Tightening torques | |
Nut fastening the silent block of the left support of the pendulum suspension | 62 Nm |
Bolts of fastening of a flange of the final pipeline | 21 Nm |
Bolts of the top fastening of Connecting drafts of a subframe of a forward suspension bracket | 21 Nm |
Bolts of fastening of a finger of the top spherical hinge of a rack of the anti-roll bar | 37 Nm |
Mounting bolt «mass» tires on gearbox | 21 Nm |
Bolt of fastening of the pipeline and low pressure of the hydraulic booster of a steering to a subframe of a forward suspension bracket | 21 Nm |
Bolts of fastening of the pipeline of the hydraulic booster of a steering on a support of a transmission | 21 Nm |
Bolts of fastening of the pipeline of the hydraulic booster of a steering on a transmission | 21 Nm |
Bolt of fastening of the pipeline of the hydraulic booster of a steering on the block of cylinders | 21 Nm |
Removing
Place the car on a two post lift.
Models with air conditioning
Drain the refrigerant circuit using the refrigerant filling station.
All models
Remove:
- engine top cover
- air intake pipe,
- air filter housing, battery,
- battery tray,
- injection computer.
Remove the bolt (1) attaching the engine wiring harness to the battery bracket.
Disconnect the engine wiring harness from the retainer at the point (2).
Loosen the mounting bolt «mass» tires (3) on the battery bracket.
Disconnect connector (4) block of pre- and post-start heating.
Disconnect check valve (5) from the vacuum pump.
Remove the fuse and relay box cover.
Remove the side shield (6) fuse and relay box.
Disconnect the engine wiring harness connector from the vehicle front wiring harness (7).
Pull the fuses and relays of the engine wiring harness (8) from the holders in the relay box and fuse box in the engine compartment.
Lay the wiring harness with fuses and relays on the engine.
Remove:
- front wheels,
- bolts of fastening of protection of the pallet crankcase of the engine,
- engine undertray protection,
- front bumper,
- front wheel arches.
Drain:
- engine oil, if necessary,
- gearbox oil,
- coolant.
Disconnect connector (9) fuel filter water sensor.
Disconnect the water sensor connector on the fuel filter bracket at the point (10).
Disconnect:
- fuel supply line (1),
- drain fuel line (12).
Attention! To prevent corrosion or damage, provide protection to areas where fuel can be hazardous.
Insert plugs into the holes in the fuel supply line.
Disconnect the pipes at (13).
Disconnect the air lines from the air cooler.
Disconnect:
- boost pressure control solenoid valve harness at point (14),
- boost pressure control solenoid valve (15) from the bracket.
Disconnect:
- air duct (16) at the exhaust gas recirculation unit,
- air line between turbocharger and cooler at point (17).
Remove:
- fastening nut (18) air lines on the gearbox
- air ducts from the air cooler.
Disconnect:
- low pressure hose of the power steering system to the power steering pump with (Mot. 1448) and drain the working fluid from the circuit,
- high pressure pipe on the power steering pump,
- block of wires from the pressure switch in the power steering system.
Models with heater
Remove:
- power steering system low pressure pipe (19) on the tank with (Mot. 1448),
- power steering pump reservoir (20),the power steering high pressure pipe bolt to the cylinder block.
Disconnect the power steering lines at the engine cooling fan bracket at the point (21).
Disconnect the wiring harness (22) from the electric fan of the engine cooling system.
Models with air conditioning
Turn away a bolt of fastening of the pipeline of a high pressure of the hydraulic booster of a steering on the block of cylinders.
Disconnect the wire blocks (23) from the electric fan of the engine cooling system.
Disconnect the engine cooling fan wiring harness at the point (24).
Loosen the mounting bolt «mass» tires (25) on the body.
Disconnect connectors (26) electric pump.
Disconnect the electric pump wiring harness at the point (27).
All models
Remove the bolt (28) fastening the power steering low pressure pipe to the holder on the front suspension subframe.
Remove:
- power steering high pressure pipe bolt
- (29) on the gearbox
- power steering high pressure pipe bolt
- (30) on the gearbox support
- fastening bolt (31) «mass» tires for gearboxes.
Models with air conditioning
Turn away bolts of fastening of unions of pipelines to the compressor.
Disconnect the compressor lines.
Note: Be sure to plug the piping openings to prevent moisture from entering the system.
Plug the openings in the pipelines.
Disconnect the refrigerant pressure sensor connector.
All models
Loosen the expansion tank nuts.
Move the expansion tank to the side.
Loosen the coolant hose clamp (32) on the thermostat housing using the tool (Mot. 1448).
Disconnect the coolant hose from the thermostat housing.
Set aside the hose clamps of the cooling system (33) on the heater core using the tool (Mot. 1448).
Disconnect the inlet and outlet hoses from the heater core.
Remove hoses of system of cooling from holders.
Remove:
- steering gear bolts
- steering heat shield,
- steering gear mounting bolts on the front suspension subframe.
Attach the steering gear to the body.
Remove:
- bolts (34) upper fastening of the connecting rods of the front suspension subframe,
- bolts of the top fastening of fingers of spherical hinges of racks of the anti-roll bar (35).
Remove:
- right front wheel drive shaft,
- drive shaft of the left front wheel.
Pass the power steering low pressure line over the transmission cover.
Disconnect:
- cables for selecting and shifting gears from the gearbox at points (36) with a screwdriver,
- selector and shift cables from shell stoppers by pressing at a point (A).
Pull the control cable away from the gearbox.
Attention! Do not pull on the latch. In case of any erroneous action, the pipeline must be replaced.
Disconnect the hydraulic clutch pipeline from the slave cylinder by pressing the lock (37).
Drain the brake fluid into a container.
Plug the openings in the pipelines.
Remove the lower jet link.
Remove:
- bolts (38) exhaust pipe flange.
- exhaust manifold gasket.
Take aside the final pipeline.
Note: Move the exhaust pipe back.
Remove the front suspension subframe.
Note: Install the fixture correctly (Mot. 1390) on the multifunctional bracket in the area (39).
Install (Mot. 1390) under the engine assembly with the gearbox.
Remove the right pendulum support.
Loosen the fastening nut (40) silent block of the left support of the pendulum suspension.
Knock out the gearbox mounting stud with a bronze drift to separate the engine and gearbox assembly from the body.
Raise the vehicle and remove the engine and transmission assembly.
Note: Make sure nothing is blocking the removal of the engine and transmission assembly from the body.
Remove the engine complete with gearbox.
Installation
Parts that must be replaced: the ring between the exhaust manifold and the catalytic converter.
Establish the engine in gathering with a transmission.
Tighten the nut securing the silent block of the left pendulum suspension support.
Torque tighten the nut of the silent block of the left pendulum suspension support (62 Nm).
Install the right swing arm support.
Remove fixture (Mot 1390) from the engine to the gearbox.
Installation is made in an order, the return to removal.
Torque tighten:
- exhaust pipe flange bolts (21 Nm),
- bolts of the upper fastening of the connecting rods of the front suspension subframe (21 Nm).
- bolts of fastening of a pin of the top spherical (37 Nm),
- fastening bolt - mass» tires on gearbox (21 Nm),
- bolt of fastening of the pipeline of low pressure of the hydraulic booster of a steering to a subframe of a forward suspension bracket (21 Nm),
- bolts of fastening of the pipeline of the hydraulic booster of a steering on a support of a transmission (21 Nm), power steering pipe mounting bolts to gearbox (21 Nm),
- bolt of fastening of the pipeline of the hydraulic booster of a steering on the block of cylinders (21 Nm).
Run:
- fill the engine oil, gearbox oil filling,
- filling the engine cooling system and removing air from it,
- bleed the air from the hydraulic clutch.
Models with air conditioning
Charge the refrigeration circuit with refrigerant using the refrigerant filling station.
All models
Fill the power steering system with working fluid.
Stop the engine first and bleed the air from the power steering system by turning the steering wheel from the left end position to the right end position.
Start the engine and bleed air from the power steering system by turning the steering wheel from one end to the other.
Top up the oil level in the power steering pump reservoir.
Make sure there is no fuel leakage.