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:
- air intake pipe,
- battery,
- intake silencer,
- air filter housing,
- fuel rail protection
- battery tray,
- injection computer.
Disconnect at a point (1) throttle cable from the throttle body.
Remove the throttle cable from the intake manifold at (2).
Remove the bolt (3) attaching the engine wiring harness to the battery bracket.
Disconnect the engine wiring harness from the retainer at the point (4).
Loosen the mounting bolt «mass» tires (5) on the battery bracket.
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:
- fuel supply line (9) from the fuel rail
- evaporative emission hose (10).
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 (11).
Disconnect connector (12) adsorber purge solenoid valve.
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 (13) on the tank with (Mot. 1448),
- power steering pump reservoir (14),
- a bolt of fastening of the pipeline of a high pressure of the hydraulic booster of a steering to the block of cylinders.
Disconnect the power steering lines at the engine cooling fan bracket at the point (15).
Disconnect the wiring harness (16) from the electric fan of the engine cooling system.
Models with air conditioning
Remove:
- power steering system low pressure pipe (17) on the tank with (Mot. 1448),
- power steering pump reservoir (18),
- a bolt of fastening of the pipeline of a high pressure of the hydraulic booster of a steering to the block of cylinders.
Disconnect the power steering lines at the engine cooling fan bracket at the point (19).
Disconnect the wire blocks (20) from the electric fan of the engine cooling system.
Disconnect the engine cooling fan wiring harness at the point (21).
All models
Remove the bolt (22) fastening the power steering low pressure pipe to the holder on the front suspension subframe.
Remove:
- power steering high pressure pipe bolt (23) on the gearbox
- power steering high pressure pipe bolt (24) on the gearbox support
- fastening bolt (25) «mass» tires for gearboxes.
Models with air conditioning
Remove:
- bolt of fastening of the holder of pipelines on the compressor,
- pipe union bolts on the compressor.
Note: Be sure to plug the piping openings to prevent moisture from entering the system.
Disconnect the compressor lines.
Plug the openings in the pipelines.
Disconnect the refrigerant pressure sensor connector.
All models
Set aside the clamps (26) hose of the cooling system on the inlet pipe of the water pump using the tool (Mot. 1448).
Disconnect:
- cooling system hoses from the inlet pipe of the water pump,
- vacuum tube on the intake manifold.
Set aside the clamps (27) fixing the cooling system hoses to the thermostat housing using a tool (Mot. 1448).
Disconnect the cooling system hoses from the thermostat housing.
Disconnect the downstream oxygen sensor harness from the steering gear heat shield.
Disconnect the downstream oxygen sensor connector.
Remove the bolt (28) securing the cooling system pipe bracket to the engine oil pan.
Remove:
- steering gear heat shield mounting bolts,
- steering heat shield,
- steering gear mounting bolts on the front suspension subframe.
Attach the steering gear to the body.
Remove:
- bolts (29) upper fastening of the connecting rods of the front suspension subframe,
- bolts (30) upper mounting pins of ball joints of racks of anti-roll bar,
- 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 (31) 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 (32).
Drain the brake fluid into a container.
Install plugs on the piping openings.
Remove the lower jet link.
Remove:
- bolts (33) exhaust pipe flange fasteners,
- exhaust manifold gasket.
Take aside the final pipeline.
Note: Move the exhaust pipe back.
Remove the front suspension subframe.
Mark on the body the position of the pendulum suspension supports of the power unit.
Establish the engine in gathering with a transmission on labels (34) using a device (Mot. 1390).
Remove the right pendulum support.
Loosen the fastening nut (35) silent block of the left support of the pendulum suspension.
Knock out the gearbox mounting pin with a bronze drift to separate the engine assembly with gearbox 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: O-ring between exhaust manifold and 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 silent block fastening nut 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 finger of the top spherical joint of a rack of the anti-roll bar (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),
- 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).
Run:
- fill the engine with oil
- filling the gearbox with oil, 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 the 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.