Attention! Disconnecting the wire «masses» when the ignition is on, it leads to the failure of the ECU-KSUD. Disconnect only when the ignition is switched off. When detaching «negative» terminals from the battery from the memory device of the computer, the fault codes of the KSUD, the codes of the anti-theft system and the individual settings of the audio equipment are erased. During installation work on the cooling system, replace the band clamps, if they were installed, cutting them off with side cutters, with screw clamps.
Note. Before undocking and removing the elements, mark them with tags or adhesive tape. Fix on the plan of the engine compartment the location of the units and parts to be removed.
Prepare your workspace before starting work (stand or workbench and shelving), fixtures («11.0.000», «51.2.170» And «00.0.200»), garage jack, jack stands (goats, stands) and lifting device type crane (hoist). Prepare a protective cover or dense fabric material to cover the surface of the wings of the engine compartment of the body during work. The engine should be removed from the car - up. With the gearbox disengaged and the hood locked in the up position.
Removing the engine must be carried out in the following order. Place the car on a ramp, overpass, lift, viewing hole or level ground using stands. Apply the parking brake. Take readings from the SHR for diagnosing KSUD. Switch off the ignition and disconnect «-» terminal from AB, insulate the terminal. Fix the hood to the body in the open position using the tool «51.2.170».
fixture «51.2.70»
Relieve pressure in the fuel lines, disconnect the pipeline from the distribution line and plug the ends of the pipelines / hoses with plugs or clamps.
Take out the plugs (arrows, see fig. 3.32) and unscrew the bolts, remove the protective covers from the engine.
Loosen the bolts (1 and 2, fig. 3.56) and remove the front panel (3) protection of auxiliary mechanisms of the engine.
Loosen the bolts (1, fig. 3.57) fastening the stiffening plate in the front, and then the bolts (2) at the rear and remove the stiffening plate.
Disconnect the loops from the oxygen content sensors in the exhaust gas.
Disconnect the oil lines from the automatic transmission heat exchanger and remove. Close the holes with plugs. Take measures against tipping over of the engine after removing the gearbox and remove it. Remove the air filter housing.
Remove the A/C compressor drive belt. Remove the air conditioning compressor from the support bracket, move it to the side and secure it to the body with a wire clamp. Leave the pipes connected.
Drain the coolant, the drain plug for the coolant from the cylinder block is located on the exhaust side, in the region of the second cylinder. The drained coolant must be disposed of.
Remove clips (1, fig. 3.58) and disconnect hoses (arrows) from the thermostat housing.
Remove the engine cooling radiator. Remove intake manifold. Disconnect the hoses from the pipes of the cooling system and from the heater valve block.
Disconnect the engine wiring harness loop at the control unit and disconnect it. Unlock the branch of the ignition coil wiring harness on the control unit and disconnect it. Wiring harnesses remain on the engine. Disconnect «+» wire from the AB output.
Remove both oxygen level test sensors. Disconnect vacuum line from brake booster. Unlock and disconnect the wire from the fuel tank vent valve.
Drain fluid from tank (reservoir) power steering pump, send the fluid for disposal. Remove bolts (pic. 3.59) fastening the tank, take it to the side and fix it with a wire bracket on the body.
Leave the pipes connected.
Remove the fan impeller together with the fan drive viscous coupling from the coolant pump. Remove the alternator drive belt. Remove the power steering pump, lay it aside and secure it to the body with a wire clamp. Leave the pipes connected.
Install lifting rigging on the lifting eyes of the engine, a tool «11.0.000» (pic. 3.60), and slightly pull it with a waist.
The arrangement of forward and back eyes for removal of the engine is shown in fig. 3.61.
Support the engine with a piece of wood attached to the front axle cross member.
Disconnect wire «masses (pic. 3.62), located on the right side of the engine.
Unscrew the nuts securing the left and right engine mounts (left arrow). Disconnect exhaust pipes from engine exhaust manifolds.
Make sure that all hoses and wiring harnesses connecting the engine to the body are disconnected.
Gently raise the engine with a hoist (crane) and remove the engine from the compartment, taking care not to damage adjacent structures if they are accidentally touched. Place the engine on a dismantling stand or on a workbench.
Attention! The engine must be constantly in a vertical position, which ensures the safety of oil in the hydraulic pusher cylinders. If it is necessary to turn the engine over, the hydraulic pushers must first be removed or the engine must be in the turned state for no more than 5 minutes. When the elements of hydraulic drives are disconnected, air enters the system. After assembling the system, it is necessary to pump it to remove air.
Install the engine in reverse order, checking the engine mounts, coolant, oil and fuel hoses for porosity, delamination and cracks. If defects are found, replace the parts with new ones.
Check the presence of a centering sleeve for connecting the engine to the gearbox. Slowly lower the engine onto its supports. Install new self-locking nuts on the engine mounts by hand, but do not completely tighten them. Install checkpoint. Bolts connecting the engine and gearbox, if there are no additional instructions, tighten the torque:
- bolts М8—25 Nm (2.5 kgf·m);
- bolts M10—45 Nm (4.5 kgf·m);
- bolts М12—60 Nm (6.0 kgf·m).
Lower the car onto wheels. With strong shaking movements, set the engine and tighten the nuts of the engine mounts to the body to a torque of 42 Nm (4.2 kgf·m). Tighten bolts connecting exhaust manifolds to exhaust system to 15 Nm (1.5 kgf·m).
Tighten the bolts for connecting the air conditioning compressor and the power steering pump to the torque:
- bolt M8 compressor 25 Nm (2.5 kgf·m);
- bolt M10 compressor 30 Nm (3.0 kgf·m);
- pump bolts 20 Nm (2.0 kgf·m).
Install the alternator drive belts, coolant pump, power steering pump and A/C compressor.
Restore all electrical connections by docking the loops. Install intake manifold. Restore all hydraulic and pneumatic connections.
Replace the O-ring on the cylinder block drain plug and tighten the plug (M 14x1.5) torque 25 Nm (2.5 kgf·m). Check the oil level in the engine and automatic transmission, antifreeze in the cooling system and the working fluid in the power steering.
Start and warm up the engine, check the tightness of the systems. Recheck oil and antifreeze levels. Check the engine speed at idle and the CO content in the exhaust gas.
Install the engine compartment stiffening plate. Be sure to install spacer washers. The tightening torque of the new mounting bolts consists of two methods - a torque of 5.6 kgf·m (56 Nm) + with a 90°turn. Install the engine accessory protection panel.