Withdrawal procedure:
- install the car on a flyover or lift;
- disconnect the wires from the battery and remove it;
- remove the front wheels and fenders;
- remove the protective cover of the power unit;
- drain the coolant by disconnecting the outlet hose from the radiator;
- drain the oil from the gearbox;
- if the engine is to be dismantled, drain the engine oil and remove the oil filter;
- remove the decorative grille of the radiator lining;
- remove the front bumper;
- unscrew the brake caliper mounting bolts and remove them together with the ABS sensors from the steering knuckles without disconnecting the brake hoses. Tie the calipers to body parts or suspension springs without stressing the brake hoses;
- disconnect the shock absorber struts from the steering knuckles by unscrewing the nuts and removing the bolts;
Pic. 3.1. Removing the heat shield (1), collar (2), connecting the catalytic converter and the front muffler, disconnecting the connector (3) exhaust gas oxygen concentration sensor
- unscrew the bolts under the car and remove the heat shield of the exhaust system (pic. 3.1);
- unscrew and remove the clamp connecting the catalytic converter and the front muffler;
- undock the connectors of the oxygen concentration sensors in the exhaust gases;
- disconnect the gearshift linkage from the gearbox (or selector cable for automatic transmission);
- disconnect tires from gearbox «weight»;
- Disconnect the fastening parts of the catalytic converter from the exhaust manifold and take it away from the intermediate part of the exhaust pipe;
- disconnect the muffler intake pipe from the engine;
- remove the intake air duct from the air filter;
- unscrew the expansion tank mounting bolts and move the tank aside. If necessary, disconnect the hoses from the thermostat housing;
- disconnect the brake booster vacuum hose from the intake manifold;
Pic. 3.2. Bolts of fastening of the case of the air filter
- remove the air filter housing by unscrewing the mounting bolts (pic. 3.2);
Pic. 3.3. Fasteners (arrows) ECU and fuel switch bracket when hitting a car
- remove the electronic control unit bracket (ECU), having previously disconnected from it the contact connector and the bracket of the inertial switch to cut off the fuel supply when the car hits (pic. 3.3);
- disconnect the vacuum hose from the brake booster;
Pic. 3.4. Fastening of heater hoses (arrows) to the motor shield
- disconnect the heater hoses from the engine shield (pic. 3.4), remembering their position, and take them aside. Hoses can be with two types of quick couplings: with an outer ring, which must be turned to the left for removal, or with plastic protrusions, which must be squeezed and removed by pressing the mount in the direction of the motor shield;
Pic. 3.5. Removing the relay block from the engine (1), pads of wires (2), fuse holders (3) and fuse boxes (4)
- disconnect the relay box, wiring block, fuse socket block from the engine and remove the fuse sockets from it (pic. 3.5);
- disconnect the block of wires from the adsorber and the adsorber hose from the intake manifold;
- Disconnect the fuel pedal cable from the throttle body;
- disconnect the clutch cable if a manual transmission is installed;
- on a car with an automatic transmission, disconnect the selector lever cable;
- remove the power steering reservoir from the bracket and place it on the engine;
Pic. 3.6. Removing the electric fan assembly from the radiator
- remove the upper radiator mounts from the cross member of the engine compartment and tie the radiator to the engine so as not to damage it. If necessary, remove the electric fan assembly from the rear of the radiator (pic. 3.6). Please note that the lower radiator supports are mounted on a subframe, which is removed with the radiator;
- disconnect the pipelines from the fuel distribution rail and plug their openings;
- on models with air conditioning, remove the compressor from the engine without disconnecting the pipelines, and fix the compressor away from the working area;
- dismantle the air conditioner condenser and fix it aside without disconnecting the pipelines from it;
- set the front wheels in a straight-ahead position, bend the protective rubber cuff on the bottom of the steering column, unscrew the nut and remove the eccentric bolt of the steering shaft universal joint yoke;
Attention! To prevent the airbag from deploying, be sure to lock the steering wheel in the straight-ahead position before disconnecting the steering shaft from the steering mechanism.
Pic. 3.7. Fitting tool Mot. 1159 between subframe and cylinder block: 1 - coupler
- fit on the right side of the engine tool Mot. 1159 between subframe and cylinder block (pic. 3.7). In the absence of a device, wedge the power unit and subframe using wooden blocks, unscrew the fastening of the coupler and remove it;
Pic. 3.8. Installing a spacer between the multifunction bracket and the subframe
- install a spacer of wood between the multifunctional bracket and the subframe (pic. 3.8);
- insert a wood gasket between the gearbox and subframe;
Pic. 3.9. Removal of the top casing of a support of a pendulum suspension bracket of the engine
- remove the upper cover of the engine swing arm support (pic. 3.9);
Pic. 3.10. Loosen the nut (arrow) on the pendulum suspension of the engine
- remove the nut on the pendulum suspension of the engine, then use a bronze drift to knock out the stud of the support (pic. 3.10);
- hang the engine with a hoist;
- dismantle the left engine mount;
Pic. 3.11. Removing the subframe reinforcement (arrow)
- disconnect the subframe reinforcements and remove them (pic. 3.11);
- loosen the subframe-to-body bolts one or two turns. Don't turn them all the way out;
- lower the front of the car so that the subframe with the power unit can be laid on the substituted wooden blocks;
- remove the subframe mounting bolts. Together with an assistant, carefully lift the front of the car, making sure that the parts, components and wiring associated with it are disconnected from the engine;
- if possible, move the car back to free up working space;
- lift the engine with a hoist to unscrew the bolts securing it to the subframe. Disconnect the front wheel drive shafts from the gearbox and remove the power unit from under the car;
- if it is necessary to disconnect the engine and gearbox, remember the location of the wires connected to the power unit.
Note. Before carrying out work that requires disconnecting the engine, gearbox and subframe, mark the position of tool Mot. 1159 on a stretcher.
Installation of the power unit is carried out in the reverse order of removal.
To help align the subframe with the body, install two threaded rods into the front mounting holes of the subframe. Tighten the front bolts of the subframe with a torque of 62 Nm, the rear bolts with a torque of 105 Nm.
Install the heat shields correctly. Apply Loctite Frenblok to the threads of the front brake caliper bolts and tighten to the specified torque. Press the brake pedal several times to set the pistons of the wheel cylinders to the working position.
Do the following:
- refueling engine and gearbox oil (if necessary);
- filling the cooling system and removing air from it.