment - contact the service station specialists.
Attention! The path of the K / V system is constantly under pressure!
7. Remove crankcase guard/multi-ribbed belt cover (depending on the model). Remove the front wheels of the car.
8. Drain the coolant and release the pressure in the fuel system through the service fitting using a special device KM-J-34730-91.
Warning! It should not be overestimated 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 not to allow fuel to come into contact with covered 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 immediately and do not store fuel-soaked rags near open flames. Keep a class B fire extinguisher handy at all times!
9. If the engine is being removed for later disassembly or transport, remove the oil filter and drain the oil. It is advisable to drain the oil from the gearbox.
10. You should also drain the headlight washer fluid.
11. Below is a list of the main operations for preparing 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 air cleaner assembly with air ducts, disconnect all air ducts of the turbocharger;
- b) Disconnect and remove the battery and battery support tray;
- c) Remove partially or completely the exhaust system and hoses of the crankcase ventilation system;
- d) Disconnect the lines of the fuel supply system;
- e) Disconnect the brake booster servo vacuum hose;
- f) Disconnect the hose from the vacuum pump and the EGR valve, - take the hose aside;
- d) Disconnect and move aside the throttle cables and (with appropriate equipment) tempostat cable - try to remember the routes for laying the cables;
- 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, remove the expansion tank;
- i) Remove the front bumper;
- j) On models equipped with an air conditioning system, disconnect from the engine and take aside the lines of the refrigeration path;
- k) Disconnect the electrical wiring;
- l) Release the wiring harnesses from all intermediate clamps and place them on top of the engine, if necessary, remove the fuse box;
- m) Disconnect from transmission draft of a gear change/selector cable;
- n) Disconnect the clutch release hydraulic hose (RKPP);
- O) On models with AT, disconnect the electrical wiring from the transmission.
12. Disconnect the intermediate shaft of the steering column, disconnect the steering rods from the steering knuckles and remove both drive shafts
13. Install the right/left support remover. Remove the right and left engine mounts.
14. Once again make sure that all communication lines are disconnected and nothing prevents the removal of the power unit from the engine compartment.
Attention! Never open the refrigeration path of the A/C system (with appropriate equipment)!
20.15 Installation of KM904 fixtures (1) and KM-6312 (2) on the front subframe: 3. Centering axes
15. Place a trolley jack under the engine. Raise and install on the front subframe fixtures KM-904 and KM-6312 (see illustration) - the devices must enter the corresponding holes of the subframe with their guide pins and firmly, without play, fix on the subframe.
Note: Centering pins are used when installing the motor, must be in the lower position when removing (see ibid).
16. Having unscrewed the fixing bolts, disconnect the front subframe from the car body.
17. 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.
18. 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.
19. Installation of all units and removed components is made in an order, the return to an order of removal.
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