Removing
Place the car on a two post lift.
Attention! When carrying out this operation, it is necessary to secure the vehicle on a lift using a safety harness to prevent the vehicle from becoming unbalanced.
Remove the engine top covers.
Remove the front wheels.
Remove the left and right fender liner.
Remove the engine undertray.
Drain the gearbox oil.
Drain the engine oil.
Disconnect the battery.
Drain the refrigerant circuit from the filling station.
Remove the side reinforcements of the subframe and the front bumper.
Disconnect the hood latch cable.
Disconnect the washer tubes.
Drain the liquid from the engine cooling system.
Pic. 2.81. Disconnecting the fuel supply line: 1 - fuel line
Disconnect the rail fuel feed line (pic. 2.81).
Disconnect the wire blocks from the electric fan of the engine cooling system.
Disconnect the engine cooling fan wiring harness.
Pic. 2.82. Disconnecting the expansion tank hoses: 1 - hoses; 2 - block of wires of the pressure sensor; 3 - pipelines of the refrigeration circuit; 4 - pipeline of the refrigeration circuit between the air conditioning compressor and the receiver-drier
Disconnect the expansion tank hoses from the engine cooling radiator (pic. 2.82).
Disconnect the wiring harness from the pressure sensor on the lower condenser piping (see fig. 2.82).
Remove the refrigerant lines from the condenser (see fig. 2.82).
Remove the refrigeration piping between the air conditioning compressor and receiver dryer (see fig. 2.82).
Note. Be sure to plug the piping and reducer openings to prevent moisture from entering the system.
Remove the engine system cooler complete with condenser.
Pic. 2.83. Removing the air filter outlet duct: 1 - outlet air duct
Remove the air filter outlet duct (pic. 2.83).
Disconnect the ECU connectors.
Loosen the bolts securing the battery tray.
Remove the battery tray and ECU bracket.
Pic. 2.84. Removing the air filter housing: 1 - filter housing
Remove the air filter housing (pic. 2.84).
Disconnect the relay harness connectors.
Pic. 2.85. Detachment «mass» body tires: 1 - tire
Disconnect «mass» body tire (pic. 2.85).
Pic. 2.86. Disconnecting the suction hose of the vacuum brake booster: 1 - hose
Remove the brake booster vacuum hose (pic. 2.86).
Disconnect the hoses with a gas station (Mot. 1202-01 or Mot. 1202-02 or (Mot. 1448).
Disconnect the wiring harness from the downstream oxygen sensor.
Pic. 2.87. Disconnecting the gear lever cable
Disconnect the cables from the levers on the gearbox by squeezing the tip of the cable at points A, pull the latch in direction B and lift the cables at point C, as shown in Figure 2.87.
Pic. 2.88. Disconnecting shift and gear selection cables: 1 - cables
Disconnect shift and select cables from gearbox (pic. 2.88).
Pic. 2.89. Removing the ball end of the multifunction switch cable and the multifunction switch drive cable: 1 - cable tip; 2 - drive cable
Remove the cable ball end and the multi-function switch cable by releasing the cable sheath stopper (pic. 2.89).
Pic. 2.90. Disconnecting the clutch hydraulic supply line: 1 - latch
Pull the latch and disconnect the clutch hydraulic supply line (pic. 2.90).
Note. Install a plug on the pipeline to prevent fluid from escaping.
Remove the left front wheel drive shaft.
Remove the right front wheel drive shaft.
Remove fastening parts of a reception pipe of system of release of the fulfilled gases.
Remove the lower tie rod and subframe.
Install a hydraulic crane with a hoist or chain.
Mark the position of the engine pendulum mount relative to the body.
Remove the engine mount.
Pic. 2.91. Transmission pendulum support
Remove the transmission swing arm support (pic. 2.91).
Remove the engine/gearbox assembly by turning it.
Installation
Install the engine and gearbox assembly to the vehicle.
Install:
- support of the pendulum suspension of the engine;
- support pendulum suspension gearbox;
- lower jet thrust;
- upper jet thrust;
- drive shaft of the left front wheel;
- right front wheel drive shaft.
Install the remaining components in the reverse order of removal.
Torque tighten:
- bolts of the upper fastening of the front panel of the body (21 Nm);
- bolts of the lower fastening of the front panel of the body (44 Nm);
- front subframe bolt (105 Nm);
- rear subframe bolt (21 Nm);
- wheel bolts (110 Nm).
Add brake fluid to the reservoir.
Bleed air from hydraulic clutch.
Fill the gearbox with oil.
Fill the engine with oil.
Fill the cooling system with fluid.
Charge the refrigeration circuit with refrigerant using a filling station.
Note. Attach the brake hose and ABS speed sensor wires correctly.
Note. Do not kink the brake hose.
Connect the battery.
Remove air from the cooling system.
Torque tighten (4 Nm) battery cover bolts.