Removal
Removal and installation of the power unit is carried out on a two- or four-post lift without removing:
- front subframe;
- bumpers;
- front body panel;
- set of cooling system elements.
Place the vehicle on a two-post lift equipped with wheel chocks.
Disconnect the wires from the battery terminals and remove the battery.
Disconnect the engine compartment wiring harness connectors and remove the 30A fuse.
Be sure to install a protective screen made independently on the radiator of the cooling system (pic. 1.53).
Pic. 1.53. Dimensions of the protective screen of the radiator of the cooling system
Screen manufacturing specification: aluminum or steel sheet with a bend for hanging on the top of the radiator.
Remove:
- protective covers under the engine;
- front wheels;
- front right and left wheel arch guards;
- protective fender liners;
- front right and left wheel arches.
Use the charging station to discharge the refrigerant from the air conditioning circuit.
Drain the power steering system
- through the low pressure pipe on the heat exchanger;
- through the high pressure pipe on the power steering pump (then plug the hole in the pump).
Remove the clamps securing the power steering pipes to the engine.
Drain the engine cooling system:
- through the lower radiator hose (water pump inlet hose);
- move away from the radiator and secure the hose to ensure free compression of the power unit:
- through the upper radiator hose (coolant supply hose from the cylinder head).
Remove the injection system control unit from the side member and disconnect the connector from it.
Disconnect the air conditioning system piping from the right pendulum suspension.
Remove (without breaking) plastic clamps for fastening the electrical wiring harness on the right wing.
Disconnect the fittings of the air conditioning system elements on the front panel.
Disconnect the wiring harness and secure it to the engine.
Remove the air filter and disconnect the vacuum hose from the brake booster.
Remove the intake silencer in front of the air filter (pic. 1.54).
Pic. 1.54. Location of the intake silencer in front of the air filter
Pic. 1.55. Fuel line disconnection point
Remove the 2 bolts and disconnect the air conditioning system pipes from the compressor. Seal the holes tightly.
Unscrew the fastening bolts «mass» tires to the gearbox.
Disconnect:
- fuel pipelines;
- ignition system power module connectors;
- absolute pressure sensor tube and connector;
- accelerator cable;
- clutch drive cable with fork.
Raise the car.
Drain the gearbox oil.
Remove:
- jet thrust;
- intake pipe flange from the manifold;
- gear shift control rod (move the bellows cover);
- right drive shaft mounting pin.
Disconnect the connector from the oxygen sensor.
Remove the drive shafts as follows.
On the right side of the car:
- remove the floating brake caliper bracket and attach it to the suspension spring (if necessary, disconnect the brake hose from the shock absorber strut);
- Unscrew the bolts securing the protective corrugated cover of the drive shaft;
- unscrew the bolts of the lower mounting of the shock-absorbing strut (pre-mark their installation position).
Disconnect the lower ball joint from the steering knuckle (using an impact puller) and tie rod end (Tav puller 476).
Pic. 1.56. Using the Tav puller. 476 to disconnect the tie rod end from the steering knuckle
Move the steering knuckle to the side, remove the right drive shaft, having first removed the pin in the connection between the drive shaft and the differential output shaft.
Pic. 1.57. Disconnecting the lower control arm ball joint from the steering knuckle
On the left side of the car:
- remove the floating brake caliper and secure it to the suspension spring;
- unscrew the bolts of the lower mounting of the shock-absorbing strut (pre-mark their installation position).
Disconnect the lower ball joint from the steering knuckle (using an impact puller) and tie rod end (Tav puller 476).
Move the steering knuckle to the side, remove the left drive shaft, having previously unscrewed the 3 bolts securing the corrugated protective cover of the drive shaft to the differential flange.
Attention. Do not damage the corrugated protective covers
Remove the exhaust pipe (pipe between exhaust manifold and catalytic converter).
Disconnect the oxygen sensor.
Lower the car.
Disconnect the lower hose from the engine cooling system radiator, bend it upward and attach it to the engine.
Disconnect:
- radiator hoses for the interior heating system from the engine,
- 2 hoses from the expansion tank of the engine cooling system.
Disconnect the high pressure hose (bottom hose) power steering from the steering gear housing (fixture Dir. 1282-01).
Pic. 1.58. Disconnection point for power steering high pressure hose from steering gear housing
To make removal of the powertrain easier, disconnect the two power steering pipe mounting brackets on the transmission and front of the engine and secure them to the top of the engine.
Disconnect the engine compartment wiring harness from the engine compartment junction box.
Place an adjustable support under the engine and carefully lower the vehicle until the power unit is suspended (perform the operation together).
Remove the bolts securing the right engine pendulum mount bracket.
Unscrew the three bolts securing the gearbox support, but do not touch the elastic cushion of the gearbox pendulum suspension.
Pic. 1.59. Engine and gearbox mounts: 1 - right engine mount bracket; 2 - elastic pillow; 3 - left engine mount bracket; 4 - bracket; 5 - jet thrust; 6 - gearbox pendulum suspension bracket
Pic. 1.60. Location of the right engine mount mounting bolts
Pic. 1.61. Location of the gearbox support bolts
Carefully lower the power unit (perform the operation together).
Installation
Place the power unit in the engine compartment.
Install the gearbox pendulum suspension, secure it to the gearbox and to the elastic cushion.
Install the engine suspension bracket and use tool Mot. 1289-02 center the suspension travel stop.
Tighten all bolts and nuts to the recommended torques.
Carry out further installation in the reverse order of removal.
Press the brake pedal several times until the pistons of the brake wheel cylinders contact the brake pads.
Apply Rhodorseal 5661 to the drive shaft pin holes.
Adjust the accelerator cable.
Install the speedometer drive cable.
Run:
- pouring oil into the gearbox;
- filling and removing air from the engine cooling system;
- filling and bleeding air from the power steering system.
Put into operation all systems that are blocked when the wires are disconnected from the battery terminals.
If the vehicle is equipped with an air conditioning system, use a charging unit to charge the air conditioning system with refrigerant.