Removing Engine

To remove the motor, do the following:

1) Remove the battery

2) Drain the engine cooling system;

3) remove the radiator, as follows:

- Disconnect the connector, remove the two bolts from the radiator fan shroud and remove elektrovenilyator engine cooling;

- Disconnect the upper and lower pipes from the radiator (Fig. 4.22);

- Disconnect the two hoses from the surge tank;

- Disconnect the hose of an automatic transmission;

- Remove the four screws on the radiator;

- Remove the radiator;

4) Remove both front wheels (Fig. 4.23);

5) on cars equipped with automatic transmission:

- Remove the ball joints from the steering gear mounts knuckles, brake pipe clamps, wire staples ABS;

- Remove the shock absorber bolts to the steering knuckle on both sides;

- Remove the left axle shaft, use Remove the plug 999 5462 (Fig. 4.24);

- Remove the heat shield and the front exhaust pipe;

- Remove the mounting bolts of the engine in front and behind;

- Remove the engine support on the part of the distributor;

- Remove the lower beam of the engine;

- Disconnect the speedometer;

6) on vehicles equipped with manual transmission:

- Remove the oil pan Transmission;

- Drain the oil and put the drain plug with a new sealing ring;

- Remove the shield under the spar Transmission;

- Remove the three screws, remove the left axle and hang it on the stabilizer bar;

- Remove the spring clip from the flexible shaft and disconnect a cable of a speedometer;

- Remove the bolts gearbox and engine in front and behind;

- Remove the right axle (remove the locking pins) and hang it on the stabilizer bar;

- Remove the gear lever Transmission;

7) Lower the vehicle;

8) Remove the battery tray;

9) disconnect the air intake hose from the air filter / air pump (Fig. 4.25);

10) Disconnect the inlet air temperature sensor;

11) Disconnect the inlet hose of the air valve (Fig. 4.26);

12) Disconnect the hose of the air valve of idling;

13) Disconnect the hose from the pump air supply to the inlet air hose;

14) disconnect the hose from the arrester inlet air hose;

15) disconnect a hose vent valve;

16) remove the hose pre-heating;

17) Remove the bolts of the air filter housing;

18) Lift the air filter and remove it;

19) Remove the throttle cable to the cam;

20) disconnect the two heater hoses and radiator hose on the side of the engine;

21) disconnect the hose from the engine brake booster (Fig. 4.27);

22) disconnect the vacuum hose from the pump system EVAP;

23) remove an arm of a cable of a gear change;

24) on cars equipped with automatic transmission:

- Disconnect the connector;

- Disconnect the shift cable from gearbox (Fig. 4.28);

- With pliers Seeger, or similar instrument, remove two oil cooler hoses from the transmission;

25) Remove the retaining bracket from the tube to the clutch slave cylinder;

26) Remove the clutch slave cylinder;

27) Remove the earth wire from the battery to the gearbox;

28) Remove the accessory drive belt;

29) Remove the five screws power steering pump and move the pump aside;

30) Remove the air conditioning compressor, for that:

- Remove the wiring from the engine mount (Fig. 4.29);

- Remove the four screws on the air conditioning compressor;

- Remove the compressor and tilt it forward as far as possible;

- Remove the mounting pipe of the air conditioner above the support of the engine;

31) Remove the engine wiring harness;

32) Disconnect all the connectors from the engine;

33) disconnect the vacuum hose of the air pressure sensor;

34) disconnect the vacuum hose from the solenoid valve of the air pump;

35) Disconnect the wires and the connector on the positive battery terminal (Fig. 4.31);

36) Remove the nut with a plastic holder wiring;

37) Remove the distributor;

38) Replace the nozzle holder 999 5533.

39) lift and place the side of the power distribution and fuel injectors;

40) disconnect the vacuum hose from the pressure regulator;

41) Remove the bracket from the power distribution of the fuel;

42) close the nozzle openings;

43) Install the lifting lugs 999 5185 and 999 5186 (Fig. 4.32);

44) Lift the engine to offload support;

45) remove the axle bolts of the engine mounts;

46) the air conditioning compressor put on a stretcher;

47) Remove the motor mount Transmission;

48) Remove the bolt on the engine side of the distributor;

49) Lift the motor using the lifting beams 999 in 2810;

50) Remove the automatic transmission:

- Remove the bolts fastening the torque converter;

- Remove the bolts the engine / gearbox, remove the box;

51) Remove the manual gearbox:

- Remove the bolts of the engine / transmission;

- Carefully remove the gearbox, taking care that it is not hanging on a splined connection, remove the primary shaft of a check point and the clutch disc;

52) Remove the drive plate and flywheel for this:

- Use a serrated lock 999 5112 for fixing the flywheel from turning;

- Remove the bolts fastening the drive plate;

- Remove the drive plate;

- Remove the flywheel bolts;

- Remove the flywheel;

53) set the engine on the stand. Use a floor stand and retainer 999 2520 999 5297;

54) Remove the lifting equipment;

55), remove the engine from the gearbox:

- The ignition coil (2 pcs.) (Fig. 4.33) and the spark plug wires;

- The camshaft position sensor;

- The lower radiator hose;

- The coolant hose;

- Speed sensor crankshaft;

56), remove the engine from the exhaust manifold (Fig. 4.33):

- Lifting lugs;

- Heat shield plate and pre-heater;

- an exhaust manifold;

- The coolant tube;

- Securing the fuel;

- The right engine support.

57), remove the engine from the intake manifold:

- Bracket accessory and a generator;

- A temperature sensor;

- The inlet manifold, the knock sensor (torque 20 Nm);

- Oil catch tank and hose;

- The dipstick with a tube;

- starter;

- The front engine support.