Removing and installing engine

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.

Engine extracted forward separately from the gearbox.

Drain coolant must be collected and disposed of.

Before disconnecting the battery, check whether you have the code switch on the radio.

Withdrawal

Open the hood.

Remove the rubber seal waterproof housing at the rear of the engine compartment.

Remove the waterproof housing 1 (Fig. 3.3.1).

Switch off the ignition and disconnect a wire of "weight" from the storage battery.

Remove the expansion tank cap.

Remove the pointer (probe) 1 (Fig. 3.3.2), the engine oil level.

Release clamps fastening, remove the three screws and remove the engine cover (see. Fig. 3.3.2).

Move the pointer 1 (see. Fig. 3.3.2), the engine oil in place.

Remove the two screws and remove the air filter cover (Fig. 3.3.3).

Remove the bolts and remove the air tubes 1 and 2 (Fig. 3.3.4).

Remove the cover from the fluid reservoir for power steering.

Unscrew the heater exhaust pipe and additional noise insulation heater (Fig. 3.3.5).

Release clamps and remove the front and rear section of the bottom mudguard of the engine compartment (Fig. 3.3.6).

Unscrew three bolts and remove an arm of the bottom mudguard of a motor compartment.

Remove the front bumper.

Release the clips and remove the power steering oil cooler duct (Fig. 3.3.7).

Unclip the ambient air temperature sensor.

Remove the screws of the oil radiator for power steering and take him aside, without disconnecting from it pipelines.

Set under the radiator cooling system of the engine sump to collect the coolant.

Rotate counter-clockwise, remove the drain plug from the radiator coolant drain shown in Fig. 3.3.8 arrow.

When installing new plugs replace its sealing ring.

Loosen the clamp and remove the lower coolant hose from the radiator.

Loosen the clamp and remove the air outlet (Fig. 3.3.9) at the bottom left on the front cross-bar.

Disconnect the turbocharger air inlet at the bottom right on the front transverse panel.

Disconnect the electrical connectors from the headlights.

Disconnect the cable of opening the bonnet of the fastening element of the castle and the front transverse panel.

Disconnect the electrical connectors 1-3 (Fig. 3.3.10), located upstream of the ABS, and take them away.

Disconnect the radiator upper hose from the coolant.

Cars with the condenser air conditioning system

Remove the bolts ducts on left and right side of the radiator.

Remove bolts 1 and 2 (Fig. 3.3.11) fixing the condenser.

Disconnect the electrical connector 3 refrigerant pressure sensor.

Remove the condenser from the clips, take aside and fix soft wire near the right front wheel.

All models

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.

Disconnect the electrical connector from the low coolant level, located at the base of the surge tank.

Disconnect the supply 1 (Fig. 3.3.12) and return 2 fuel hoses from the fuel filter, and carry them away.

Disconnect the electrical connector 1 (Fig. 3.3.13).

2 Remove the screw (see. Fig. 3.3.13), release and remove the air inlet.

Loosen the clamp and disconnect the air pipe from the charge air cooler.

Loosen the clamp and disconnect the coolant hose from the oil heat exchanger located in the base of the oil filter. Drain the coolant hose to the sump.

Loosen the clamp and disconnect the other coolant hose from the oil heat exchanger.

Disconnect the coolant hose from the thermostat.

Unplug electrical connector 2 (see. Fig. 3.3.46) of the air flow meter.

Remove the screws that secure the wires to the terminals of the air filter housing and take wires aside.

Loosen the clamp and disconnect the air pipe 3 (see. Fig. 3.3.46) from the air filter housing.

Remove the bolt 1 (see. Fig. 3.3.46) and remove the air filter housing.

Remove the bolt electromagnetic EGR valve and remove the valve from the suction tube (Fig. 3.3.14). Disconnect the electrical connector from the valve, take him aside.

Disconnect the vacuum hose from the vacuum brake booster bulkhead.

Blade screwdriver to release clamps (Fig. 3.3.15) securing the cover of the electronic engine control unit and remove it.

Blade screwdriver to release clamps of fastening of the electronic engine control unit and lift the unit.

Loosen the clamp and disconnect the unit from the power connectors 1 and 2 (Fig. 3.3.16).

Blade screwdriver to release the lock and lift up an additional block of the relay located in the box for the electronic engine control unit.

Disconnect the electrical connectors at the rear of the block connectors.

Release clamps and remove the fuse holders up to an additional block of the relay (Fig. 3.3.17).

Using the device VAS 1978/8, separate two-contact electrical connector (see. Fig. 3.3.17).

Remove the nut and disconnect a wire of "weight" 6 (Fig. 3.3.18).

Release the latches, disconnect the electrical connectors 1 and 2 (see. Fig. 3.3.18) and move wires aside.

Disconnect the left side of the gearbox the speedometer sensor electrical connector and move it to the side.

Disconnect an electric socket of the switch of light of a backing from the gearbox and take him aside.

Loosen the tension on the serpentine belt, which wrench for the bolt head rotate counterclockwise tension roller (see. Fig. 3.3.28).

Remove V-ribbed belt, starting with the alternator pulley.

Remove the pulley power steering pump, and the hold of the pulley rotation.

Remove the screws power steering pump, remove the pump and, without disconnecting from it hoses attach to the body (Fig. 3.3.19).

Right under the exhaust manifold clamp Unscrew the starter.

Remove the turbocharger mounting bolts to the catalytic converter.

Remove the clamping sleeve front support exhaust system.

Remove the catalytic converter from a reception exhaust pipe.

Cars with air conditioning

Drive by a separate air conditioner compressor Poly-V belt.

Loosen the bolts tensioning poly V-belt air conditioning compressor and remove the belt from pulleys.

Disconnect the electrical connector 1 (Fig. 3.3.20) of the electromagnetic compressor clutch.

Remove the air conditioning compressor mounting bolts and the compressor a soft wire tie to the body (see. Fig. 3.3.20). Remove the nut and disconnect the motor connection with "weight" of the car from the right engine support.

Disconnect the wires from the starter 1 and 2 (Fig. 3.3.21).

Remove the nut 3 (Fig. 3.3.21) fastening clip harness to the starter.

Remove the starter mounting bolts to the transmission and remove the starter.

Note the location of the threaded connections 1 (Fig. 3.3.22) and locating sleeves 2 on the right and left engine support.

Remove the nuts a few turns 1 Fixing of the left and right engine mounts.

The bottom of the car, remove the bolts available transmission to the engine.

Bottom support the transmission and the engine lifting mechanism (eg, VAS 6100) to support a platform (eg, VA G 1202A) about support compensator reactive moment. Note that it does not damage the pipeline.

Remove the nuts left and right engine support (Fig. 3.3.23).

Completely remove the upper bolts transmission to the engine, while leave one bolt in place, tighten it by hand.

Remove the protective cover from the top of the front suspension struts.

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.

Remove the top casing of a gear belt.

3 Remove the screws (see. Fig. 3.3.35), and remove the cover 2.

Remove and move aside the solenoid valve 1 of the turbocharging.

Hang on a hoist lifting device 2024A and secure it with clamps 2024A / 1 on the engine.

Remove the last remaining upper bolt transmission to the engine.

Make sure that all electrical wires, hoses, tubes and pipes are disconnected from the engine.

Carefully lift the engine to thread the bolts came out of the support of the engine, and then carry him from the gearbox and pull up from the engine compartment.

Setting

Engine installation is carried out in sequence, return to removal, taking into account the following.

Replace with new self-locking nuts and bolts are tightened dovorachivaniem at a certain angle, as well as seals and gaskets.

Check dowel sleeves (Fig. 3.3.24) defining the relative position of the engine and gearbox.

Manual 5-speed gearbox

Manual 6-speed transmission

When connecting the motor to the gearbox, be careful not to damage the engine speed sensor.

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.

Mount the motor in place, and shake it from side to side, ensure the correct location on the supports.

Install air conditioning compressor and the power steering pump.

Install poly V-belt.

Install the front transverse panel normal position.

Check that the exhaust systems are properly installed on the suspension and do not touch the body with shaking.

Check the connection of the electrical connectors.

Fill the cooling system with coolant. In case the cylinder head was removed and replaced with the cylinder block coolant reuse is allowed.

Fill the power steering system and bleed the circuit.

Fill the engine with engine oil.

Connect a 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.