1. Cylinder head mounting support. 2. Front side spar. 3. Engine with gearbox assembly. 4. Front side spar. 5. Gearbox support. 6. Jet thrust of the engine. 7. Rear elastic engine mount.
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
1. Place the vehicle on a two post lift.
2. Remove the battery from the shelf.
3. Remove the engine air filter assembly.
4. Remove the front wheels from the vehicle.
5. Remove the front fenders.
6. Remove the engine protection tray.
7. Remove the front bumper.
8. Using a special station, drain the refrigerant from the air conditioning circuit.
9. Drain the coolant from the cooling system.
10. Drain the gear oil from the gearbox.
11. If necessary, drain the engine oil from the engine.
12. Remove the catalytic converter bolts.
13. Remove the catalytic converter pipe coupling clamp.
14. Remove the lower engine mount:
- Remove the lower tie rod bolt from the subframe.
- Loosen the lower tie rod bolt from the support.
- Remove the lower engine tie rod.
- Loosen the mounting bolts and remove the lower engine mount.
15. Remove the front right drive shaft (see chapter "Drive shafts and final drive").
16. Remove the front left drive shaft (see chapter "Drive shafts and final drive").
17. Tie the cooling system radiator to the front body panel with safety straps.
18. Remove the front subframe from the car (see chapter "Suspension").
19. Using Hose Clamp Pliers (Mot. 1448) remove the following clamps:
- inlet pipe of the radiator from the water chamber;
- heater outlet pipe from the heater core;
- inlet pipe of the heater from the heater core;
- water pump inlet hose from the inlet pipe
- water pump.
20. Disconnect:
- radiator inlet pipe from the water chamber;
- heater outlet pipe from the heater core;
- heater inlet pipe from the heater core;
- water pump inlet hose from the water pump inlet.
21. Unhook:
- shift control cables (1) from the ball joints of the selector using an open-end wrench;
- shift control cables (2) from their supports.
22. Remove shift control cables from manual transmission.
23. Loosen the bolts of the refrigerant connecting pipes "compressor-condenser" And "intermediate pipe-compressor" from the compressor.
24. Remove the refrigerant connecting pipes "compressor-condenser" And "intermediate pipe-compressor" from the compressor.
25.3 plug the openings of the pipelines and the refrigerant compressor with plugs.
26. Disconnect the brake booster vacuum hose (6), fuel vapor pipeline (5) and pressure fuel line from the fuel rail.
27. Close the holes formed with plugs.
28.Remove the clip (7) hydraulic clutch release pipeline.
29. Disconnect the hydraulic clutch release pipe from the clutch release cylinder and plug the holes with plugs.
30.Unhook the pipeline of the hydraulic clutch release from the holders (8).
31. Remove the hydraulic clutch release pipeline to the side.
Note: Before removing the earth cable, mark its position with a marker or felt-tip pen by circling the cable terminal on the gearbox housing. Incorrect location of the earth cable on the gearbox during assembly may cause further damage to the terminal or earth cable.
32. Loosen the bolt (9) ground cable from the gearbox.
33. Remove the ground cable from the gearbox housing.
34. Unscrew the mass nut from the left side body side member.
35. Disconnect the injection control unit connectors (10).
36.Remove the cover from the engine compartment junction block (11).
37. Unhook the front section (12) from the junction block in the engine compartment.
38. Loosen the nut (13) and unhook the fuse holder (14), then unplug the connector (15).
39.Disconnect from radiator fan:
- radiator fan connector (16);
- resistor connectors (17).
40. Disconnect the radiator fan wiring.
41. Disconnect the pressure sensor connector in the refrigerant circuit.
42.Disconnect connector (21) fuel vapor absorber solenoid valve.
43. Unhook the wiring and put it aside.
44. Disconnect the downstream oxygen sensor connector and set the wires aside.
45. Support the power unit (engine with gearbox assembly) at the points indicated in the figure (22) with engine/gearbox support stand (Mot. 1390).
Note: Mark the position of the engine mounts on the body.
46.Remove the right engine mount:
- Unhook the fuel line (3) and electrical wire (4).
- Set aside the expansion tank of the cooling system.
- 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.
47. Remove left engine mount:
- Loosen the nut (1).
- Move support (2) to the side.
- Loosen the nuts (3) and remove supports (4)
- Mark the position of the left engine mount on the body.
- Loosen the gearbox support nuts from the rubber cushion.
- Loosen the left mounting bracket bolts from the gearbox.
- Remove the left mounting support from the gearbox.
- Loosen the mounting bolts and remove the left mounting support pad from the body.
48. Raise the car with a lift.
49. Remove the support stand with the power unit (engine and gearbox assembly) from under the car.
Installation
Attention:
- Be sure to replace the new gasket between the catalytic converter and the downpipe.
- To prevent leakage, make sure that the gasket and contact surfaces of the nozzles are in good condition. Contact surfaces must be clean and free from scratches.
- Plugs should be removed from any component openings immediately prior to component installation. In addition, new parts must also be removed from the packaging just before installation
Installation is carried out in the reverse order of removal, observing the required tightening torques.
Bleed hydraulic clutch.
Fill the engine cooling system and remove air from it.
Fill the gearbox with oil.
Using a special station, fill the air conditioning system.
If necessary, add engine oil to the engine.
Tightening torques for threaded connections
Threaded connections | Torque |
Gearbox ground cable bolt | 44 Nm |
Nut of fastening of a cable of weight to a body | 8 Nm |
Bolts of fastening of the left mounting support | 62 Nm |
Nuts of fastening of the left mounting support | 105 Nm |
Bolts of fastening of the right mounting support | 62 Nm |
Rear mount and engine tie rod bolts | 105 Nm |