Removal and installation the engine with the subframe
Removal
1. Place the vehicle in the service position (only on vehicles with rear air suspension).
2. Disconnect the negative cable from the battery.
3. Drain the cooling system coolant and empty the air conditioning system.
4. Remove the front bumper, front cross member, radiator grille, air filter, right headlight, air intakes, front wheels and windshield washer reservoir.
5. Disconnect the 4th cooling system hose from the Y37 cycle valve (see figure 5.1).
Figure 5.1. Removing and installing the engine with the subframe:
1, 2, 3, 5, 6, 7. Vacuum tubes,
4. Cooling system pipe,
8. EGR valve,
9. Throttle valve,
10. Retainer,
11. Hydraulic pipeline,
16. Air conditioning system tube,
17. Nut,
18. Bolt,
19. Bracket,
20. Sealing ring,
Y37. Cycle valve,
Y80. Compressed air vacuum pressure sensor,
Y80.1. Compressed air pressure vacuum sensor wiring connector.
6. Disconnect fuel lines 21 and 22 (see figure 5.2).
Figure 5.2. Removing and installing the engine with the subframe:
21. Fuel injection line,
22. Fuel drain line,
23. Cooling system pipe,
24. EGR cooling unit,
25, 28, 31. Bolt,
26. Exhaust system,
27. High pressure chamber for exhaust gases,
29. Heat shield,
30. Brake mechanism support,
32. Spring,
33. Gasket,
34. Rubber supports,
B79. ABS wheel speed sensor.
7. Disconnect pipe 23 from the EGR system cooling block 24.
8. Disconnect vacuum tubes 5, 6 and 7.
9. Disconnect the gear shift lever.
10. Disconnect the wiring from the engine.
11. Disconnect the clamp 10 of the hydraulic line 11 from the clutch slave cylinder and remove it.
12. Disconnect the drain pipe from the windshield washer reservoir.
13. Unscrew bolt 18 from bracket 19.
14. Disconnect the air conditioning system tubes 16 from the expansion valve. Replace sealing ring 20.
15. Unscrew bolt 25 securing the exhaust gas high pressure chamber.
16. Remove the exhaust system 26 as an assembly.
17. Remove the Y80 turbo boost pressure control vacuum sensor from the bracket on the subframe 35 (see figure 5.3).
Figure 5.3. Removing and installing the engine with the subframe:
35. Subframe,
36. Nut,
37. Shock absorber strut,
38. Front cross beam,
39. Right engine mount,
40. Plate,
41, 43, 45, 46, 49, 50, 51, 56, 58. Bolts,
42. Rubber support,
44. Upper engine mount,
47. Steering shaft joint,
48. Steering gear pinion,
52. Left engine mount,
53. Transmission,
54. Front limiter,
55. Air intake,
57, 59. Gasket.
18. Disconnect vacuum pipe 3 from turbocharger pressure control vacuum sensor Y80.
19. Remove the brake calipers 30.
20. Remove the B79 ABS wheel speed sensors. Do not disconnect the wiring.
21. Unscrew bolt 46. Mark the position of steering gear pinion 48 and steering shaft joint 47 (arrow).
22. Remove rubber bushing 42 and plate 40 from the longitudinal beam on both sides.
23. Unscrew nut 36 securing shock absorber strut 37 on both sides.
24. Install the removed elements below the subframe 35 using a tension strap.
25. Unscrew the fastening of the right 39 and upper 44 engine mounts.
26. Unscrew bolt 51 securing the left engine support 52.
27. Remove limiters 54 from subframe 35.
28. Secure disconnected electrical wiring, pipes and fittings, etc. removed elements without damaging them from the side.
29. Unscrew bolts 56 and 58.
30. Slowly lower the engine with subframe 35 down and remove it. Rotate the steering shaft until it is completely disconnected from the steering gear pinion.
Installation
31. Installation is carried out in the reverse order of removal. Replace the self-locking nuts, bolts 41 and 43.
Removal and installation of the engine with transmission
Removal
1. Remove the engine together with the subframe.
2. Unscrew the bolts securing the axle shafts 1 to the gearbox (see figure 5.4).
Figure 5.4. Removing and installing the engine with transmission:
1. Left axle shaft,
2. Radiator of the cooling system,
3. Compressed air intermediate cooling radiator,
4. Bolt,
5. Power steering pump,
6. Clamp,
7. Power steering fluid reservoir,
8. Support bracket,
9. Right eye,
10. Left eye.
3. Remove the radiator 2. Compressed air intermediate cooling radiator (intercooler) 3 is attached to radiator 2.
4. Remove the generator drive belt.
5. Unscrew the 4 bolts securing the power steering pump to the timing chain cover.
6. Remove clamp 6 securing power steering fluid reservoir 7 to bracket 8.
7. Attach the lift to eyes 9 and 10.
8. Remove the engine from the subframe.
Installation
9. Installation is carried out in the reverse order of removal.