Contents: Removal ↡ Installation ↡
Removal
Note: This operation requires a suitable hoist and winch. You will also need a new oil pan gasket and a new subpan gasket if applicable. You will also need new front suspension to crossmember bolts.
1. Disconnect the negative battery terminal.
2. If necessary, remove the lower engine guard in accordance with chapter 11.
3. Remove the front stabilizer bar as described in chapter 10. Note that the stabilizer bar can be left in place under the car, if you provide conditions for unscrewing the mounting bolts. Note that the stabilizer bar should be on the left when viewed from underneath the car, its removal should ensure unhindered removal of the support bolts.
4. Disconnect the steering rod on the left side and the steering damper on the right side, in accordance with chapter 10.
5. Drain the engine oil as described in chapter 1B.
6. If necessary, remove the engine travel limiter in accordance with paragraph 16.
7. Where provided, unscrew the two bolts securing the engine shock absorber on the left side of the vehicle.
8. Unfasten the fan shroud and place it on top of the fan blades as described in chapter 3.
9. Disconnect the starter ground bus from the body and, where provided, unscrew the engine speed sensor.
10. If necessary, disconnect the wire from the engine oil level sensor.
11. Disconnect the oil cooler hoses from the hard tubes. Plug or clamp the open ends of the hoses and plug the tubes to prevent dirt from getting into them.
12. Attach the slings to the special rigging brackets at the front of the engine.
13. Unscrew the bolts of the left and right engine mounts from the crossmember, in accordance with paragraph 16.
14. Carefully raise the engine as far as possible until the rear of the cylinder head touches the bulkhead. Be careful not to damage any parts in the engine compartment.
15. Remove the front suspension coil spring as described in chapter 10.
16. Loosen the upper bolt of the steering column clamp to the coupling and disconnect the steering column from the coupling as described in chapter 10.
17. Support the front suspension cross member with a jack and a wooden spacer, then remove the four mounting bolts (to access the rear bolts, remove the bolts and plastic covers) and lower the beam so that it is held by the shock absorbers - see. "Front Lower Arm - Removal and Installation" v chapter 10. Discard the crossbar mounting bolts - use new ones when installing. Be careful not to stretch any tubes, hoses or wires when lowering the crossbar.
18. On models with an additional section secured to the right side of the tray, unscrew the bolts and remove the side section. Remove the washers and gasket.
19. If necessary, remove the two lower engine-to-gearbox bolts that secure the gearbox to the oil pan.
20. Gradually, in a diagonal order, unscrew and remove the pan mounting bolts. Since the bolts are of different lengths, note the location of each of the removed bolts so that you can replace them in their proper places during assembly. Also note the location of the brackets secured with bolts (please note that some bolts may already be removed to allow the transmission fluid and oil cooler tubes to be removed from the pan).
21. Lower the pan by moving it forward and down, and remove the gasket. If it is necessary to move the crankshaft cheeks and provide sufficient space for removing the pan, turn the crankshaft by the pulley/damper mounting bolt,
Installation
22. Begin installation by removing any remaining gasket from the pan and cylinder block. Wipe them dry.
23. Place the new gasket on the pan, then lift the pan into place and insert the bolts into place.
24. Gradually tighten the bolts to the required torque.
25. If necessary, install the lower engine to transmission mount bolts that secure the oil pan to the transmission.
26. On models with an additional side section, install the side section using a new gasket and, making sure the washers are in place, tighten the mounting bolts.
27. Raise the front suspension cross member and secure it with new bolts as described in paragraph "Front Lower Arm - Removal and Installation" v chapter 10. Tighten the bolts to the required torque.
28. Connect the steering column to the coupling, making sure that the column and coupling are correctly aligned as described in chapter 10.
29. Install the front suspension coil spring as described in chapter 10.
30. Carefully lower the engine into place. Install the engine mounting bolts. Tighten the bolts to the required tightening torque. Remove the hoist and winch slings.
31. Connect the oil cooler hoses to the rigid tubes and tighten the clamp bolts.
32. If necessary, connect the engine oil level sensor wires.
33. Connect the starter ground bus to the body and install the engine speed sensor.
34. Install the fan shroud as described in chapter 3.
35. Install and adjust the engine shock absorber as described in paragraph 16.
36. Connect the steering rod and shock absorber as described in chapter 10.
37. Install the anti-roll bar as described in chapter 10.
38. After ensuring that the oil drain plug is tightened, install the lower engine guard.
39. Connect the negative battery terminal, fill the engine with engine oil and, if necessary, check the automatic transmission fluid level as described in chapter 1B.