Removing and installing engine

Recommendations about engine removal

Before proceeding, please read this section.

If the engine is removed for repair, you must choose a place for work, provide space for maintenance and storage of spare parts. Repair is recommended at the service station or in a garage with a flat, level floor and a clean hard surface.

Before removal, clean from dirt and clean the engine and engine compartment. When lifting, use hoist with sufficient capacity to safely lift the engine.

If you remove the engine for the first time, invite an experienced specialist. Some of the work should be performed with an assistant.

All clips and clamps that when removing the engine will be damaged or cut, the assembly of the engine replaced.

Engine extracted forward separately from the gearbox.

Drain coolant must be collected and disposed of.

Before disconnecting the battery, check whether you have the code switch on the radio.

Withdrawal

Switch off the ignition and disconnect a wire of "weight" from the storage battery.

Remove the screws and remove the engine cover (Fig. 3.4.1).

Remove the screws and remove the two sections of the bottom mudguard of the engine compartment (Fig. 3.4.2).

Remove the front bumper.

Remove the air tube 1 (Fig. 3.4.3) and the air filter cover 2.

Disconnect the air tube from the air cooler.

On the left front side of the engine compartment, remove the screw fastening the bracket supporting the air-conditioning duct system.

Disconnect the air pipe cooler air from the suction pipe.

Install the front transverse panel in service position.

Remove the bolt radiator fan with viscous coupling, keeping the axis of rotation of the fan the other wrench (see. Fig. 3.4.15).

Remove the cover of the expansion tank.

Disconnect an electric socket of the electromagnetic clutch of the compressor air conditioning, located near the surge tank, and take him aside.

Remove the left and right casings of a gear belt.

Disconnect an electric socket of the gauge charge air and move it to the side.

Remove the screws and remove the cover V-belt (see. Fig. 3.4.16).

Remove the bolts (Fig. 3.4.4) and remove thermofilter on turbocharger.

Remove the bolts a reception exhaust pipe to the turbocharger (Fig. 3.4.5).

Loosen the hose clamps and remove the front exhaust pipe with catalytic converter.

Disconnect the compensator reactive torque from the front of the engine.

Remove the cap from the V-ribbed belt tensioner compressor.

Loosen the bolt and remove the clip from the belt pulleys (see. Fig. 3.4.17).

Remove the bolts and the air conditioning compressor without disconnecting from it hoses, take the compressor aside and secure the wire to the front suspension. Do not hang the hoses on the compressor!

Allen wrench, turn counterclockwise the main tensioner V-ribbed belt to loosen the tension. Lock the tensioner in this position pin 1 (see. Fig. 3.4.18) and remove the belt.

Hold the V-belt pulley of power steering pump special tool, remove the pulley bolt (Fig. 3.4.6).

Remove the bracket located under the power steering pump.

Remove the screws power steering pump to the bracket and, without disconnecting from it hoses, take the pump aside.

Disconnect air hose 1 (Fig. 3.4.7) of the air filter.

Unplug electrical connector 2 and remove the top section of the air filter inlet pipe.

Remove the generator.

Disconnect the wires from the starter, remove the screws and remove the starter.

Remove the spring clamp 1 (Fig. 3.4.8) and remove the gauge from the cooling hoses.

Remove the drain plug 2 (Fig. 3.4.8).

On the left side of the engine, disconnect the hose 1 (Fig. 3.4.9) of the oil cooler.

Disconnect the coolant hoses 2 and 3 (Fig. 3.4.9).

Loosen the hose clamps and disconnect the hoses from the surge tank.

Remove the screws, disconnect the coolant level sensor, and remove the expansion tank.

Disconnect an electric socket of the gauge needle lift and move it aside.

Disconnect the hose with check valve on the vacuum pump.

Disconnect pipelines of giving and return of fuel from the fuel pump and move them aside.

Disconnect vacuum hose pressure control valve and move it aside.

Loosen the clamps and disconnect coolant hoses going to a heater.

Disconnect the electrical connectors 1-3 (Fig. 3.4.10) and move them aside.

Disconnect the electrical connector 4 (see. Fig. 3.4.10) from the fuel pump and move it to the side.

Disconnect the electrical connector 5 from the coolant temperature sensor and move it to the side.

Disconnect the electrical connectors from the glow and move them aside.

Remove the nuts left and right engine mounts A (Fig. 3.4.11).

Remove the rack from the hood bonnet support. Install the hood vertically and secure it in this position.

Remove the upper bolts transmission to the engine, leaving a top bolt in place.

Hang on a hoist lifting gear in 2024 and secure the clamps on the engine.

Unscrew remaining bolt transmission to the engine.

Check that all electrical wires, hoses, tubes and pipes were disconnected from the engine.

Carefully lift the engine, then release it from the gearbox and pull up from the engine compartment.

Setting

Installation is spent to sequences, return to removal, taking into account the following.

When installing the motor must be replaced all the self-locking nuts and bolts (Fig. 3.4.12), which delayed dovorachivaniem at a certain angle, as well as seals and gaskets.

Before installing the motor secure the sides of the engine compartment, electric wires and hoses to prevent damage to their engines.

When installing, check for centering sleeves A, determining the relative position of the engine and gearbox.

Clean input shaft splines. When reusing the clutch disc to remove a corroded. Lubricate the splines of the shaft with a thin layer of greasing G 000 100.

Check the condition of the clutch release bearing and replace it if necessary.

Using a mandrel, align the clutch disc.

Check the condition of the needle bearing in the end of the crankshaft on the flywheel side. If necessary, replace the bearing.

Mount the motor in place and, shaking it from side to side, ensure the correct location on the supports.

Before wrapping the air conditioning compressor mounting bolts, make sure that the dowel sleeves compressor are in place.

Check the fluid level in the hydraulic power steering.

Check that the exhaust system components are correctly installed on the suspension and do not touch the body when it is swinging.

Fill the cooling system with coolant. In case the cylinder head was removed and replaced with the cylinder block coolant reuse is allowed.

Set the compensator reactive torque and screw it to the engine and the body, tightening the bolts to 45 Nm.

Install poly V-belt air conditioning compressor and adjust its tension.

Torque wrench with hexagon head 6 mm Turn tensioner pulley V-belt air conditioning compressor counterclockwise until 7 Nm. Hold the torque wrench in this position, a second wrench to tighten a bolt of 1 fastening of a roller-ribbed belt 25 N ?� m (see. Fig. 3.4.20).

Before first starting the engine bleed the fuel system, since otherwise it will damage the fuel pump.

Before starting the engine, check the availability and level of oil in the engine.

Check the connection of the electrical connectors.

Attach the wire of "weight" to the battery.

Turn on the radio and enter the code.

Lift up the power window glass until it stops. Then press all the switches window again, at least 1, in the closed position of the control unit to activate windows.

Set the clock.