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Removing and installing engine
The engine is removed from the vehicle with the transmission from the engine compartment up. This requires special lifting yoke, since lifted the hood to remove the engine using a crane is not possible. For operations below the car will also require a 4-post lifts or pit. Depending on the date of manufacture and assembly of the engine wiring harnesses, fuel lines, vacuum hoses and water hoses in the engine compartment have different wiring. Because in this manual can not be considered in detail all the options kits, offer details of the recorded mark paint or tags, to avoid any problems during installation.
4-cylinder in-line engine
NOTE The order of operations for removing and installing the 6-cylinder engine similar to the above for the 4-cylinder. |
Withdrawal 1. Set the hood in a vertical position, which open the hood, press it and hold in this position. Press the locking lever with the inscription ?�PRESS?� near the right hinge and release the hood. Gas-filled shock absorbers will lead him to the upright position. 2. Remove the cover from the bottom of the engine compartment. For models with the release of 06.1996 06.1995 of air-conditioned: 3. Remove the viscous clutch fan cooling system. It should take into account that the mountings have a left-hand thread. For all models: 4. Drain the coolant and remove the radiator.
A WARNING On vehicles equipped with air conditioning, it is necessary to protect the radiator after removing the condenser plate 400 x 680 x 1 mm, which can be made independently from the tin and secure mounting brackets. |
5. Unplug the connector from the air mass meter. 6. Remove the cross tube with the top cover of the air filter and air mass meter. 7. Disconnect the negative battery terminal.
A WARNING At the same time the memory of electronic devices are erased code anti-theft system, radio, radio. Subsequently, they should be restored. |
8. Remove the control unit. 9. Remove the pin control unit, lifting clamps up. 10. Disconnect protection against voltage spikes occur. 11. Disconnect the wires from the generator. 12. Remove the pin oxygen concentration sensor. 13. Disconnect the tire of "weight" from the engine. For vehicles with automatic transmission (automatic transmission): 14. Remove the pin in the engine compartment front left. This should unscrew the mounting and lift the tank with a liquid for washing of glasses. For all models: 15. Remove the wire outside the body is connected to the contact "30", located in the footwell of the driver.
| Fig. 5.10. The wire that connects the engine to the body: 1 - Wire
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16. Remove the mounting wire 1 (Fig. 5.10), the "masses", which connects the body with the engine. For models with air conditioning: 17. Unplug the connector from the compressor. For all models: 18. If the transmission is disconnected from the engine, remove the starter. 19. Remove the vacuum hose from the valve of the absorber. 20. Remove the thrust of the accelerator. 21. Open for a short time the fuel tank cap to relieve excess pressure of the fuel vapor.
A WARNING Because of the danger of fire, do not use open fire, hot objects, do not smoke. Gasoline vapors are poisonous, so ensure good ventilation of your workplace. Wear protective glasses as the fuel system is under pressure. When disconnecting its components may be ejected fuel. |
22. Mark the fuel lines using labels or adhesive tape and disconnect them, after silencing the hole and pinching the hose clamps against leaking fuel. The flowed out fuel, remove the cloth. 23. Disconnect the vacuum pipes from the intake manifold by unscrewing the union nuts.
| Fig. 5.11. Removing the hydraulic fluid from the power steering reservoir: 1 - Syringe
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24. Pump with a syringe 1 hydraulic fluid from the power steering reservoir (Fig. 5.11), and then disconnect the hoses drowning holes technological stoppers.
| Fig. 5.12. Disconnecting the power steering hoses: 1 - a returnable hose; 2 and 3 - high pressure hose; 4 - the suction oil line
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25. Disconnect the return hose 1 (Fig. 5.12) and the high pressure hose 2 from the power steering pump. For vehicles with leveling: 26. Disconnect the optional high-pressure hose 3 and the suction oil line 4, after loosen clamps and sliding them. For all models: 27. Disconnect the coolant hoses from the cylinder head and the back of the coolant pump, before it loosen the clamps and slide them.
A WARNING Do not open the refrigerant circuit - hit the refrigerant to the skin can cause local freezing. |
For models with air conditioning:
| Fig. 5.13. Removing mounting air conditioning compressor 1 - compressor
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28. Remove the bolts (Fig. 5.13, arrow) of fastening of the compressor 1, and then, without disconnecting the hoses and hang it to the body with wire. For all models: 29. Drain the coolant from the cylinder into a suitable container by removing the drain plug. After draining plug wrap. 30. Disconnect the gearbox control rods.
| Fig. 5.14. Removing the pipe from the slave cylinder clutch
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31. Disconnect the pipe from the clutch slave cylinder (Fig. 5.14). 32. Remove the exhaust system.
| Fig. 5.15. Rear cross beam of the power unit 1 - a beam; 2, 3 - Bolts
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34. Remove the rear crossmember 1 (Fig. 5.15) of the power unit with the support. 35. Remove the bolts from the engine mounts to the body and the front suspension crossmember. 36. If the transmission is disconnected from the engine, remove the bottom bolts of fastening of a transmission to the engine. 37. Hook the sling lifting mechanism for the eyes of the engine and lift the power unit so that the cables taut. 38. Remove the upper bolts of a transmission to the engine.
| Fig. 5.16. The rise of the power unit
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39. Press via the engine mount from the gearbox and lift up. Provide an inclined position of the power unit at an angle of 45 ?� (Fig. 5.16).
A WARNING With the rise of the power unit, take care not to damage the car body. Pay particular attention to the back of the eyelet and the oil filter. |
40. Remove the engine from the vehicle, remove the gearbox.
Check technical details Condition Make sure that the rubber mounts on the power unit, coolant hoses, pipes for cracks and breaks. A ball bearing disposed on the crankshaft must rotate easily and without jamming. Make sure that the clutch rotates easily and is not jamming in the axial movement. Check the thickness of the friction linings clutch disc. Setting 41. Connect the gearbox to the engine if it has been removed. 42. Install the power unit in the engine compartment from the top, making sure that when lowering were not damaged parts of the power unit and the body. 43. Connect the gearbox with an intermediate flange motor wrapped bolts moments: M10 x 40-55 Nm M10 x 45-55 Nm M10 x 90-45 Nm. 45. Install the bolts of the front support of the power unit and tighten them by hand. 46. Tighten the bolts back support of the following: on engines series 111 and 104 - 25 Nm; the engine 112 series - 30 Nm; - 3 screws securing the rear crossmember to the body - 40 Nm; - Bolts and nuts to the back support of transmission - 40 Nm; 47. Tighten bolts of a forward support the following points: - The bolts to the beam front suspension: on engines of series 111 and 104 - 55 N ?� m; the engine 112 series - 35 Nm; - The bolts to the engine block: on engines series 111 and 104 - 25 Nm; the engine 112 series - 20 Nm; - The heat shield bolt - 10 Nm; 49. Install starter (if the engine is removed without gearbox). 50. Connect the motor wire "mass" coming from the body. 51. Connect the gearbox control mechanism. 52. Connect the clutch slave cylinder with the pipe, then remove the air from the clutch. 53. Set the details of the exhaust system. For models with air conditioning: 54. Install the compressor 1 (see. Fig. 5.13) by tightening bolts to 25 Nm and remove the protective plate of the capacitor. For all models: 55. Install the accessory drive belt. 56. Install the heat sink. 57. Install the coolant hoses and secure them with clamps. For models with the release of 06.1996 06.1995 of air-conditioned: 58. Install the viscous clutch fan cooling system. It should take into account that the mountings have a left-hand thread. For all models: 59. Install the bottom panel of the engine compartment. 60. Lower the car. 61. Attach the return hose 1 (see. Fig. 5.12) and the high pressure hose 2 to the power steering pump mechanism. For vehicles with leveling: 62. In addition to the previous operation - connect the hose 3 high pressure and suction oil line 4. For all models: 63. Connect the fuel lines. 65. Replace the cover of the box of the control unit. For models with automatic transmission: 66. Attach the tubing to the valve block. For all models: 67. Attach the vacuum hose to the valve of the absorber. 68. Install the cross tube of the air filter, the air flow sensor and the upper part of the air filter. 69. Connect the connector to the air flow sensor. 70. Check brake fluid level in the tank, if necessary, make up the volume to its rules and bleed the brake system. 71. Fill the hydraulic fluid in the power steering reservoir and remove air from the system. 72. Fill the coolant in the coolant expansion tank. 73. Check the oil level in the engine and gearbox, if necessary, to make up its volume. 74. Connect the wire to the negative terminal of the battery. 75. Start up the engine and warm it up to operating temperature, check the coolant level in the cooling system, as well as the tightness of hose connections. 76. Close the hood by pressing the lever near the right hinge of the hood. 77. Set the clock. 78. Enter the code anti-theft system and radio. 79. Consider the possible engine fault codes and eliminate these faults.
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