Contents: Removal ↡ Installation ↡
Removal
1. Set the rear suspension of the vehicle to the position "Service Mode" (only on vehicles with rear air suspension).
2. Disconnect the negative cable from the battery.
3. Drain the refrigerant from the air conditioning system (if it is installed).
4. Drain the coolant.
5. Remove the lower sound insulation.
6. Remove the bumper 3 (see figure 4.1).
Figure 4.1. Removing the engine:
2. Radiator grille,
3. Bumper,
6. Front cross beam,
7. Air filter,
8, 9. Air intake tubes.
7. Remove the radiator grille 2, front crossbar 6, air filter 7, air intake pipe 9.
8. Disconnect the engine wiring.
9. Disconnect the wiring connectors from the radiator.
10. Disconnect the cooling system hose 13 from the adapter 12 (see figure 4.2). Check pipe 13 and its mounting clamp; replace them if necessary.
Figure 4.2. Removing the engine:
12. Adapter,
13. Cooling system pipe,
14. Fuel supply control rod,
15. Bowden cable,
S19. Brake light switch,
S19.1. Brake light switch wiring connector.
11. Disconnect fuel supply control rod 14 from the bracket.
12. Disconnect the accelerator pedal position sensor from the Bowden cable 15 (only on cars with automatic transmission).
13. Disconnect the wiring connector from the brake light switch S19 (only on cars with automatic transmission).
14. Unscrew the air conditioning system pipes 20 from the expansion valve (only on cars with air conditioning).
15. Cut the tie straps (arrows) securing fuel lines 22 and 25 and vacuum tubes 23 and 24 (see figure 4.3). When installing the tape, it must be replaced.
Figure 4.3. Removing the engine:
16, 21. Nut,
17. Bolt,
18. Bracket,
19. Seals,
20. Air conditioning system pipes,
22. Fuel drain line,
23, 24. Vacuum tubes,
25. Fuel injection line,
32. Wheel.
16. Remove vacuum tubes 23 and 24.
17. Disconnect fuel lines 22 and 25.
18. Disconnect the gear shift lever.
19. Remove the front wheels 32.
20. Remove the air heater.
21. Unscrew the shock absorber strut mounts 67 (see figure 4.4).
Figure 4.4. Removing the engine:
54, 56. Bolt,
55. Front limiter,
57, 59. Gasket,
65. Subframe,
66. Jack,
67. Fastening the shock absorber strut.
22. Remove the brake calipers 35 (see figure 4.5). Do not stretch the brake hoses.
Figure 4.5. Removing the engine:
33, 36, 46, 47. Bolt,
34. Protective shield,
35. Brake caliper,
45. Plate,
48. Support bushing,
B79. ABS system sensor.
23. Remove the B79 ABS sensors and the protective shield 34 from the steering knuckles.
24. Remove support bushings 48 and plates 45 from both sides of the wheel arches.
25. Disconnect connector X106 from the automatic transmission (see figure 4.6).
Figure 4.6. Removing the engine:
49, 51. Bolts,
50. Clutch slave cylinder,
52. Steering shaft cardan joint,
53. Steering gear pinion,
58. Exhaust pipe,
G4. Speed sensor,
X106. Automatic transmission connector.
26. Disconnect the clutch slave cylinder 50 from the gearbox. do not disconnect the pipes.
27. Remove the G4 speed sensor from the gearbox. Do not disconnect the electrical wiring.
28. Using a marker, mark the relative positions of the steering gear pinion 53 and the steering shaft universal joint 52 (arrow).
29. Unscrew bolt 51.
30. Disconnect the ground connection from the frame.
31. Disconnect the exhaust pipe 58 from the manifold.
32. Install jack 66 under engine subframe 65 (see figure 4.4).
33. Secure all disconnected pipes and wiring to the side so that it does not interfere with the removal of the engine.
34. Slowly lower the subframe 65.
35. Disconnect axle shafts 1 and 7 from the flanges and secure them to the side (see figure 4.7).
Figure 4.7. Removing the engine:
1. Right axle shaft,
2, 8. Bolt,
4. Discharge pipeline,
5. Drain pipe,
6. Power steering fluid reservoir,
7. Left axle shaft.
36. Remove the fluid from the power steering reservoir 6. Disconnect the pressure 4 and drain 5 pipes from the power steering pump.
37. Remove the radiator.
38. Cut the tie tape (arrow) securing the air conditioning system pipes and remove the tank 13c from the bracket together with the pipes and disconnect them (see figure 4.8).
Figure 4.8. Removing the engine:
9. Nut, 10. Front engine mount,
11, 16. Bolt,
12. Front engine bracket,
13. Tank,
14. Rear engine bracket,
15. Protective plate,
17. Gearbox support,
18. Lift.
39. Raise the engine using the hoist 18 until the gearbox is disconnected from the supports.
40. Unscrew bolts 11 securing engine supports 1214 14 to brackets 10.
41. Unscrew bolt 16 securing gearbox 17.
42. Remove the engine by lifting it to the required height.
Installation
43. Installation is carried out in the reverse order of removal.