If the engine is removed for repair, it is necessary to select a place for work, provide space for maintenance and storage of spare parts. Engine repairs should be carried out at a workshop or in a garage with a flat, horizontal floor with a clean hard surface.
Before removing, clean and wash the engine and engine compartment. To remove the engine, use a lifting device that allows you to safely lift the power package.
If you are removing the engine for the first time, you must invite an experienced specialist. Some work is done with an assistant.
All clips and clamps that will be damaged or cut when removing the engine must be replaced with new ones when assembling the engine.
The engine is removed forward without a gearbox.
Drained coolant must be collected and disposed of.
Before disconnecting the battery, find out if you have a radio activation code.
Withdrawal
Turn off the ignition and disconnect the wire «masses» from the battery.
Pic. 3.3–24. Location of engine cover screws
Loosen the screws and remove the engine cover (see fig. 3.3–24).
Pic. 3.3–1. Location of protective covers (1–4) at the rear of the engine compartment
Remove protective covers 1-4 at the rear of the engine compartment (pic. 3.3–1).
Remove the expansion tank cap.
Pic. 3.3–25. Location of the front air ducts
Remove front air ducts (see fig. 3.3–25).
Loosen the viscous radiator fan mounting bolt while holding the fan shaft from turning with another wrench.
Unscrew the radiator fan shroud.
Remove the viscous fan with shroud.
Pic. 3.3–2. Shroud retainer location and direction of rotation when removing the electric radiator fan
To remove the electric radiator fan, disconnect the electrical connector from the fan, remove the shroud retainer, turn the shroud in the direction of the arrow (pic. 3.3–2) and remove the fan.
Pic. 3.3–27. Arrangement of screws of fastening of a casing of a v-ribbed belt
Loosen the screws and remove the V-ribbed belt cover (see fig. 3.3–27).
Warning: Using chalk, marker or paint, mark the direction of rotation of the V-ribbed belt. If the V-ribbed belt rotates in the opposite direction during installation, this will lead to its destruction.
Pic. 3.3–28. Arrangement of a bolt of fastening of a tension roller of a poly-v-ribbed belt of the compressor of the conditioner
Loosen the bolt securing the tension roller of the V-ribbed belt of the air conditioning compressor and remove the belt from the pulleys (see fig. 3.3–28).
Pic. 3.3–29. The weakening of the tension of the main V-ribbed belt
Using a socket wrench, turn the main V-ribbed belt tensioner counterclockwise, as a result of which the belt tension will loosen, fix the tensioner in this position with the pin (pos.1, see fig. 3.3–29) and remove the belt.
Pic. 3.3–3. The location of the vibration damper mounting bolts
Remove the eight bolts and remove the vibration damper from the crankshaft pulley (pic. 3.3–3).
Pic. 3.3–4. The location of the bolts for securing the heat shield above the turbocharger
Remove the bolts (pic. 3.3–4) and remove the heat shield above the turbocharger.
Pic. 3.3–5. Arrangement of bolts of fastening of a reception exhaust pipe to a turbocharger
Turn out bolts of fastening of a reception exhaust pipe to a turbocharger (pic. 3.3–5).
Pic. 3.3–34. Location of screws for fastening the exhaust pipe heater and noise insulation of the additional heater
Turn out screws of fastening of an exhaust pipe heater and a noise isolation of an additional heater (see fig. 3.3–34).
Pic. 3.3–35. The location of the fastening latches of the lower mudguard of the engine compartment
Release the latches and remove the lower mudguards of the engine compartment, consisting of two sections (see fig. 3.3–35).
Pic. 3.3–36. Arrangement of bolts of fastening of an arm of the lower mudguard of a motor compartment
Turn out two bolts and remove a bracket of the bottom mudguard of a motor compartment (see fig. 3.3–36)
Loosen the clamps and remove the front exhaust pipe with catalytic converter.
Install a coolant collection pan under the engine.
Pic. 3.3–6. Location of the coolant drain valve (1) and drain bolt (2)
Drain the coolant by turning valve 1 90° (pic. 3.3–6) at the base of the pipe and unscrewing the drain bolt 2.
Unscrew the air conditioning compressor from the bracket and, without disconnecting the hoses from it, take it to the side.
Unscrew the torque compensator from the engine and body.
Unscrew the elastic support on the lower right side of the frame.
Pic. 3.3–7. Arrangement of bolts of fastening of a starter: 1 – a nut; 2 - electrical connector
Disconnect the electrical connector from the starter, then unscrew the nut 1 (pic. 3.3–7) and disconnect the positive wire from the starter.
Unscrew the two bolts shown by arrows in fig. 3.3–7 and, being careful, remove the starter.
Pic. 3.3–8. Location of torque converter mounting bolt
Through the hole opened after removing the starter, unscrew the three bolts securing the torque converter (pic. 3.3–8). To access each subsequent bolt, it is necessary to turn the engine crankshaft in the direction of its working rotation by 1/3 of a turn.
Note: The crankshaft pulley bolt must be used to rotate the crankshaft.
Vehicles with manual transmission
Unscrew and remove the casing from the side of the right drive shaft.
In the right distribution block, disconnect the electrical connector and, unscrewing the nut, remove the starter wire lug. Then unscrew the wire clamp bolt and move the starter wire to the side.
Disconnect the electrical connector from the reversing light switch.
All models
Unscrew and remove the cover from the left side of the drive shaft.
Remove the heat shield from the left side of the gearbox.
Disconnect the electrical connector from the speedometer sensor.
Pic. 3.3–9. Electrical connector location (1), speedometer sensor, engine speed sensor (2) and bolt (3) fastenings of the pipeline of an automatic transmission
With sensor 2 (rice. 3.3–9) engine speed G28, unscrew it. Sensor 2 is located on the front left side of the transmission.
Unscrew a bolt 3 fastenings of the pipeline of an automatic transmission and move the pipeline aside.
Release from the bracket and disconnect the electrical connectors of the wiring harness and multifunction switch.
Disconnect the electrical connectors on the left side of the engine.
Unscrew the bottom bolts of fastening of a transmission to the engine.
Pic. 3.3–10. Bolt location (arrows) engine mounts to bottom frame
Unscrew the lower bolts shown by arrows in fig. 3.3-10, fastening the engine to the lower frame.
Pic. 3.3–11. Location of the clamps for fastening the cooling system hoses to the heater fittings on the bulkhead of the engine compartment
Loosen the clamps (pic. 3.3–11) and disconnect the coolant hoses going to the heater.
Remove the vacuum hose from the brake booster.
Loosen the clamps and disconnect the cooling system hoses from the engine.
Pic. 3.3–12. Sensor electrical connector location (1) in the hose (2) air supply to intake manifold
Disconnect the electrical connector from the air inlet sensor 1 (pic. 3.3–12).
Remove hose 2 for air supply to intake manifold.
Pic. 3.3–21. The location of the bolts of the poly V-belt pulley of the power steering pump and a special tool to keep the pulley from turning
Unscrew the bolts securing the poly V-belt pulley of the power steering pump, holding the pulley from turning with a special tool (see fig. 3.3–21).
Loosen the clamps and remove the air pipe from the air filter.
Pic. 3.3–13. Electrical connector location (1) radiator fan sensor and hose clamps for cooling system hoses from the sensor (2) and additional heater (3)
Disconnect from sensor 2 (pic. 3.3–13) cooling fan electrical connector 1 and coolant hose.
Loosen the clamps and disconnect the cooling system hoses from the auxiliary heater 3.
Disconnect the fuel hoses from the fuel filter.
Remove the air filter cover.
Pic. 3.3–14. Air flow meter electrical connector location
Disconnect the electrical connector from the air mass meter (pic. 3.3–14) and release the wires from the clamps.
Disconnect the electrical connectors from the solenoid valve and EGR valve (EGR).
Disconnect the vacuum hoses from the turbocharger and mechanical EGR valves and move the hoses to the side.
Pic. 3.3–15. The location of the screws and the direction of removal of the casing of the control unit: 1 - the direction of removal
Rotate the left protective cover of the control box in the direction of arrow 1 (pic. 3.3–15) and remove the rear right screw.
Turn out the remained screws of fastening shown by arrows on fig. 3.3–15.
Remove the control box cover.
In the control unit, disconnect the electrical connectors from the engine and transmission control units. Release the relay mount, for which, using a screwdriver with a thin blade, wring out the side latches.
Disconnect the remaining connectors and remove the wiring harness from the top of the engine.
Remove the upper gearbox-to-engine bolts, leaving one bolt in place.
Loosen the bolt at the rear of the turbocharger.
Pic. 3.3–16. Bolt location (A) rack mounts (IN) on the back of the turbocharger
A (pic. 3.3–16), rotate the stand clockwise and tighten the bolt again.
Disconnect the hood support struts from the hood. Install the hood vertically and secure it in this position.
Hang lifting clamp 2024 on the hoist and fasten its clamps to the engine.
Unscrew bolts of fastening of a transmission to the engine.
Check that all electrical wires, hoses, fittings and pipes are disconnected from the engine.
Vehicles with automatic transmission
Pic. 3.3–17. Using a large screwdriver to press the torque converter against the engine when removing the engine
Before removing the engine, use a large screwdriver to press the torque converter against the engine (pic. 3.3–17).
Being careful, lift the engine, then take it away from the gearbox and remove it up from the engine compartment.
Vehicles with automatic transmission
Attach the torque converter to the engine.
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
When installing the engine, it is necessary to replace it with new self-locking nuts and bolts, which were tightened by additional turning to a certain angle, as well as sealing rings and gaskets.
Before installing, make sure the rack IN (see fig. 3.3–16) on the back of the turbocharger is turned clockwise.
Before installing the engine, secure the electrical wires and hoses to the sides of the engine compartment so that they are not pinched by the engine.
When installing, check the presence of centering bushings that determine the relative position of the engine and gearbox.
Vehicles with manual transmission
Clean the splines of the drive shaft and, when reusing the clutch disc, remove traces of corrosion from it. Lubricate the splines of the drive shaft with a thin layer of grease G 000 100.
Check the condition of the clutch release bearing and replace it if necessary.
Using a drift, check the centering of the clutch disc.
Check the condition of the needle bearing at the end of the crankshaft on the flywheel side. Replace bearing if necessary.
Vehicles with automatic transmission
To attach the torque converter to the flywheel, you must use bolts of the original design.
Pic. 3.3–18. Measuring the distance between the bearing surface for the torque converter mounting bolts and the bearing surface of the crankcase
Check the correct installation of the torque converter. If the distance between the bearing surface for the torque converter mounting bolts and the surface of the crankcase is 19 mm, then the torque converter is installed correctly. With an incorrectly installed torque converter, this distance is about 14 mm (pic. 3.3–18). In this case, the driving disk of the torque converter and the automatic transmission pump are destroyed.
Install the engine in place and, rocking it from side to side, ensure the correct position on the supports.
Install the A/C compressor and power steering pump.
Before screwing in the A/C compressor mounting bolts, make sure that the compressor centering sleeves are in place.
Install power steering pump pulley.
Install poly V-belt.
Install a viscous radiator fan.
Install the torque compensator and screw it to the engine and body.
Fill the cooling system with coolant. Coolant must not be reused if the cylinder head has been removed or the cylinder block has been replaced.
Check that the elements of the exhaust system are correctly installed on the suspensions and do not touch the body when it is rocking.
Check that the electrical connectors are connected correctly.
Connect wire «masses» to the battery.
Turn on radio and enter the code into it.
Raise the windows with the power windows up to the stop. Then press all power window switches again for at least 1 second to the closed position to activate the power window control unit.
Set the time on the clock.
Before starting the engine for the first time, it is necessary to bleed the fuel system, otherwise the fuel pump will be damaged.
Before starting the engine, check the presence and level of oil in the engine.
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