Table of contents: Removal ↓ Installation ↓
Removal
Petrol engines
1. Raise and support the front of the vehicle.
2. Remove the hood.
3. Disconnect the negative battery cable.
4. Drain the oil and coolant.
5. Remove the top engine cover.
6. Disconnect the hoses from the radiator and expansion tank.
4-cylinder petrol engines
7. Remove the radiator cooling fan.
5-cylinder petrol engines
8. Remove the front bumper and radiator fan.
9. Remove the radiator.
10. On models with air conditioning, remove the radiator bolts, unscrew the radiator bracket and slide the radiator forward, securing it to the support.
11. On AAR and ANN models, disconnect the hoses and remove the coolant pipe on the left side of the engine. Remove the cover from the left drive shaft and disconnect the exhaust pipe and catalytic converter from the exhaust manifold.
12. Disconnect the outlet pipe from the bracket. Disconnect the fuel pipes from the fuel distributor.
All models
13. Disconnect all wires that interfere with engine removal.
14. Disconnect the pipe connecting the air filter and the throttle body.
15. Disconnect the fuel supply and return lines. Disconnect the accelerator cable.
16. Disconnect the hoses from the heater core.
17. Disconnect the wire from the reverse light switch located on the transmission.
18. Remove the additional belts.
19. Remove the air conditioning compressor without disconnecting the hoses from it.
20. Remove the power steering pump without disconnecting the hoses from it.
21. On engines with an automatic transmission, disconnect the transmission fluid lines from the engine oil pan.
22. Remove the starter.
23. Remove the bolts securing the drive disc to the torque converter.
24. Disconnect the exhaust pipe from the manifold.
25. Remove the bolts that secure the gearbox to the engine. Leave the top bolt in place.
26. Secure the engine to the lift.
27. Loosen the engine mounting nuts.
28. Place a jack under the gearbox.
29. Remove the last bolt and remove the engine.
If necessary, remove the engine intermediate plate and clutch.
Diesel engines
1. Remove the hood.
2. Disconnect the negative battery cable.
3. Drain the oil and coolant.
4. Raise and support the front of the vehicle.
4-cylinder diesel engines
5. Remove the top engine cover.
6. Remove the cooling fan.
7. Remove the air intake located on the radiator.
8. Remove the air filter.
9. Disconnect the pressure control solenoid valve.
10. Remove the pipes connecting the heat exchanger and the intake manifold, and the heat exchanger and the turbocharger.
11. Disconnect the exhaust pipe from the turbocharger.
5-cylinder diesel engines
12. Remove the front bumper and radiator fan.
13. Remove the radiator.
14. On models with air conditioning, Remove the radiator bolts, unscrew the radiator bracket and slide the radiator forward, securing it to the support.
15. Remove the crossmember located at the rear of the gearbox (ABP, AAT, AEL). On AAS models, remove the front engine mount.
16. Remove the fuel pump drive belt cover.
17. Remove the air filter.
18. Remove the pipes connecting the heat exchanger and the intake manifold, and the heat exchanger and the turbocharger.
19. Disconnect the hoses from the intake manifold and the exhaust gas control valve.
20. Disconnect the ground wire from the right engine mount bracket.
21. Disconnect the fuel filter bracket from the left engine mount bracket.
22. Remove the front engine mount.
All models
23. Disconnect the hoses from the radiator, cylinder head and expansion tank.
24. Disconnect the wires from the generator.
25. Disconnect the wiring that interferes with engine removal.
26. Disconnect the fuel supply and return lines from the fuel pump.
27. Disconnect the accelerator cable.
28. Disconnect the vacuum hoses.
29. Disconnect the hoses from the heater core.
30. Disconnect the wires from the speedometer sensor and the reverse light switch.
31. Remove the additional belts.
32. Remove the air conditioning compressor without disconnecting the hoses from it.
33. Remove the power steering pump without disconnecting the hoses from it.
34. Remove the bolts and pulley from the power steering pump.
35. Unscrew the bolts and remove the pump.
36. On engines with an automatic transmission, disconnect the transmission fluid lines from the engine oil pan.
37. Remove the starter.
38. Remove the bolts securing the drive disc to the torque converter.
39. Disconnect the exhaust pipe and catalytic converter from the exhaust manifold.
40. Remove the bolts that secure the gearbox to the engine. Leave the top bolt in place.
41. Secure the engine to the lift.
42. Unscrew the support nut and remove the washers.
43. Place a jack under the gearbox.
44. Remove the last bolt and remove the engine.
45. Remove the clutch if necessary.
Installation
All engines
Installation is carried out in the reverse order of removal, but do not forget to lubricate the splines of the engine drive shaft with high melting point grease.