Caution: Gasoline is extremely flammable, so special care must be taken when working on any part of the fuel system. Do not smoke or allow open flames in the work area. If gasoline comes into contact with skin, wash immediately with plenty of soap and water. Wear safety goggles and have a fire extinguisher handy when working on any component of the fuel system.
Removal and installation of the M52 series engine
Electrical wires and/or vacuum and coolant hoses may be located and connected differently in the engine compartment depending on model date and equipment. Since it is impossible to cover all options in one section, it is recommended to mark all wires and hoses with adhesive tape before disconnecting. This describes the removal of a 6-cylinder gasoline engine of the M52 series.
Before removing the engine, you must remove the gearbox. The engine without gearbox is removed upwards. The exhaust manifold and alternator remain on the engine, the intake manifold is removed. A crane is required to remove the engine (hoist or winch).
Since it will be necessary to loosen or disconnect some connections under the car, it is necessary to support the car with four stands or use a special lift. Before working in the engine compartment, the wings must be covered with a cloth.
Withdrawal
Disconnect the ground wire from the battery.
Attention: This will erase the data from the electronic memory blocks, for example, from the memory of the diagnostic device.
Remove the hood.
Remove the gearbox.
Lower the car.
Remove the air filter with air flow meter.
Remove intake pipe (collector).
Remove fairing.
Disconnect the brake booster vacuum hose from the intake manifold, not the brake booster. It takes some effort to remove.
Remove the oil filler cap. Pry off the small covers with a screwdriver and unscrew the screws underneath. Remove the two plastic covers.
Disconnect the lambda probe wire connections. Remove the plug from the VANOS solenoid valve.
Remove the injector connector bar and set it aside.
Remove the cover from the intake manifold. Unscrew the anchor point for the positive battery cable and squeeze the two clips together. Unhook the plinth down.
Disconnect the fitting of the crankcase ventilation system.
Collect the leaking fuel with a rag. Disconnect the fuel supply line from the distribution pipe first (1) (from the filter), then fuel return line (2), by loosening the clamps. Clamps must be replaced after removal.
Attention: On some models, the fuel supply line can be screwed directly into the distribution pipe, therefore, during installation, always replace the O-ring and lubricate it with petroleum jelly. In another version, the fuel hoses are attached with clips, in which case a special tool is needed to loosen the clips. Before installing, check the O-ring and replace it if damaged.
Remove the throttle body.
Attention: cable (thrust) The throttle actuator and coolant hoses for heating the throttle body remain connected.
Remove the oil return hose from the dipstick guide tube after loosening the clamp.
Remove the oil dipstick guide tube from the intake manifold.
Loosen the bolts and remove the intake manifold support, as well as the coolant pipe support bracket from the manifold.
Disconnect the plug (1) from the fuel tank vent valve. Pull the valve up from its mounting. Press the bracket (2) and pull off the hose. Remove the intake air temperature sensor and idle speed control valve connectors from the intake manifold.
Remove the intake manifold-to-cylinder head bolts.
Caution: Make sure that no objects fall into the intake air ducts. If this does happen, then you need to remove these items in any way, otherwise the engine will be seriously damaged.
Check all o-rings before installing intake manifold (arrow) and if damage is found, the rings must be replaced.
Remove the fan. Remove poly V-belt. Drain the coolant. Remove the radiator.
Attention: If the coolant hoses are secured with clamping clamps, these clamps must be cut off when removing and then replaced with screw clamps.
Remove the spark plugs.
After loosening the clamps, remove the coolant hoses from the valve (crane) heater and from the heater radiator.
Disconnect the plugs by pressing the wire clips.
1 - temperature sensor;
2 - remote thermometer;
3 — the switch of a control lamp of pressure of oil;
4 - idle speed control valve.
Remove the plugs from under the intake pipe: knock sensor plug, knock sensor (generator) crankshaft pulses, cylinder recognition sensor.
Disconnect the wires from the generator and starter.
Remove the bolts and disconnect the wire cover from the cylinder block, set the harness aside.
Remove the bolts, remove the power steering pump and set it aside with the attached hoses.
Caution: If hydraulic lines are disconnected, air must be bled from the system after installation.
Remove the two bolts and remove the power steering fluid reservoir.
Vehicle with air conditioning: remove the bolts, remove the compressor and set it aside with the connected pipes.
Attention: Do not open the refrigerant line under any circumstances, as The refrigerant is poisonous and may cause frostbite if it comes into contact with the skin.
Hang the engine on cables. To do this, attach winch cables or chains to the bearings to lift the engine. Raise the engine slightly.
Remove the nuts from the left and right engine mounts, and remove the ground wire (masses) engine on the right side.
Check that all hoses and wires coming from the engine are disconnected. Then lift the engine with a crane (winch).
Caution: When lifting, the engine must be carefully steered so as not to damage the bodywork. The removed engine must not be kept upside down for more than 10 minutes, as oil flows from the valve lifters and they will not work. If you need to turn the engine over, then the hydraulic pushers (hydraulic lifters) need to be removed.
Installation
The engine is installed in the reverse order of removal.
Removal and installation of the M30 series engine
Withdrawal
Disconnect the ground wire from the battery.
Raise the car with a lift.
Remove the gearbox.
Remove the engine mudguard.
Drain the coolant into a container.
The coolant can be reused if it is not older than two years.
Remove the radiator.
Remove the poly V-belt of the hydraulic pump.
Remove the hydraulic pump and tie it with wire to the side wall. The wires remain connected.
Remove the complete air filter.
Loosen clamp (1), nut (3), disconnect the connector (2) idle air control valve and remove the idle air regulator.
Remove all coolant hoses engine-expansion tank-washer.
Remove the expansion tank. Disconnect the level control transmitter connector.
Detaching the staples (1-3), remove the airflow meter.
Disconnect the throttle cable and speed control cable from the throttle body.
Remove the intake manifold holder.
Disconnect connectors (1-4) and loosen the power cable at the starter.
Remove the alternator air cooler hose.
Disconnect the connector (1), disconnect the connection (2) and turn off the lambda probe (3).
Disconnect the fuel lines (1) And (2).
Remove the fuel line, disconnect the throttle switch connector, remove the cover and remove the injection valve cable harness bar.
Remove ground bar (1) and loosen the left and right front engine bearing nuts (2).
Attach the engine puller to the lift and hook the hooks into the studs.
Remove the engine from the engine compartment. Installation
The engine is installed in the reverse order of removal.
Removal and installation of the M70 series engine
Withdrawal
Disconnect the ground wire from the battery.
Raise the vehicle with a hoist and remove the engine mudguard.
Remove the gearbox.
Drain the coolant.
Remove the radiator and expansion tank. Remove the corresponding pipelines of the cooling system.
Remove both air filters as a set.
Loosen the oil filter bolt.
Remove the oil lines to the oil cooler on the filter housing and plug them immediately.
Disconnect the sensor connector.
Remove the washer reservoir. Remove the oil pressure switch center cover.
Remove the wiring harness bracket.
Disconnect the connectors on the front of the motor as shown in the figure.
1 - pulse sensor of cylinders;
2 - cylinder identification sensor;
3 - cylinder identification sensor;
4 - cylinder pulse sensor.
Disconnect the plugs of the twelve injection valves. Disconnect the cable harness and set aside. Disconnect the temperature sensor plug.
Disconnect both plugs from the air intake chambers. Disconnect the alternator cable at the battery positive connection point. Disconnect the generator connection.
Disconnect the cable from the starter. Remove the positive battery cable anchor point holder and cable harness connector.
Remove the A/C compressor drive belt.
Remove the air conditioning compressor. The hoses remain connected.
Disconnect the oil level switch sensor connection.
Unscrew the oil filter housing from the body.
Remove the fuel lines and return line. Mark the fuel lines so you can reinstall them later.
Remove heater hoses from manifold and coolant pipe.
Remove the activated carbon filter hoses.
Unscrew the piping from the twin pump (steering/brakes).
Unscrew the ride height oil line from the oil pan.
Disconnect the ground wire from the engine mount bracket.
Remove both exhaust pipes on the right and left.
Mount the tool on a hoist and hang the engine by the studs. Raise the engine slightly.
Release both engine mounts on the right and left.
Remove the engine and lay it down so that it cannot tip over.
Installation
The engine is installed in the reverse order of removal.