1. Cylinder head mounting support. 2. Engine with gearbox assembly. 3. Front spar. 4. Front subframe of the car. 5. Rear engine mount. 6. Jet thrust of the engine. 7. Gear tube support. 8. Front spar.
Attention:
- Use protective gloves during work.
- To avoid refrigerant leaks from the air conditioning system, be careful not to damage the piping (do not deform, twist, etc.). To prevent the penetration of atmospheric moisture into the air conditioning system, it is necessary to plug all openings of the refrigerant circuit in time.
Removing the power unit
Attention: To prevent the car from falling off the lift, tie it to the lift with safety straps.
1. Place the vehicle on a two post lift.
2. Remove the battery.
3. Remove the front wheels from the car.
4. Unscrew the fastening bolts and remove the engine protective tray.
5. Remove the front bumper from the car.
6. Remove the front fenders.
7. Drain the engine oil from the engine.
8. Drain the gear oil from the gearbox.
9. Drain the liquid from the cooling system
10. Disconnect connector (1) from the diesel filter.
11. Unhook the wiring from the bracket (2).
12. Disconnect connector (3) air conditioning pressure sensor.
13. Remove the air intake and air filter unit.
14. Loosen the ground nut (4).
15. Unhook the wire from the holder (5).
16.Disconnect connectors (6) from the injection control unit.
17. Remove the cover of the relay and fuse box.
18.Remove the side protection (7) relay and fuse box.
19. Unhook the relay and fuse board (9) from the support in the relay and fuse box in the engine compartment.
20. Loosen the bolt (10) mass tires from car body.
21. Disconnect connectors (11) pump.
22.Unhook the pump wiring from the holders (12).
23. Place wiring, fuses and relays on the engine.
24. Disconnect fuel return line connection (13) high pressure fuel pump from fuel pump protection.
25. Loosen the bolt (14) protection of the high pressure fuel pump.
26. Remove the protection of the high pressure fuel pump.
27. Unhook the fuel supply line from the cover of the right engine mount.
28. Disconnect the fuel supply line from the high pressure fuel pump (15).
29. Fit suitable plugs to the open holes of the fuel supply line and high pressure fuel pump.
30.Unhook the fuel return line from the right engine mount cover.
31. Install suitable plugs on the disconnected fuel return line and high pressure fuel pump return port opening.
32.Unhook the fuel lines from the holders (19).
33.Remove the low pressure hose of the power steering pump using hose clamp pliers (Mot. 1448) and drain the hydraulic fluid from the power steering hydraulic circuit.
34.Remove the high pressure pipe from the power steering pump.
35.Install the plugs on the opened holes.
36. Disconnect connector (23) pre-post heating systems
37. Disconnect connectors (24) cooling fan drive.
38. Unhook the fan wiring from the holders (25).
39. Loosen the bolt (29) ground tires from the gearbox.
40. Remove the outlet and inlet pipes of the intercooler (intercooler).
41. Remove the intercooler (intercooler).
42. Loosen the bolts (30) piping connections to the compressor.
43.Disconnect the compressor lines and plug the holes immediately.
Note: Cap hoses to prevent atmospheric moisture from entering the air conditioning system.
44. Disconnect the vacuum line (31) from the vacuum pump.
45. Disconnect the hose clamps of the cooling system (32) from the heater core using hose clamp pliers (Mot. 1448).
46. Disconnect the cooling system hoses from the heater core.
47. Remove the cooling system hoses from the holders.
48. Disconnect the top hose from the cooling chamber.
49.Disconnect the water pump inlet hose.
50.Unscrew the mounting bolts and remove the heat shield on the steering gear.
51. Loosen the bolts securing the steering gear to the subframe and tie the steering gear to the vehicle body.
52.Remove the right and left front drive shafts.
53.Unhook the shift control cables from the gearbox using a screwdriver (35).
54. Squeezing the latches (A), unhook the shift control cables from the thrust bushing holders.
55. Remove the shift control cables from the gearbox.
56.Disconnect the clutch lines from the clutch master cylinder.
57. Collect escaping brake fluid in a suitable container.
58.Clog the open openings of the pipelines with plugs.
59. Remove jet thrust engine:
- Loosen the bolt securing the engine tie rod to the subframe.
- Loosen the bolt securing the engine tie rod to the support.
- Remove the engine tie rod.
- Loosen the engine tie rod mounting bolts and remove it.
60.Remove the front subframe from the vehicle.
61. Loosen the exhaust flange nuts.
62.Move exhaust pipe to one side.
63.Place the stand for removing/installing the engine/gearbox assembly (Mot. 1390) under the engine with gearbox.
Note: Make sure the engine/gearbox assembly stands (Mot. 1390) correctly located under the power unit.
64.Remove the right engine mount:
- Disconnect fuel line connectors (7) and unhook the fuel lines (8).
- Move the expansion tank of the cooling system to the side.
- Install a traverse for hanging the engine with multiple adjustments and rigging (Mot. 1453), by attaching the engine lifting eye on the timing drive side.
Note:
- Some vehicles are not equipped with engine lugs on the timing drive side.
- Lifting eyes can be purchased separately by ordering from the spare parts catalogue.
- Always use only new bolts to fasten lifting eyes.
- Mark the position of the right engine mount on the body.
- Loosen the bolts securing the right mounting support to the engine.
- Loosen the bolts securing the right engine mount to the body.
- Remove the right engine mount.
65.Remove the nut on the left motor mount:
- Loosen the nuts (5) and bolt (6) and remove the air filter shelf (7).
- Mark the position of the left engine mount on the body.
- Loosen the nuts and bolts securing the mounting bracket to the gearbox.
- Loosen the bolts securing the left mounting support to the body and remove the left mounting support.
66. Using a copper hammer, drive in the gearbox stud to disconnect the engine with gearbox assembly from the car body.
67. Raise the car with a hoist to remove the engine with gearbox from the car.
Note: Make sure that the engine and gearbox do not catch on the body.
68. Remove the support stand with the power unit (engine and gearbox assembly) from under the car.