Withdrawal
1. Park the vehicle on a firm, level surface with sufficient space around it.
2. Remove the battery - see chapter 5A.
3. Put wedges under the rear wheels, tighten the hand brake. Loosen the front wheel bolts. Raise the front of the vehicle and install safety stands.
4. If installed, unscrew the fastening screws and remove the protective casing of the power unit from under the car.
5. If provided, remove the engine top cover (pic. 4.5).
6. Remove the front bumper as described in chapter 11 (pic. 4.6).
7. As described in chapter 1A, do the following:
- A) Drain the coolant. The drain plug is installed on the front left of the radiator (pic. 4.7), some engines have another plug installed in the water pump bearing housing.
- b) Drain the engine oil.
8. Remove the two bolts securing the power steering cooling tube to the front of the radiator and move it aside. Tie up the outdoor temperature sensor in its place.
9. Loosen the clamps and disconnect the upper and lower radiator hoses. On an ADR engine, the top hose is easier to disconnect from the engine (pic. 4.9). On AHL engines, disconnect hoses from engine oil cooler and drain remaining coolant.
10. Remove the air duct leading from the hood lock bracket to the air filter (pic. 4.10, a, b).
11. Disconnect the wiring from the headlights and headlight beam corrector units (pic. 4.11).
12. Disconnect the bulb holders from the front direction indicators (pic. 4.12).
13. Disconnect the hood lock control cable from the lock bracket.
14. On models with an electric cooling fan, disconnect the wiring from the thermostatic sensor located at the bottom left of the radiator. Move the wiring aside.
15. Disconnect the wiring from the klaxons and take it aside.
16. On models equipped with air conditioning, unscrew the bolts and remove the air deflectors from both sides of the radiator, then unscrew the condenser mounting bolts. Disconnect the wiring from the low pressure sensor and disconnect the wiring from the A/C magnetic clutch at the bottom of the hood lock bracket. Remove the condenser from the bracket, unfold and tie it to the front wheel to secure it when removing the engine - cover the condenser with cardboard or rags.
Attention! Never open the refrigerant circuit of the air conditioner.
17. On models with automatic transmission, place suitable dishes under the radiator, loosen the union nuts and disconnect the hydraulic pipes from the bottom of the radiator. Plug the pipes and holes in the radiator to keep dirt out. Also remove the pipe mounting bracket from the engine.
18. Remove the cap from the power steering reservoir (pic. 4.18).
19. Disconnect the wiring from the ABS blocks, which are located on the left side of the engine compartment and from the anti-theft sensor under the hood in front (pic. 4.19).
20. At the top left of the hood lock bracket, disconnect the anti-theft system wiring connector.
21. Remove the bolts securing the hood lock bracket, then, together with an assistant, remove the entire front panel and move it as far as possible from the body (pic. 4.21, a, b).
22. Remove the air filter assembly along with the air ducts.
23. Disconnect the central wire of the ignition system, disconnect the wiring, take it away from the engine. If necessary, disconnect the wiring from the oxygen sensor.
24. As described in chapter 4A, depressurize the fuel system, and disconnect the fuel rail supply and return lines.
25. Loosen the clamps and disconnect the small hoses from the expansion tank of the cooling system on the left side of the engine compartment. Disconnect the wiring from the coolant level sensor, remove the expansion tank (pic. 4.25, a-c).
26. On models with cruise control, disconnect the actuator rod from the throttle control and pull off the vacuum hose from the vacuum block.
27. Disconnect the accelerator cable from the throttle body and mounting bracket and move it aside.
28. Disconnect vacuum hoses from charcoal canister purge valve and brake booster (pic. 4.28, a, b).
29. On models with automatic transmission, disconnect the wiring from the sensor "kickdown".
30. On left-hand drive models, remove the engine control unit from the left side of the engine shield, as described in chapter 4A. To do this, first dismantle the cover of the electronic unit, release the latches and disconnect the wiring. On all models, release the wiring where necessary, unscrew the fastening screw "mass" wires and move the wiring aside.
31. Disconnect the crankcase ventilation hoses from the valve cover and throttle body (pic. 4.31).
32. Loosen the clamps and disconnect the heater hoses from the lower cooling system pipe and outlet flange at the rear of the cylinder head.
33. Disconnect the wiring from the speedometer sensor on the left side of the gearbox.
34. On models with manual transmissions, disconnect the wiring from the reverse sensor on the left side of the transmission.
35. Remove auxiliary drive belts as described in chapter 2A.
36. As described in Chapter 3, remove the A/C compressor from the engine. Tie up the compressor by moving it to the side.
Attention! Be careful and never open the refrigerant circuit of the air conditioner.
37. Remove the pulley from the power steering pump, dismantle the power steering pump from the mounting bracket and tie it up, moving it to the side (pic. 4.37, a-g). Do not disconnect hydraulic hoses and pipes from the pump.
38. Disconnect the muffler downpipe from the exhaust manifold as described in chapter 4B. Do not kink overly flexible downpipe section.
39. Remove the heat shield from the right engine mount. Loosen the top nuts on the right and left engine mounts. Loosen the screw, remove "mass" wire from the right support.
40. Remove the starter as described in chapter 5A.
41. On models with automatic transmission, remove the three torque converter mounting nuts that are now accessible through the starter opening. In order to unscrew all the nuts, the engine will have to be turned. To prevent the faceplate from turning when the nuts are loosened, insert a screwdriver between the crown teeth or hold the crankshaft by the sprocket center bolt.
42. Mark the position of the engine mounts on the subframe so that you can install it correctly afterwards. Loosen the bottom nuts a few turns.
43. Attach the hoist to the engine and slightly raise the power unit. Make sure the motor is securely fastened to the hoist.
44. Turn away bolts of fastening of a check point to a back part of the engine, lower the engine into place. In this position, leave one bolt baited.
45. Put a rolling jack under the gearbox, laying a piece of board between them. It is possible to transfer the weight of the gearbox to a beam laid in the wing grooves.
46. Remove the last bolt. Make sure that all wires and hoses are disconnected and remove the engine from the engine compartment (pic. 4.46). On models with automatic transmission, make sure that the torque converter remains inside the bell housing and does not fall. Fix it in the bell by screwing an iron strip across the bell with two bolts.
47. If the guide bushings have a loose fit, remove them from the back of the block. If necessary, remove the intermediate plate from the rear of the engine.
48. On manual transmission models, remove the clutch as described in chapter 6.
Installation
49. Installation - reverse procedure. Before installation on models with manual transmissions, lubricate the splines of the transmission shaft with a small amount of high-temperature grease. Lightly lubricate the release bearing contact surface, but DO NOT LUBRICATE the release bearing guide bushing. On models with automatic transmission, check correct alignment of the torque converter on the automatic transmission shaft by measuring the distance between the bell housing mating surface and the torque converter surface should be approximately 23.0 mm. If only 13 mm, the torque converter has not completely entered the bell. Make sure that the engine and gearbox mounts are not overloaded, tighten the threaded connections to the prescribed torques. Install all attachments as described in the relevant chapters. Fill the engine with clean engine oil and fill the system with coolant as described in chapter 1A.
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