Removal
- Removal - installation is 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 engine and transmission oil, then replace the drain plugs with new O-rings.
- Remove:
- protective shields under the worker;
- protective guards for wheel arches.
- Remove the oil heat exchanger by disconnecting it from the engine cooling system radiator.
- Disconnect the oil cooler hose mounting bracket in the oil filter area (When installing, replace the sealing gaskets).
- Install a self-made engine cooling radiator shield (pic. 3.39).
Pic. 3.39. Dimensions of the protective screen of the radiator of the cooling system
Pic. 3.40. Location of the hose through which the power steering fluid must be drained
- Drain the liquid from the engine cooling system by unscrewing the screw plug on the cylinder block (rice. 3.76).
- Use the charging station to discharge the refrigerant from the air conditioning circuit.
- Drain the power steering system by disconnecting the left hose from the heat exchanger under the car's bottom.
- Disconnect the high pressure hose (bottom hose) power steering from the steering gear housing (fixture Dir. 1282-01).
- Remove the jet thrust completely.
- Remove:
- intake pipe of the exhaust system;
- hard plastic inlet pipe of the 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, but do not allow coolant to enter the ABS unit
- Remove the drive shafts as follows.
Pic. 3.41. Engine mount torque rod location
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 (rice. 3.26).
- Remove the two bolts securing the drive shaft intermediate support to the support bearing (rice. 3.27).
- Using the Tav puller. 476 remove the tie rod end (rice. 3.28).
- Disconnect the wire from the brake pad wear sensor.
- Disconnect the wire from the wheel speed sensor.
- Unscrew the bolts of the lower fastening of the shock absorber strut to the steering knuckle.
- Remove the wheel speed sensor if the vehicle is equipped with an ABS system.
- Loosen the lower ball joint pin nut as much as possible and use a ball joint puller to press the joint out of the steering knuckle (rice. 3.29).
- Remove the drive shaft - steering knuckle - brake disc assembly. Do not damage the corrugated covers of the drive shafts.
On the left side of the car
- Remove the floating brake caliper bracket and attach it to the suspension spring.
- Remove the three bolts securing the corrugated cover of the drive shaft (rice. 3.34).
- Using the Tav puller. 476 remove the tie rod end.
- Disconnect the wire from the brake pad wear sensor.
- Remove the wheel speed sensor.
- Remove the bolts from the lower mounting of the shock absorber strut to the steering knuckle.
- Disconnect the tie rod ends and lower ball joints from the steering knuckles.
- Remove the drive shaft - steering knuckle - brake disc assembly.
- Disconnect «massive» tire from the gearbox.
- Disconnect the speedometer sensor from the rear of the transmission.
- Sequentially disconnect and remove the gear shift control cable.
- Remove the 2 bolts and disconnect the clutch slave cylinder from the gearbox.
- Lower the car.
- Remove:
- air intake pipe mounted on the front panel of the body;
- a rubber tube between the air-to-air heat exchanger and the intake manifold;
- plastic pipe between the turbocharger and the 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 shift control cable.
- Disconnect the radiator hoses of the interior heating system.
- Open the engine compartment junction box cover and disconnect the relay and engine compartment wiring harness connectors.
- Disconnect the upper radiator hose of the engine cooling system.
On the right side of the car
- Disconnect the injection system control unit from the right wing.
- To ensure removal of the injection system control unit, remove the fastening of the air conditioning system hoses on the fuel filter.
- Cut the 2 plastic clamps that secure the electrical 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 suspension strut support cup.
- Pass the injection system control unit under the air conditioning system hoses and secure to the engine.
- Raise the car
- Install a universal support and lift the engine up until it hangs out (do it together).
- Remove the right engine pendulum mount bracket (4 bolts) together with the pendulum suspension 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 underside of the engine compartment.
- When removing the power unit, pay attention to the following:
- the power steering pump, which runs close to the radiator of the engine cooling system;
- crankcase gas sump, which can touch the sub-engine frame;
- When removing the exhaust pipe, simultaneously move the power unit slightly to the left as the car moves.
Installation
- Installation is carried out in the reverse order of removal.
- Using tool Mot 1289-02, adjust the position of the stroke limiter of the right-hand pendulum engine mount
- Execute
- pouring oil into the gearbox,
- pouring oil into the engine;
- refilling the power steering system,
- filling and removing air from the engine cooling system;
- refilling the air conditioning system.
- Adjust the accelerator cable.
- Tighten the spring-loaded bolts of the clamps securing the exhaust pipe flanges. Tighten the bolts until they stop.
- Press the brake pedal several times. so that the pistons of the brake wheel cylinders come into contact with the brake pads.
Pic. 3.42. Engine/gearbox mounting components: 1 - bracket for the elastic cushion of the front right pendulum suspension; 2 - elastic cushion of the front right pendulum suspension; 3 - bracket for the left pendulum suspension of the gearbox; 4 - jet thrust bracket; 5 - rear engine mount bracket; 6 - jet thrust
Pic. 3.43. Bolt (1) clamp for fastening the exhaust pipe flanges