Removal and installation of the G8T TURBO — PK1 engine (Renault Espace III)

Removal

• Removal and installation are carried out on a two- or four-post lift, without removing:

- front subframe;

- bumpers;

- front body panel;

- a 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.
• Drain the oil from the engine and gearbox, then reinstall the drain plugs using new O-rings.
• Remove:

- protective shields under the doer;

- protective wheel arch shields.

• Remove the oil cooler by disconnecting it from the engine cooling system radiator.
• Disconnect the oil cooler hose mounting bracket near the oil filter (replace sealing gaskets during installation).
• Install a self-made protective screen for the engine cooling system radiator (Fig. 3.39).

• Drain the fluid from the engine cooling system by unscrewing the threaded plug on the cylinder block (fig. 3.76).
• Use the charging station to discharge the refrigerant from the air conditioning system circuit.
• Drain the fluid from the power steering system by disconnecting the left hose from the heat exchanger under the vehicle.
• Disconnect the high pressure hose (lower hose) power steering from the steering gear housing (device Dir. 1282-01).
• Remove the thrust rod completely.
• Remove:

- intake pipe of the exhaust gas system;

- rigid plastic inlet pipe of air-to-air heat exchanger;

- clamp for fastening the air intake pipe to the side member

• Disconnect the lower hose from the engine cooling system radiator, while not allowing coolant to come into contact with the ABS unit
• Remove the drive shafts as follows.

On the right side of the car

• Remove the front right floating brake caliper bracket and secure it to the suspension spring to protect the brake hose from damage (fig. 3.26).
• Remove the two bolts securing the intermediate support of the drive shaft in the support bearing (fig. 3.27).
• Using the Tav. 476 puller, remove the steering rod end (fig. 3.28).
• Disconnect the wire from the brake pad wear sensor.
• Disconnect the wire from the wheel speed sensor.
• Loosen the lower mounting bolts of the shock absorber strut to the steering knuckle.
• Remove the wheel speed sensor if the vehicle is equipped with ABS.
• Loosen the lower ball joint pin nut as much as possible and use a ball joint impact remover to press the joint out of the steering knuckle (fig. 3.29).
• Remove the drive shaft - steering knuckle - brake disc assembly. Do not damage the drive shaft corrugated boots.

On the left side of the car

• Remove the brake caliper floating bracket and secure it to the suspension spring.
• Remove the three bolts securing the drive shaft corrugated boot (fig. 3.34).
• Using the Tav. 476 puller, remove the steering rod end.
• Disconnect the wire from the brake pad wear sensor.
• Remove the wheel speed sensor.
• Remove the bolts that secure the lower shock absorber strut to the steering knuckle.
• Disconnect the steering rod ends and lower ball joints from the steering knuckles.
• Remove the drive shaft - steering knuckle - brake disc assembly.
• Disconnect the ground bus from the gearbox.
• Disconnect the speedometer sensor from the rear of the transmission.
• Disconnect and remove the gear shift control cable in sequence.
• Remove 2 bolts and disconnect the clutch slave cylinder from the gearbox.
• Lower the car.
• Remove:

- air intake pipe fixed to the front panel of the body;



- a rubber tube between the air-to-air heat exchanger and the intake manifold;

- plastic pipe between turbocharger and heat exchanger;

- a rubber tube between the turbocharger and the heat exchanger;

- air filter;

- air filter bracket;

- aluminum air filter bracket supports.

• Remove the intermediate air intake pipe from the side member.
• Disconnect the brake booster vacuum hose.
• Disconnect the tubes from the EGR solenoid valve.
• Remove the gear shift control cable.
• Disconnect the interior heating system radiator hoses.
• Open the engine compartment junction box cover, disconnect the relay and engine compartment wiring harness connectors.
• Disconnect the upper radiator hose from the engine cooling system.

On the right side of the car

• Disconnect the injection system control unit from the right wing.
• To enable removal of the injection system control unit, remove the air conditioning system hose fastening on the fuel filter.
• Cut the 2 plastic cable ties securing the wiring harness to the shock absorber support cup.
• Disconnect the fuel heater.
• Disconnect the fuel line from the injection pump
• Disconnect the fuel return line from the reservoir on the shock absorber support cup.
• Pass the injection system control unit under the air conditioning hoses and secure it to the engine.
• Raise the car
• Install a universal support and lift the engine up until it is free (do it together).
• Remove the right engine swingarm mount bracket (4 bolts) together with the swingarm mount travel limiter.
• Unscrew the lower nut of the left pendulum suspension (1 bolt).
• Lower the power unit (do it together).
• The engine is removed through the bottom of the engine compartment.
• When removing the power unit, pay attention to the following:

- power steering pump, which runs close to the engine cooling system radiator;



- a crankcase gas sump that can come into contact with the engine subframe;

- remove the exhaust pipe and simultaneously move the power unit slightly to the left in the direction of the vehicle.

Installation

• Installation is carried out in the reverse order of removal.
• Using tool Mot 1289-02, adjust the position of the right engine pendulum mount travel limiter
• Do it

- pouring oil into the gearbox,

- filling the engine with oil;

- filling the power steering system,

- filling and removing air from the engine cooling system;

- filling the air conditioning system.

• Adjust the accelerator cable.
• Tighten the spring-loaded bolts of the exhaust system intake pipe flange clamps. Tighten the bolts until they stop.
• Press the brake pedal several times until the pistons of the working brake cylinders come into contact with the brake pads.

[Article reprinted from the website: renaultbook.ru]