5.9. Removal and installation of the engine

The manufacturer recommends to take out the power unit (the engine with coupling and the transmission) down. The elevator is for this purpose necessary to lift above a forward part of the car. In garage conditions in the absence of the elevator the jack, and also strong and rather high support will be required to establish on them the raised forward part of the car that it will give the chance to take from under it the engine lowered on a garage floor.

GOOD ADVICE The engine is very heavy therefore we recommend to remove it with the assistant, using the special equipment (the elevator, a telfer and t. п).

    

PREVENTION At removal and installation of the power unit assembled having big weight use only completely serviceable load-lifting mechanisms calculated on the corresponding loading and especially carefully control correctness and reliability of accession to transport eyes of the engine of cables, a traverse, etc.

1. For convenience of work remove a cowl (see. "Removal and installation of a cowl").

2. Reduce pressure in a power supply system (see. "Pressure decrease in a power supply system").

3. Remove the rechargeable battery (see. "Removal and installation of the rechargeable battery").

4. Remove the right mudguard of the engine (see. "Removal and installation of mudguards of the engine").

5. Merge liquid from the cooling system (see. "Replacement of cooling liquid").

6. If you remove the engine for repair, merge oil from an oil case (see. "Replacement of oil in the engine and an oil filter").

7. Take off a conditioner compressor drive belt (see. "Replacement of a belt of the drive of the compressor of the conditioner").	8. Remove drives of forward wheels (see. "Removal and installation of drives of forward wheels").

    

NOTE Drives of forward wheels can be not disconnected from the transmission. In this case fix the drives disconnected from naves on the power unit in any available way (for example, bind a wire).

9. Remove a reception pipe of system of production of the fulfilled gases (see. "Replacement of a reception pipe").

10. Remove the working cylinder of a hydraulic actuator of coupling from an arm (see. "Replacement of the working cylinder of a hydraulic actuator of switching off of coupling"), without disconnecting from it a hose, also take the cylinder aside.	11. For convenience of work remove the air filter (see. "Removal and installation of the air filter, muffler of noise of an admission and air duct") …

12. … have a bite bokorezam (or knife) a collar of fastening of a wire to a hose and take a plait of wires aside that it did not prevent work.

NOTE Collar of one-time use. At assembly do not forget to replace it with a new collar that the wire was surely fixed.

13. Separate a block of a plait of wires of the sensor of concentration of oxygen.	14. Disconnect from the thermostat …

15. … and a radiator the bringing cooling system hose also remove it.	16. Similarly disconnect the taking-away hose from a water distribution pipe and a radiator, and then remove it.

17. Weaken an inhaling of a collar of fastening of a liquid hose …	18. … also remove a hose from a branch pipe of a broad tank.

19. Weaken fastening collars …	20. … also disconnect heater hoses from heater radiator branch pipes on a body front board.

21. Weaken an inhaling of a bolt of a klemmovy clip of the drive of control of the mechanism of gear shifting and separate draft and a tip of the lever of gear shifting.	22. Disconnect blocks of a motor plait of wires from the idling regulator …

23. … and sensor of provision of a butterfly valve.	24. Disconnect from branch pipes of throttle knot a hose to the sensor of absolute pressure …

25. … hoses of giving and discharge of cooling liquid …	26. … and also adsorber purge hose.

27. Disconnect a tip of a cable of the drive of a butterfly valve from the sector of throttle knot …	28. … and from an arm on an inlet pipe a cable cover (see. "Adjustment and replacement of a cable of the drive of a butterfly valve").

29. Disconnect blocks of a motor plait of wires from the speed sensor …	30. … and backing light switch.

31. Disconnect a block of a plait of wires from the sensor of 1 index of temperature of cooling liquid and disconnect the holder 2 motor plaits from an arm.	32. Disconnect blocks of a plait of wires from nozzles and take a plait of nozzles aside.

33. Disconnect blocks of a plait of wires from the sensor of temperature of cooling liquid of a control system of the engine …	34. … the electromagnetic valve of system of recirculation of the fulfilled gases …

35. … from the ignition coil …	36. … and from the conditioner compressor coupling.

37. Take off a belt of the drive of the generator and pump of the hydraulic booster of steering (see. "Replacement of a belt of the drive of the generator and pump of the hydraulic booster of steering").

38. Turn out three bolts of fastening of a pulley of the pump of the hydraulic booster of steering, holding a pulley from a provorachivaniye the screw-driver …	39. … also remove a pulley.

40. Holding the union from a provorachivaniye, the second key turn off a nut of the pipeline of system of the hydraulic booster of steering …	41. … also take the pipeline from the union of the pump of the hydraulic booster.

    

NOTE Connection of the pipeline with the pump is condensed with a rubber ring which needs to be replaced at each separation.

42. Squeeze passatizham the unbent collar short moustaches, shift a collar towards the pump …	43. … also remove a hose from a tube of the pump of the hydraulic booster of steering.

PREVENTION Take measures against an effluence of working liquid from pipelines, having muffled them, for example, wooden traffic jams.

44. Remove a collar from a tube.

45. Disconnect a block of a plait of wires from the generator.	46. Turn off a nut of fastening of a wire to a conclusion of "BAT" of the generator …

47. … also remove a wire from a conclusion.	48. Turn off nuts of fastening of wires to conclusions of a starter and remove wires from conclusions.

49. Disconnect a block of a plait of wires from the sensor of an alarm lamp of emergency pressure drop of oil.	50. Separate a block of a plait of wires of the sensor of provision of a bent shaft.

51. Disconnect a discharge hose from the fuel pressure regulator union …	52. … and from the fuel filter the taking-away hose, having squeezed clamps of locking elements of tips of hoses.

    

NOTE Need of a detachment of a hose from the fuel filter, but not from a stage is caused by the fact that its detachment from a stage requires special adaptation (see. "Removal and installation of a fuel stage") which is expedient for using only when replacing a hose.

53. Weaken a collar of fastening of a hose of the vacuum amplifier of brakes, having squeezed passatizham his unbent ears, shift a collar on a hose …	54. … also disconnect a hose from an inlet pipe.

55. Turn out two lower bolts of fastening of the compressor of the conditioner to an arm on the engine …	56. … then two top bolts also take the compressor aside, without disconnecting from it pipelines.

57. Fix slings of the load-lifting mechanism for a lobby …	58. … and back transport eyes, pull slings to unload support of the power unit …

59. … also establish for an insurance a reliable support under a transmission case.	60. Turn out two bolts of fastening of an arm of the right support of a suspension bracket of the power unit to a support …

61. … three bolts of fastening of an arm to the engine also remove an arm.	62. Turn out two bolts of fastening of the left support of a suspension bracket of the power unit to a body longeron.

63. Turn off a nut of a bolt of fastening of a back support of a suspension bracket of the power unit to an arm on the transmission and take a bolt from openings of a support and an arm.

64. Double-check whether all wires, hoses and hinged knots are disconnected from the engine.

65. Raise the power unit a little, remove a support from under the transmission and lower the power unit down on a floor.

66. You will hang out a forward part of the car (lift the car on the elevator) on height sufficient for extraction from under the car of the power unit, and establish reliable support under a body.

67. Install the engine and all removed knots and details in the sequence, the return to removal, taking into account the following:

– before installation of the power unit clear a tap of a rust carving openings of fastening of its support;

– apply the fixing structure on a carving of bolts of fastening of support (for example, Loctite);

– it is more convenient to fix support of the power unit in the following order: back, forward left, forward right;

– surely replace laying of a reception pipe new;

– at connection of wires and pipelines carefully you watch correctness of their arrangement in a motor compartment, without allowing contact with the heating-up and moving elements of the power unit.

After installation of the engine execute the following operations.

1. Fill in oil (see. "Replacement of oil in the engine and an oil filter").

2. Fill in cooling liquid (see. "Replacement of cooling liquid").

3. Adjust a tension of a belt of the drive of the generator and pump of the hydraulic booster of steering (see. "Check and adjustment of a tension of a belt of the drive of the generator and pump of the hydraulic booster of steering"), and also a conditioner compressor drive belt (see. "Check and adjustment of a tension of a belt of the drive of the compressor of the conditioner").

4. Adjust the drive of a butterfly valve (see. "Adjustment and replacement of a cable of the drive of a butterfly valve").

5. Adjust the drive of control of the gear shifting mechanism (see. "Adjustment of the drive of control of the transmission").

6. Launch the engine and check whether there is no leak of fuel, oil and cooling liquid. Check oil pressure. Listen to the engine, it has to work exactly, without extraneous noises and knocks.