 printable version
Refitting
Recommendations about engine removal Before proceeding, please read this section. If the engine is removed for repair, you must choose a place for work, provide space for maintenance and storage of spare parts. Repair is recommended at the service station or in a garage with a flat, level floor and a clean hard surface. Before removal, clean from dirt and clean the engine and engine compartment. When lifting, use hoist with sufficient capacity to safely lift the engine. If you remove the engine for the first time, invite an experienced specialist. Some of the work should be performed with an assistant. All clips and clamps that when removing the engine will be damaged or cut, the assembly of the engine replaced. Depending on the year of manufacture and the vehicle in the engine compartment may be located on different electrical wires, pipes and hoses. Therefore, before disconnecting the electrical connectors and disconnecting pipes and hoses recommended adhesive tape to attach labels to them with signatures. Engine extracted forward separately from the gearbox. On vehicles with automatic transmission, set the selector lever to position N. Drain coolant must be collected and disposed of. Before disconnecting the battery, check whether you have the code switch on the radio.
Withdrawal Switch off the ignition and disconnect a wire of "weight" from the storage battery.
| Fig. 3.2.1. Location screws engine cover
|
| Fig. 3.2.2. Location screws bottom mudguard of a motor compartment
|
Remove the screws indicated by arrows in Fig. 3.2.2, and remove the bottom mudguard of a motor compartment. Remove the front bumper. Remove the oil radiator for power steering and take him aside, without disconnecting from it pipelines. Remove the expansion tank cap.
A WARNING When you open the cover of a broad tank on the hot engine must be careful, because the pressurized steam can cause severe burns. Close the expansion tank with a thick layer of tissue and slowly remove the lid until the hissing sound. After the cessation of fizz slowly unscrew and remove the cap from the expansion tank. |
Set under the radiator drain pan coolant.
| Fig. 3.2.3. Location cork drain coolant from the radiator
|
Rotate counter-clockwise, remove the drain plug from the radiator coolant drain shown in Fig. 3.2.3 arrow. When installing the plug, replace the O-ring.
| Fig. 3.2.4. Location tube draining coolant from the engine block
|
Remove from the engine block drain plug drain the coolant as shown in Fig. 3.2.4 arrow. When installing the plug, replace the O-ring.
Cars with air conditioning
A WARNING Do not open the refrigerant circuit! |
| Fig. 3.2.5. Location of components on vehicles with air conditioning: 1, 2 - bolts of the capacitor; 3 - C pressure sensor connector; 4 - bolt duct
|
Remove the 4 screws (Fig. 3.2.5) securing air ducts on the left and right sides of the radiator. Remove bolts 1 and 2 (see. Fig. 3.2.5) fixing the condenser. Disconnect the electrical connector 3 C pressure sensor. Remove the condenser from the fixtures, take aside and fix soft wire near the right front wheel.
All models
| Fig. 3.2.6. Location of electrical connectors on the front of the ABS unit
|
Disconnect the electrical connectors from the front of the unit ABS (Fig. 3.2.6). Release clamps and remove the electrical bracket. Remove the upper and lower hoses from the radiator. Remove the mounting bolts of the air pipe to the front transverse panel. Remove the screws and assemble the front cross bar in the service position. Disconnect hoses from the surge tank, loosen the screws and remove the tank. Loosen the hose clamps and remove the air tube connecting the air flow meter and a curved inlet pipe. Disconnect the electrical connector and pull, remove the valve of the coal fuel vapor absorber (ACF). Disconnect the electrical connector from the air mass meter.
A WARNING The fuel system is pressurized. Before releasing elements of the fuel system to relieve pressure in the system. To do this, close the connection point of the fuel system and a clean cloth, being careful, gently loosen the union nut. |
Loosen the union nut and remove the hoses and the return of fuel from the fuel line.
Vehicles with exhaust gas recirculation
| Fig. 3.2.7. The direction of rotation to release the connecting pipe EGR
|
Turn clockwise by 45 ?� connecting pipe EGR and disconnect the air filter (see. Fig. 3.2.7).
All models Remove the bolt and remove the air filter. Remove the wiper arms.
| Fig. 3.2.8. Location clamps (1 and 3) of the waterproof case and the lid (2) electronic engine control unit
|
3 Remove the mounting clamps on the left and right sides of the waterproof housing. Remove the waterproof casing. Remove the screws and remove the cover 2 (see. Fig. 3.2.8) with electronic engine control unit. Release clamps and disconnect the electrical connectors from the electronic engine control unit and the sensor height. Release the harness from the clips and take him aside.
| Fig. 3.2.9. Location nuts (2) securing the wire connection with "weight" and nuts (1) bracket assembly of the ignition system on a partition of the plenum
|
Remove the nut 2 (Fig. 3.2.9) and remove a wire connection with "weight" of the car. Remove nuts 1 and remove the bracket assembly of the ignition system to partition the plenum. Release the harness from the clips and take him aside. Loosen the clamps and disconnect coolant hoses going to a heater. Unplug electrical connectors: blue - from the overload valve on the intake manifold; green - from the EGR valve; black - temperature sensor of air entering the engine. Release the wires from the clamps and move them aside.
| Fig. 3.2.10. Places hose connections and location of bolts: 1 - the mounting bolt to the base plate; 2, 3 - and bolts to the intake manifold; A - point of attachment of the hose to the brake booster; B - a pressure regulator; C - to a tee
|
Disconnect vacuum hose A (Fig. 3.2.10) of the brake booster, the fuel pipes from the pressure regulator and hose with off the tee. Remove the bolt 1 from the baseplate and bolts 2 and 3 from the rear portion of the inlet manifold. Remove the hoses that connect the vacuum brake booster and the resonator. Remove the bolt block the cruise control system to the bracket and remove the rod from the throttle. Disconnect the electrical connector from the valve phase change valve opening. Disconnect the hose between the ventilation valve of the coal fuel vapor absorber (ACF) and the throttle body. Loosen the hoses and cables from the clips and move them aside. Remove the resonator. Disconnect the accelerator cable from the throttle body and the cover of a cable from the bracket and move in the direction of the cable. Disconnect the electrical connectors on the right side of the plenum (front windshield) and move them aside.
| Fig. 3.2.11. Use clamps 3094 for clamping the power steering hose and place of disconnecting the supply hose
|
Clamps (for example, 3094) to pinch hoses into hydraulic power assisted steering (Fig. 3.2.11). Disconnect the supply hose hydraulic power assisted steering pipe from under the left cylinder head. In order to collect the liquid flowing under the seat detaching hook rags.
| Fig. 3.2.12. Designated disconnecting hydraulic pressure hose pipe from the rear of the cooling system and the right cylinder head
|
Disconnect the hydraulic hose from the back of the high-pressure pipe cooling system and the right cylinder head (Fig. 3.2.12).
| Fig. 3.2.20. Wrenching bolts radiator fan
|
Hold the pulley radiator fan from turning a special key 3212, a conventional key, remove the pulley bolt. The bolt has a left-hand thread for unscrewing it must rotate clockwise (see. Fig. 3.2.20).
| Fig. 3.2.21. Easing tension on the serpentine belt tensioner pulley with an external hexagon. The arrows indicate the location of the pins 3204
|
Spanner 17 mm turn clockwise tensioner V-ribbed belt, causing the belt tension will ease. Lock the tensioner in this position, the pins 3204 (see. Fig. 3.2.21) and remove the belt from the alternator.
A WARNING Chalk, markers or paint mark the direction of rotation of poly V-belt. After setting the belt rotates in the opposite direction, which may result in its destruction. |
Remove ribbed belt.
| Fig. 3.2.13. Location nuts wire motor connection with "weight" and clips of fastening of wires starter and generator
|
Remove the nut and disconnect the motor connection with "weight". Loosen the clamp on the starter and generator, disconnect the wires from the starter and generator, and carry them away. Remove the bolt and move the alternator generator to the front of the engine compartment.
| Fig. 3.2.14. Location nuts reception exhaust pipe to front muffler
|
The bottom of the car, loosen the nuts reception exhaust pipe to front muffler (Fig. 3.2.14). Remove the upper bearing bolts to support catalytic converters. Disconnect the exhaust system from the rear pillars exhaust manifolds. Remove the starter mounting bolts and remove it by moving back and forth between the drive shaft and the sub-frame.
Cars with automatic transmission
| Fig. 3.2.15. Location torque converter bolts
|
Through the hole opened after removing the starter, remove the three bolts securing the converter (Fig. 3.2.15). To access each successive bolts, turn the crankshaft of the engine in the direction of its working rotation 1/3 turn. For cranking using a central bolt crankshaft pulley. Secure one screw on the bracket of the engine generator.
Cars with air conditioning
A WARNING Do not open the refrigerant circuit! |
Loosen the clamp on the tubes of air conditioning and oil cooler from the front of the engine. Loosen the clamp on the air conditioning system of tubes under the oil filter. Set the pan under the engine to collect the oil. Remove the oil filter and oil cooler. Remove the bracket bolts the air conditioning compressor, take aside the compressor together with attached wires and tubes. Soft wire fix it on the body.
All models
| Fig. 3.2.16. Location nuts (1) and fastening the mounting sleeve (2) engine mount
|
Note the location of the threaded connections 1 (Fig. 3.2.16) and locating sleeves 2 on the right and left engine support. 1 Remove the nuts securing the base left and right engine mounts. Remove the top and bottom bolts of a transmission to the engine. Remove the protective cover from the top of the front suspension struts.
A WARNING For various modifications of engines using different arrangements of screw connections and mounting bushings. |
Install the support bar 10-222 on the top of the front suspension struts. Install adapter 10-222A / 2 on the support bar 10-222 3147 capture and secure adapter on the gearbox. Turn the screw of the lifting device, tighten the grip so that the weight of the gearbox was seen lifting device. Hang on a hoist lifting capture 2024A and attach it to the engine. Make sure that all electrical wires, hoses, tubes and pipes are disconnected from the engine.
Cars with automatic transmission Before removing the engine push the torque converter to the engine mount.
All models Carefully lift the engine, then release it from the gearbox and pull up from the engine compartment.
Cars with automatic transmission Secure the torque converter to the engine.
Setting Engine installation is carried out in sequence, return to removal, taking into account the following.
| Fig. 3.2.17. Location and numbering bolts manual gearbox to the engine: A - installation location centering sleeve
|
Replace with new self-locking nuts and bolts (Fig. 3.2.17), which delayed dovorachivaniem at a certain angle, as well as seals and gaskets. Check centering sleeves, determine the relative position of the engine and gearbox.
Pos. | Bolt | Tightening torque Nm | 1 | M12x67 | 45 | 2 | M12x90 | 65 | 3 | M12x80 | 65 | 4 | M10x45 | 45 | 5 | M10x135 | 45 |
Vehicles with manual transmission Clean input shaft splines. When reusing the clutch disc to remove a corroded. Lubricate the splines of the shaft with a thin layer of greasing G 000 100. Check the condition of the clutch release bearing and replace it if necessary. Using a mandrel, align the clutch disc. Check the condition of the needle bearing on the end of the crankshaft on the flywheel side. If necessary, replace the bearing.
Cars with automatic transmission To attach the converter to the master drive must use the original screws.
| Fig. 3.2.18. Measure the distance between the supporting surface for the torque converter bolts and the support surface casing
|
Be sure to install the converter. If the distance between the supporting surface for the torque converter bolts and the surface casing is 23 mm, then the converter is installed properly. If improperly installed torque converter, this distance is 11 mm (Fig. 3.2.18). Improper installation of the converter will lead to the destruction of the torque converter pump and an automatic transmission. Mount the motor in place, and shake it from side to side, ensure the correct location on the supports.
All models Install poly V-belt. Fill the cooling system with coolant. In case the cylinder head was removed and replaced with the cylinder block coolant reuse is allowed. Install the front transverse panel normal position. Check that the exhaust systems are properly installed on the brackets and do not touch the body with shaking. Check the connection of the electrical connectors. Attach the wire of "weight" to the battery. Turn on the radio and enter the code. Lift up the power window glass until it stops. Then click on all window switches again for at least 1, in the closed position of the control unit to activate windows. Set the clock. Before starting the engine, check the availability and level of oil in the engine. After separation of the various electrical connections in the memory control unit writes error information to be erased after installation. Adjust headlights.
| 
