Table of contents: Removal and installation the G266… ↓ Removal and installation the lower… ↓ Removal and installation the BTR… ↓ Removal and installation the oil… ↓ Removal and installation the upper… ↓ Removal and installation the oil… ↓ Removal and installation the oil… ↓ Removal and installation the PCV… ↓ Removal and installation the… ↓ Removal and installation the engine… ↓
1. The installation details of the lubrication system components are shown in the illustrations.
44.1a. Details of the installation of the oil pump and sections of the oil pan of the BTR engine:
1 - Nut, 9 Nm;
2 - Sensor "G266" of engine oil level and temperature;
3, 6, 7, 11, 19, 21, 29 - Gasket, subject to replacement;
4 - Lower section of the oil pan;
5 - Oil intake pipe;
8, 10, 12, 26, 27 - Bolt, 9 Nm;
9 - Oil pipe;
13 - Relief plate;
14 - Coolant pump drive shaft;
15 - Upper section of the oil pan;
16, 17 - Sealing ring, subject to replacement;
18 - Bolt, to be replaced, 5 Nm, then 10 Nm, then tighten by 90°;
20 - Service hole plug, 35 Nm;
22 - Centering bushings, 2 pcs.;
23 - Oil pump, cannot be disassembled;
24 - Oil pump drive shaft;
25 - Spring;
28 - Bolt, to be replaced, 5 Nm, then 8 Nm, then tighten by 90°;
30 - Drain plug, 30 Nm.
44.1b. Installation details of the oil pump and oil pan sections of CCFA/CCFC engines:
1 - Nut, 9 Nm;
2 - Sensor "G266" of engine oil level and temperature;
3, 23, 25, 33 - Gasket, subject to replacement;
4 - Lower section of the oil pan;
5 - Oil intake pipe;
6, 8, 9, 21, 29 - Bolt, 9 Nm;
7 - Bolt, to be replaced, 8 Nm, then tighten by 90°;
10 - Relief plate;
11 - Oil pipe;
12, 19, 30 - Sealing ring, subject to replacement;
13 - Coolant pump drive shaft;
14 - Upper section of the oil pan;
15, 16 - Centering bushings, 2 pcs.;
17, 18 - Sealing ring, subject to replacement; secure it in the groove in the cylinder block using a little coolant;
20 - Valve "N428" for regulating engine oil pressure;
22 - Bolt, 5 Nm, then 15 Nm;
24 - Service hole plug, 35 Nm;
26 - Oil pump, cannot be disassembled;
27 - Oil pump drive shaft;
28 - Spring;
31 - Bolt, to be replaced, 5 Nm, then 8 Nm, then tighten by 90°;
32 - Drain plug, 30 Nm.
44.1c. BTR engine oil cooler, PCV valve, and oil filter housing installation details:
1, 5, 11, 15, 21 - Gaskets, subject to replacement;
2 - Mounting plate for oil cooler, PCV valve and oil filter housing;
3, 12, 17, 22 - Sealing rings, subject to replacement;
4 - Connecting coolant hoses;
6 - Oil cooler;
7, 23 - Bolt, to be replaced, 8 Nm, then tighten to an angle of 90°;
8 - Coolant hose, to EGR radiator;
9 - PCV pressure control valve;
10 - Bolt, 6 Nm;
13, 18 - Bolt, 9 Nm;
14 - Lid;
16 - Filter element;
19 - Holder;
20 - Oil filter housing.
44.1d. Installation details of oil cooler, PCV valve and oil filter housing for CCFA/CCFC engines:
1, 3, 8, 11, 17 - Gaskets, subject to replacement;
2 - Mounting plate for oil cooler, PCV valve and oil filter housing;
4 - Oil cooler;
5, 19 - Bolt, subject to replacement, 8 Nm, then tighten to an angle of 90°;
6 - PCV pressure control valve;
7 - Bolt, 6 Nm;
9, 13, 18 - Sealing rings, subject to replacement;
10 - Lid;
12 - Filter element;
14 - Bolt, 9 Nm;
15 - Holder;
16 - Oil filter housing.
2. On the BTR engine, the lubrication system sensors are located on the front side of the engine (see illustration) and are accessible for removal after removing the top engine cover (see Section 19 of Chapter 1).
44.2. BTR engine lubrication system sensors:
1 - D/V "F1" engine oil pressure, 20 Nm;
2 - Sensor "G8" engine oil temperature, 14 Nm.
The "F1" sensor should be removed after disconnecting the "G8" sensor connector. Use new sensor sealing rings when installing.
3. On CCFA/CCFC engines, the lubrication system sensors are located on the front side of the engine (see illustration) and are accessible for removal after removing the top engine cover (see Section 19 of Chapter 1).
44.3. CCFA/CCFC engine lubrication system sensors:
1 - D/V "F378" low pressure engine oil, 20 Nm;
2 - Sensor "G8" engine oil temperature, 20 Nm;
3 - D/V "F22" engine oil pressure, 20 Nm.
When installing, use new sensor sealing rings.
Removal and installation the G266 engine oil level and temperature sensor
4. Drain the engine oil (see Section 6 of Chapter 1). For CCFA/CCFC engines, proceed to paragraph 11.
5. Disconnect the negative battery cable (see Chapter 5).
6. Loosen the clamp (1 in illustration 35.21) and disconnect the air tube from the left air cleaner cover. Disconnect the connector (2) of the MAF sensor No. 2 "G246", release the clips (3) and remove the air cleaner cover.
7. Remove the bolts (arrows in illustration 35.23), loosen the nut (3) and set the fuel filter aside without disconnecting the hoses (1 and 2).
8. Remove the bolts (1-4 in illustration 4.14) and move the fuel cooler to the side. The fuel filter bracket remains in place.
9. Open the lid (arrow in illustration 4.15) terminals B+, disconnect the positive wire (1) going to the starter and generator, and move it to the side.
10. Remove the bolts (1 in the illustration) and remove the guide tube of the "B+" wire to the side.
44.10. Bolts (1) of the B+ wire guide tube.
11. Give the nuts (1 in the illustration) and move the guide tube of the "B+" wire to the side.
44.11. Bolts (arrows) of the guide tube of the B+ wire.
12. Disconnect the connector (3 in illustration 13.2). Loosen the nuts (1) and remove the engine oil level and temperature sensor (4).
13. Installation is carried out in reverse order. Use a new gasket (2 in illustration 13.2).
Removal and installation the lower section of the oil pan
14. Disconnect the negative cable from the battery (see Chapter 5).
15. Remove the front lower coolant pipes (see Chapter 3).
16. Remove the top engine cover (see Section 19 of Chapter 1).
17. Remove the front wheels and both front wheel arch liners (see Chapter 10).
18. Loosen the clamp (1 in illustration 35.21) and disconnect the air tube from the left air cleaner cover. Disconnect the connector (2) of the MAF sensor No. 2 "G246", release the clips (3) and remove the air cleaner cover.
19. Disconnect the connector (3 in illustration 36.5) and unscrew the bolt (1). Loosen the clamps (2 and 5) and remove the left air pipes.
20. On BTR and CCFA engines, follow the steps in paragraphs 7-9.
23. On the CCFC engine, open the cover (arrow in illustration 15.4) terminals 30, unscrew the bolt (1), remove the stud (2) of the positive battery terminal and move it to the side.
24. Remove the bolts (1 in illustration 44.10) and remove the guide tube of the "B+" wire to the side.
25. Give the nut (arrow in illustration 36.8) fastening the left engine support to its bracket.
26. Cut the clamp (arrow in illustration 35.11) and remove the electrical wiring from the air cleaner.
27. Remove the air cleaner cover as described in paragraphs 10-13 of Section 16 of Chapter 1.
28. Disconnect the connector (5 in illustration 35.49) and unscrew the bolt (1). Loosen the clamps (2 and 4) and remove the right air pipes.
29. Give the nut (arrow in illustration 35.52) fastening the right engine support to the bracket.
30. Loosen the bolt (1 in illustration 36.15) and unscrew the bolt (2) with the nut. Remove the rear right coolant pipe from the rear right engine lifting eye.
31. Remove the hood seal on both sides (see illustration 36.9).
32. Install beam No. 10-222A with supports T10-222A / 22 and two spindles on the front fender flanges (1 in illustrations 36.10 and 36.17). Hook the spindle hooks into the rear lifting eyes.
33. Prepare to collect ATF. Remove the bolt (2 in illustration 35.58) fastening of ATF lines, unscrew the bolt (1 in the illustration 35.50) and move the ATF lines and the right air tube to the side.
34. On both sides, remove the fasteners (2 in illustration 4.35) and separate the anti-roll bar from its strut.
35. Remove the heat shield (And in illustration 4.43) steering mechanism. Set the front wheels in the straight ahead position and secure the steering wheel with tape to prevent it/steering column from changing position. Remove the hinge mounting bolt (B) and separate it from the steering gear.
36. Unscrew the ground connection bolt on the right side member (see illustration 4.47).
37. Mark the installation position of the subframe and engine crossmember relative to the side members, and then unscrew the bolts (3 and 4 in illustration 4.51) and lower the front side of the subframe with the engine crossmember.
38. Disconnect the engine oil level/temperature sensor connector (1 in the illustration), unscrew the bolt (2) and push the power steering fluid line aside. Unscrew the bolts and remove the lower section of the engine oil pan (arrow).
44.38. Removing the lower section of the oil pan.
Note: There is still some oil left in the pan.
39. Using a drill with a plastic brush attachment, remove any remaining sealing materials from the mating surfaces of the upper and lower sections of the oil pan. Clean mating surfaces from oil and grease.
40. Apply a 2mm bead of silicone sealant to the tray as shown in the illustration.
44.40. Sealant application diagram.
After applying the sealant, the tray should be installed within 5 minutes.
41. Install the pan, tighten all its bolts in a diagonal order to 5 Nm, then tighten them in the same order to 10 Nm and finally tighten them to an angle of 90°.
42. Install the power steering fluid line. Install the subframe (see Chapter 9) and engine cross member (see Section 36). Install the remaining parts. Finally, fill the engine oil (see Chapter 1).
Removal and installation the BTR engine oil pump
43. On engines with a number from 004507, remove the power unit and separate the AT from the engine.
44. Remove the lower section of the engine oil pan (see subsection above) and the coolant pump (see Chapter 3).
45. On engines with a number from 004507, remove the accessory drive mechanism (see Section 41).
46. Remove the bolts (see illustration) and remove the sedative plate.
44.46. Fastening of the damper plate.
47. Remove the bolts (see illustrations) and remove the suction and connecting oil pipes.
44.47a. Suction fasteners (oil intake) tubes.
44.47b. Fastening of connecting oil pipe.
48. Remove the bolts (see illustration) and remove the oil pump.
44.48. Oil pump fasteners.
49. On engines with a number up to 004506, firmly squeeze the drive shaft with long pliers (1 in the illustration) oil pump and press on the shaft, overcoming the resistance of the spring.
44.49. Pressing in the oil pump drive shaft.
50. Make sure that two centering bushings are present for the oil pump.
51. On engines with a number up to 004506, firmly squeeze the drive shaft again with long pliers (1 in illustration 44.49) oil pump and press on the shaft, overcoming the resistance of the spring. Install the oil pump by inserting its drive shaft into the pump mechanism, then release the pliers and allow the shaft to enter the pump.
52. Tighten the pump mounting bolts.
53. On engines with a number up to 004506, make sure that the oil pump drive shaft has entered the pump: when trying to turn the pump gears from the inlet side (see illustration) the gears should not turn.
44.53. Turning the pump gear from the inlet side.
54. Install the remaining parts. Use new sealing elements.
Removal and installation the oil pump for CCFA/CCFC engines
55. Remove the power unit and separate it from the engine. Remove the lower section of the engine oil pan (see subsection above) and the coolant pump (see Chapter 3).
56. Remove the accessory drive mechanism (1 in illustration 41.12), as described in Section 41, remove the spring (2) and drive shaft (3).
57. Remove the bolts (see illustration) and remove the sedative plate.
44.57. Fastening of the damper plate.
58. Remove the bolts (see illustration) and remove the connecting oil pipe.
44.58. Fastening of connecting oil pipe.
59. Remove the bolts (see illustration) and remove the oil pump.
44.59. Oil pump fastener.
60. Make sure that two centering bushings are present (1 and 2 in the illustration) in the oil pump. Insert the gasket (3) into the indicated location.
44.60. Centering bushings (1 and 2) and gasket (3).
Caution: Do not insert the gasket into the position indicated by the arrow.
61. Installation is carried out in reverse order. Use new sealing elements.
Removal and installation the upper section of the oil pan
62. Remove the power unit and separate it from the AT engine.
63. Remove the generator (see Chapter 5), the right coolant pipe (see Chapter 3), auxiliary unit drive mechanism (see Section 41) and front sealing flange (see Section 38).
64. Remove the oil pump (see the relevant subsection above) and the fuel cooling pump "V166" (see Chapter 3).
65. Remove the bolts (1-3 in the illustration) and disconnect the left return oil pipes.
44.65. Fastening of left return oil pipes.
66. Remove the bolts (1-3 in the illustration) and disconnect the right oil return pipes.
44.66. Fastening of right return oil pipes.
67. On CCFA/CCFC engines, disconnect the connector (1 in the illustration) valve "N428" for regulating oil pressure.
44.67. Connector (1) and bolt (2) of the "N428" oil pressure adjustment valve.
68. Loosen the bolts (1 in the illustration) in a diagonal order and remove the upper section of the oil pan (it is held in place by sealant and centering bushings).
44.68. Bolts for fastening the upper section of the oil pan.
69. Using a drill with a plastic brush attachment, remove any remaining sealing materials from the mating surfaces of the cylinder block and the upper section of the oil pan. Clean mating surfaces from oil and grease.
70. Apply beads of silicone sealant into the groove on the upper mating surface of the upper section of the oil pan (arrows in illustrations).
44.70a. Sealant application diagram (bTR engine).
44.70b. Sealant application diagram (cCFA/CCFC engines).
The roller should completely fill the groove and protrude 1.5-2.0 mm beyond it. After applying the sealant, the top section of the tray should be installed within 5 minutes.
71. Apply a small amount of sealant to the O-rings (3 and 4 in the illustration) and secure them in the grooves of the cylinder block. Make sure that there are two centering bushings for the upper section of the oil pan in the cylinder block.
44.71. Sealing rings (3 and 4).
72. Install the upper section of the oil pan. Tighten the bolts that secure it (1-4 in illustration 44.68) in a diagonal order with a force of 5 Nm, and then pull them to an angle of 90°.
73. Install the remaining parts in the reverse order of their removal. Finally, fill the engine oil and adjust the coolant level (see Chapter 1).
Removal and installation the oil cooler
74. Drain the coolant and refrigerant from the climate control system (see Chapter 3). Remove the upper section of the intake manifold (see chapter 4) and the air conditioning system compressor (see chapter 3).
75. On CCFA/CCFC engines, remove the right coolant pipe for the EGR system (see Chapter 3).
76. On the BTR engine, remove the left idler roller (1 in the illustration) drive belt as described in Section 37, remove the bolt (2) and pull out the dipstick guide tube.
44.76. Removing the oil dipstick guide tube.
77. Disconnect the PCV tube from the hoses (arrows in illustration 38.4). On the BTR engine, additionally unscrew the bolts (1 and 2) and remove the tube.
78. Loosen the bolts (1 in the illustration) and press the EGR switching flap actuator (2) to the right.
44.78. PCV valve actuator bolts (1).
79. Disconnect the coolant hose from the left EGR connection unit (see illustration).
44.79. Coolant hose at left PCV connection point.
80. Disconnect the hose from the PCV control valve (arrow in the illustration).
44.80. Clamp (arrow) of the hose on the PCV valve.
81. Disconnect the coolant hose (1 in the illustration), unscrew the bolts (arrows) and remove the oil cooler, collecting the leaking coolant with a cloth.
44.81. Oil cooler mounting.
82. Installation is carried out in reverse order. Use new sealing elements. Finally, fill up with engine oil and coolant (see Chapter 1).
Removal and installation the oil filter housing
83. Remove the upper section of the intake manifold (see Chapter 4) and the filter element of the oil filter (see Section 6 of Chapter 1).
84. Remove the bolts (see illustration) and remove the oil filter housing.
44.84. Fastening of oil filter housing.
85. Installation is carried out in reverse order. Use new seals, a new filter element and fresh oil.
Removal and installation the PCV pressure control valve
86. Remove the EGR cooler (see Chapter 4), on the BTR engine - with a switching valve.
87. Disconnect the hose from the PCV control valve (arrow in illustration 44.80), unscrew the bolts (1 and 2) and remove the valve.
88. Installation is carried out in reverse order. Use new sealing elements. Finally, fill up the coolant (see Chapter 3).
Removal and installation the mounting plate
89. Remove the oil cooler (see the relevant subsection above) and the front upper coolant pipe. Remove the EGR radiator (see Chapter 4), on the BTR engine - with a switching valve.
90. Unscrew the bolt (2 in the illustration) front central coolant pipe.
44.90. Connections and fasteners of the central front coolant pipe.
91. Remove the bolts and the mounting plate from the cylinder block (see illustration).
44.91. Mounting plate fastener (bolts are highlighted in light).
92. Installation is carried out in reverse order. Use new sealing elements. Finally, fill the engine oil (see Chapter 1) and coolant (see Chapter 3).
Removal and installation the engine oil pressure control valve "N428" (cCFA/CCFC engines)
93. Remove the front sound insulation panel under the engine compartment (see Section 19 of Chapter 1).
94. Loosen the clamp (1 in illustration 35.21) and disconnect the air tube from the left air cleaner cover. Disconnect the connector (2) of the MAF sensor No. 2 "G246", release the clips (3) and remove the air cleaner cover.
95. Disconnect the connector (3 in illustration 36.5) and unscrew the bolt (1). Loosen the clamps (2 and 5) and remove the left air pipes.
96. Disconnect the connector (1 in illustration 44.67), unscrew the bolt (2) and remove the valve "N428".
97. Installation is carried out in reverse order. Use a new O-ring.