Required special tool
- Mot. 1040-01 Trolley for removal and installation of the power unit.
- Mot 1159 Tool for fixing the engine to the subframe.
- Mot. 1202, Mot. 1448 Pliers for flexible clamps.
- Mot. 1311-06 Tool for removing fuel lines.
Tightening torques Nm
- Subframe front mounting bolts: 62.
- Rear subframe bolts: 105.
- Bolts for fastening to the engines of the upper bracket of the front right support of the engine pendulum suspension: 62.
- Nut of fastening of the upper bracket of the front right support of the suspended engine suspension: 44
- Support pad mounting nut on the front left side member bracket: 62.
- Bolts of fastening of a shock-absorber rack of a clip connection: 180.
- Floating caliper bolt: 40
- Steering shaft universal joint yoke bolt: 30.
- Wheel bolts: 90
Removing
1. Place the vehicle on a two post lift.
2. Remove the battery.
3. Drain:
- coolant from the cooling system by disconnecting the outlet hose from the radiator;
- gearbox and engine oil (if necessary).
4. Remove:
- engine hood;
- front wheels;
- connecting rod between the subframe and the body;
- fastening bolts 1, turn the floating brake calipers and fix them on the suspension springs (pic. 3.2).
5. Remove:
- bolts for fastening the shock absorber struts to the steering knuckles;
- the heat-reflecting shield of the exhaust system, as well as the gearshift linkage by disconnecting it from the gear selector and gearshift lever.
6. Remove:
- clamp for fastening the exhaust pipe of the system between the catalytic converter and the front muffler;
- mass bus on the gearbox;
- front bumper;
- air intake pipe of the air filter;
- bracket for the injection computer, having previously disconnected the 55-pin connector and the inertia switch connector.
7. Disconnect:
- fasteners and hoses from the thermostat bracket;
- hoses from the expansion tank;
- hose from the vacuum brake booster;
- heater radiator hoses (with plastic (pic. 3.5a) or metal (3.5b) nozzles).
8. Disconnect:
- relay block 4, connector 5, as well as fuse block 6, while removing the fuse links 7.
9. Remove:
- absorber tube;
- fuel supply and return pipes with Mot. 1311-06 by removing the engine top cover;
- throttle and clutch release cables.
10. Release the power steering reservoir from the latches and place it on the engine.
11. Remove:
- details of the upper mounting of the radiator and fix the radiator to the engine;
- nut and eccentric bolt of the terminal connection of the universal joint yoke of the steering shaft, having previously displaced the protective cover.
Attention! Features of vehicles equipped with a driver's airbag.
To prevent damage to the slip ring under the steering wheel, the following rules must be observed:
- before disconnecting the steering column and the steering mechanism, the steering wheel should be locked in the straight ahead position with a special device, and the steering wheel should remain locked during the entire time of work;
- if in doubt about the correct centering of the contact plate, remove the steering wheel and center it.
12. Install tool Mot. 1159 between subframe and cylinder block.
13. Install retaining bar Mot. 1159 in place of the coolant hose on the cylinder block.
14. Remove the upper arm of the pendulum engine mount.
15. Install a wedge between the gearbox and subframe.
16. Remove nut 1, then use a bronze drift to knock out the pin of the pendulum suspension.
17. Remove the mounting bolts.
18. Install cart 1040-001 from below the subframe.
19. Lower the axle until the cart wheels are in contact with the floor.
20. Remove the subframe mounting bolts and remove the power unit by lifting the body up.
Note. If for the performance of work it is required to separate from each other the parts of the power unit, which consists of the engine, gearbox and subframe, then it follows. tag position fit» Mot. 1159 on a stretcher.
Installation
1. Alignment of the subframe with the body is made easier by inserting two threaded tools Mot. 1233-01 front subframe mounting holes.
2. Tighten the subframe mounting bolts to 62 Nm at the front and 105 Nm at the rear.
Pic. 3.14
3. Install in the reverse order of removal.
4. Install the heat shields correctly.
5. Install the floating caliper mounting bolts, lubricating them with Loctite FRENBLOC sealant, and tighten them to the prescribed torque.
6. Press the brake pedal several times to set the brake pistons to the working position.
7. Do:
- refueling gearbox and engine oil (if necessary);
- filling with coolant and removing air from the cooling system (see chapter «Maintenance»).
Installing the engine on the base plate
Attachment pins Mot. 1132 (Q, S, R) are fixed on the cylinder block so that they fit into the holes (12, 27 and 7) plates.