Table of contents: Removal and installation the lower… ↓ Removal and installation the oil and… ↓ Removal and installation the upper… ↓ Removal and installation the oil… ↓ Removal and installation the oil… ↓ Removal and installation the oil… ↓
1. The installation details of the lubrication system components are shown in Illustrations 33.1a-e.
33.1a. Details of installation of oil pump and lower section of oil pan:
1 - Oil level and temperature sensor "G266";
2 - Gasket, subject to replacement;
3 - Bolt, subject to replacement;
2 Nm, then 3 Nm, then tighten to a 90° angle;
4 - Lower section of the oil pan;
5 - Bolt, to be replaced, 3 Nm, then tighten to an angle of 90°;
6 - Relief plate;
7 - Return oil pipe;
8, 10, 21 - Bolt, 9 Nm;
9 - Suction tube;
11, 14 - Sealing ring, subject to replacement;
12 - Bolt, subject to replacement, tighten first by hand, then with a force of 8 Nm, then tighten to an angle of 90°;
13 - Oil pump with brake booster vacuum pump, cannot be disassembled;
15 - Centering bushings, 2 pcs.;
16 - Oil pump drive shaft;
17 - Spring;
18 - Clutch;
19 - Oil pump drive sprocket;
20 - Bolt, to be replaced, 30 Nm, then tighten to an angle of 90°;
22 - Gasket, subject to replacement;
23 - Drain plug, 30 Nm;
24 - Nut, 9 Nm.
33.1b. Upper oil pan section installation details:
1, 8, 21 - Bolt, 9 Nm;
2 - Valve "N428" for regulating oil pressure;
3, 9, 20 - Sealing rings, subject to replacement;
4 - Upper section of the oil pan;
5, 11, 13, 16 - Gasket, subject to replacement;
6, 14 - Centering sleeve;
7 - Guide tube of the feeler gauge 10;
10 - Sealing plug;
12 - Oil return valve for oil cooler;
15 - Bolt, to be replaced, 2 Nm, then 5 Nm, then tighten to an angle of 90°;
17 - Service hole plug, 25 Nm;
18 - Vacuum line of the vacuum pump;
19 - Bolt, to be replaced, 3 Nm, then tighten to an angle of 45°.
33.1c. Oil filter housing and sensor installation details:
1 - Bolt, 9 Nm;
2 - Oil filter housing, must be replaced after removal;
3 - Gasket, inseparably attached to sensor 4, not supplied separately;
4 - D/V "F22" oil pressure (with green insulation, 2.0-2.5 bar), 20 Nm;
5 - Gasket, inseparably attached to sensor 6, not supplied separately;
6 - D/V "F378" low oil pressure (with gray insulation, 0.75-1.05 bar), 20 Nm;
7, 9 - Bolt, 4 Nm, not on all models;
8 - Housing holder 2, not on all models;
10 - Plug with bypass valve, 35 Nm;
11 - O-ring, must be replaced;
12 - Filter element.
33.1d. Oil cooler installation details:
1 - Plate gaskets 2;
2 - Oil cooler mounting plate;
3, 5, 8 - Bolt, 9 Nm;
4 - Oil cooler gasket, must be replaced;
6 - Oil cooler;
7 - Coolant shut-off valve;
9 - Valve gasket 7, must be replaced.
33.1e. Oil cooler temperature regulator installation details:
1 - Regulator cover 4;
2 - Bolt, to be replaced, 3 Nm, then tighten to an angle of 90°;
3 - O-ring, must be replaced;
4 - Oil cooler temperature regulator;
5 - Front sealing flange.
Sensor No. 2 "G664" of engine oil temperature is installed on the front side of the engine (see illustration 28.14) and is accessible after removing the top engine cover.
Removal and installation the lower section of the oil pan
2. Drain the engine oil (see Section 6 of Chapter 1).
3. Remove the air cleaner filter element (see Section 16 of Chapter 1).
4. Remove both sound insulation panels under the engine compartment (see Section 19 of Chapter 1).
5. On both sides of the engine, loosen the nuts securing the engine brackets to the supports (see illustration 5.6).
6. Install beam No. 10-222A with supports No. 10-222A/22 and two spindles No. 3033 located at the rear onto the flanges of the front wings (see illustration 26.8). Hook both spindles into the rear lifting eyes of the engine.
7. Unscrew the two bolts and 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.
8. Loosen the clamps (1 and 4 in illustration 26.11) and separate the air hoses. Remove the bolts (2 and 3) and remove the air tube downwards.
9. Raise the engine evenly on spindles #3033 until its brackets are positioned above the support studs. Support the power unit with a transmission jack (see illustration 13.8).
10. On both sides, remove the fasteners (2 in illustration 4.35) stabilizer on its struts.
11. Mark the position of the subframe and engine crossmember on the side members. Remove the bolts (3 and 4 in illustration 4.51) and lower the front part of the subframe with the engine crossmember.
12. Disconnect the oil level and temperature sensor connector (arrow in the illustration), unscrew the bolts in order (14-1) and remove the lower section of the engine oil pan, carefully separating it from the glued connections.
33.12. Connector (arrow) of engine oil level/temperature sensor and bolts (1-14) of oil pan.
Note: There is still some oil left in the pan.
13. 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.
14. Apply a 2mm bead of silicone sealant to the tray as shown in the illustration.
33.14. Sealant application diagram.
After applying the sealant, the tray should be installed within 5 minutes.
15. Install the pan, tighten all its bolts in order (1-14 in illustration 33.12) with a force of 2 Nm, then in the same order tighten them to a force of 3 Nm and, finally, tighten them to an angle of 90°.
16. Install the steering gear joint (see Chapter 9). Install the crossmember and engine brackets (see section 26).
17. Install the subframe (see Chapter 9) and the remaining parts.
18. Finally, fill the engine oil (see Chapter 1).
Removal and installation the oil and vacuum pump assembly
19. Remove the lower section of the oil pan (see subsection above).
20. Remove the bolts (see illustration) and remove the sedative plate.
33.20. Fastening of the damper plate.
21. Remove the bolts (1-3 in the illustration).
33.21. Removing the oil pump.
Press down on the pump drive shaft against the spring resistance and remove the oil and vacuum pump assembly. The drive shaft remains in place.
22. Installation is carried out in reverse order. Before installation, make sure that the pump has two centering bushings.
Removal and installation the upper section of the oil pan
23. Remove the engine and secure it to the mounting stand.
24. Remove the lower timing chain cover (see Section 29) and the auxiliary drive chain (see Section 30).
25. Remove the front sealing flange (see Section 28).
26. Remove the oil pump (see subsection above).
27. Remove the lower left coolant pipe (see Chapter 3).
28. Disconnect the connector (1 in the illustration) sensor "N428".
33.28. Electrical wiring connector (1) and bolt (2) of the oil pressure adjustment sensor "N428".
29. Loosen the bolts in sequence (12-1 in the illustration), then completely unscrew them, carefully release the upper section of the tray from the glued connections, squeeze it out of the centering bushings and remove it.
33.29. Bolts (1-12) for fastening the upper section of the oil pan.
30. 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.
31. Apply a bead of silicone sealant to the groove on the upper mating surface of the upper section of the oil pan (arrows in the illustration).
33.31. Sealant application diagram.
The roller should completely fill the groove and protrude 3.5 mm beyond it. After applying the sealant, the top section of the tray should be installed within 5 minutes.
32. Install the top section of the tray, tighten its bolts (1-12 in illustration 13.21) with a force of 2 Nm, and then in the same order tighten them to a force of 5 Nm and tighten them to an angle of 90°.
33. Install the remaining parts in the reverse order of removal.
Removal and installation the oil filter housing
34. Remove the top engine cover (see Section 19 of Chapter 1).
35. Remove the front coolant pipe (see Chapter 3).
36. Remove the oil filter element (see Section 6 of Chapter 1).
37. Remove the drive belt (see Section 27).
38. If present, remove the bolt (2 in the illustration) from the intake manifold bracket (on the right side).
33.38. Intake manifold bracket fastener.
Remove sensors "F22" and "F378" (4 and 6 in illustration 33.1c).
39. Disconnect the coolant hoses from the oil filter housing (1 and 2 in the illustration), unscrew the bolts (arrows), remove the filter housing and disconnect the connector (3).
33.39. Connections (1-3) and fasteners (arrows) of the oil filter housing.
40. Installation is carried out in reverse order. Use new seals, a new filter element and fresh oil.
Removal and installation the oil cooler and its mounting plate
41. Remove the EGR cooler (see Chapter 4).
42. Remove the bolts (arrows in the illustration), disconnect the coolant hose (1) from the oil cooler and remove the oil cooler.
33.42. Removing the oil cooler.
43. If necessary, after removing the oil cooler, you can remove its mounting plate. To do this, unscrew the bolts (arrows in the illustration) and move the coolant shut-off valve (1) to the side.
33.43. Removing the oil cooler mounting plate.
44. Installation is carried out in reverse order. Use new gaskets.
Removal and installation the oil cooler temperature regulator
45. Remove the drive belt and coolant pump pulley (see Section 27).
46. Unscrew the bolt (arrow in the illustration) lids (1).
33.46. Regulator cover bolt.
Collect any leaking oil with a cloth.
47. Screw in the M6 bolt (1 in the illustration) into the thread of the cover (2) and pull it out by pulling the bolt.
33.47. Removing the regulator.
After removing the cover, pull out the temperature regulator (4) and replace the sealing ring (3).
48. Installation is carried out in reverse order.
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