 printable version
Removal and installation of the power unit
The power unit consists of an engine, clutch and gearbox. Shoot it using the hydraulic lift or hoist, dropping out of the engine compartment on the truck. When this tip shaft drives the front wheels are disconnected from the power unit and remain in the car.
Removal of the power unit: Methods and Safety If the decision to lift the engine for overhaul or repair of the basic knots it is necessary to spend certain preparatory measures. It is important to determine the place where the work will be carried out. Undoubtedly, the best place for this - the studio. It is important to have the equipped working platform, and also a place for car storage. If neither a workshop, nor the garage is not present, the equal smooth concrete or asphalt platform. Flushing the engine compartment and the engine before removing allow to keep the tool clean and a constant working condition. Also you need a lift or hoist. Make sure that these devices have a stock on load-carrying capacity and are capable to lift the engine with all ancillaries. Observance of security measures plays a paramount role, as lifting of the engine from the car - a potentially dangerous operation. If you work for the removal of the engine are carried out by inexperienced person, you need an assistant. Consult and ask for help from anyone who has experience of such work. There are many ways of working to lift the engine from the engine compartment which exclude their performance alone. In advance plan the actions. Obtain all the necessary tools and equipment before you start work. To some adaptations providing safety when removing and installing the engine, as well as reducing labor costs include (besides the lift) the strong supports, a full set of keys and mandrels, wooden shoes, rags and solvent for cleaning of inevitable pools from the spilled fluids. If you plan to take the lift hire, then arrange in advance and do all the work for which this mechanism is not required. This will save money and time. Keep in mind that, perhaps for a long time, you can not use the car. For some works inaccessible in the "home" conditions (due to the lack of special equipment) will have to seek the services of a service station or a specialized workshop. These companies are working on the plan, so it is advisable to consult it before the removal of the engine, to accurately estimate the time required for the repair and restoration of components. When removing the engine always be very careful. Rash actions and haste can cause serious injury. In advance consider the actions. Do not spare the time for it, because the main thing - is to work injury-free.
Cars with engine capacity of 1.1 liters and 1.3 Removal and installation of the power unit
NOTE When removing the power unit follow the correct installation of jacks and stands, as well as the correct strapping the engine. |
A WARNING Take measures to prevent slipping and falling from the vehicle stands during the work under the vehicle. |
Open the hood, disconnect the wires from the battery and remove it. Remove the windscreen wiper arms, together with the brushes. Uncover the air intake of the ventilation system of the car. Remove the wiper motor assembly with rods. Remove the lower guard. Disconnect the electrical harness connectors electronic control system of the engine and an electric socket lamps reversing light. On cars with a manual five-speed gearbox, remove clutch slave cylinder. Disconnect the electrical connectors sensor oxygen concentration sensor and the oil pressure warning lamp. Disconnect the electrical connectors rear oxygen concentration sensor and ignition coils. Disconnect the electrical connectors coolant temperature sensor and TDC of first cylinder. Disconnect the motor bridge (bus) connection with "weight" of the body. Disconnect the hose from the vacuum nozzle selection on the housing of the vacuum brake booster. Disconnect from the engine inlet and drain the fuel supply system. Disconnect hoses from the engine crankcase ventilation system.
NOTE Before disconnecting the fuel pre-release pressure in the fuel system of the engine. |
Drain the cooling system. Disconnect hoses from the oil cooler automatic transmission (if the car has an automatic transmission) (only for vehicles with engine capacity of 1.3 liters).
NOTES Before disconnecting the hoses put on their labels not to mix them at installation sites. Make sure that the hoses are not detachable from the liquid and poured oil. Stop the holes to protect against contamination. |
Disconnect from the engine inlet and outlet radiator hoses, then remove the heat sink assembly with hoses. Disconnect the heater hoses from the engine compartment (inlet and outlet). Disconnect the cable from the engine throttle control. On vehicles with manual transmission disconnect a cable of a drive gear. On vehicles with automatic transmission disconnect a cable of a drive control of the gearbox (only for vehicles with engine capacity of 1.3 liters). Disconnect from a transmission flexible shaft drive speedometer. Unscrew the air conditioning compressor and remove it from the mounting bracket. Remove the dust cover of the steering mechanism, remove the screw terminal connections steering shaft and remove the steering.
NOTE Pre-apply labels of mutual position of terminal connections and pinion steering mechanism. |
Extend the jack and remove the wheel. Remove the brake from the knuckle and hang it on the wire hooks to the front suspension. Unscrewing the bolts, remove the rack from the suspension knuckle. Remove the knuckle the wheel speed sensor (in the presence of anti-lock brakes). Disconnect the front exhaust pipe from the exhaust manifold.
NOTE At the time of the works hang the front exhaust pipe on the hook of the solid wire to the body. |
Suspend the engine by chains or ropes. With a little lift hoist power unit (to a height that allows to perform further operations). Unscrew the mounting bracket to the engine. Slowly lift the power unit (to relieve the load on the suspension brackets) and temporarily leave it in this position.
NOTE Making sure that the engine and disconnect the cables, hoses, wires, electrical connectors, etc. |
Remove the plug located on the right fender liner, and remove the mounting bracket bolts of the gearbox. Remove the bolts and the nuts cross. Remove the power unit from the engine compartment by tilting it down transmission. The installation of the power unit spend in reverse order of removal. After joining the throttle, adjust it as described in the "Power supply system."
Cars with engine capacity of 1.5 liters and 1.6 Removal of the power unit
NOTE When removing the power unit follow the correct installation of jacks and stands, as well as the correct strapping the engine. |
A WARNING Take measures to prevent slipping and falling from the vehicle stands during the work under the vehicle. |
Open the hood, disconnect the wires from the battery and remove it. Remove the windscreen wiper arms, together with the brushes. Uncover the air intake of the ventilation system of the car. Remove the wiper motor assembly with rods. Remove the lower guard. Disconnect the electrical harness connectors electronic engine management system. Disconnect the electrical connector and the generator oil pressure in the lubrication system of the engine. Disconnect the hose from the vacuum nozzle selection on the housing of the vacuum brake booster. Disconnect from the engine inlet and drain the fuel supply system. Disconnect hoses from the engine crankcase ventilation system. Disconnect hoses from the oil cooler automatic transmission (if the car has an automatic gearbox).
NOTES Before disconnecting the hoses put on their labels not to mix them at installation sites. Make sure that the hoses are not detachable from the liquid and poured oil. Stop the holes to protect against contamination. |
Drain the cooling system. Disconnect from the engine inlet and outlet radiator hoses, then remove the heat sink assembly with hoses. Disconnect the motor bridge (bus) connection with "weight" of the body. Disconnect the heater hoses from the engine compartment (inlet and outlet). Disconnect the cable from the engine throttle control. On vehicles with automatic transmission disconnect a cable of a drive control of the transmission. Disconnect the electrical connector switch and solenoid valve fuel cut. Unscrew the air conditioning compressor and remove it from the mounting bracket. Raise the vehicle. Disconnect the front exhaust pipe from the exhaust manifold.
NOTE At the time of the works hang the front exhaust pipe on the hook of the solid wire to the body. |
Remove the knuckle from the strut front suspension. Remove the brake from the knuckle and hang it on the wire hooks to the front suspension. Remove the knuckle the wheel speed sensor (in the presence of anti-lock brakes). Suspend the engine by chains or ropes. With a little lift hoist power unit (to a height that allows to perform subsequent operations). Remove the screw terminal connections of a steering shaft. Unscrew the mounting bracket to the engine. Slowly lift the power unit (to relieve the load on the suspension brackets) and temporarily leave it in this position.
NOTE Making sure that the engine and disconnect the cables, hoses, wires, electrical connectors, etc. |
Remove the plug located on the right fender liner, and remove the mounting bracket bolts of the gearbox. Remove the bolts and the nuts cross. Remove the power unit from the engine compartment by tilting it down transmission. The installation of the power unit spend in reverse order of removal. After joining the throttle, adjust it as described in the "Power supply system."
| 
