Attention! Disconnect the "–" terminal of the battery only when the ignition is off.
Before disconnecting and removing the elements, mark them with tags or adhesive tape. Fix the locations of the removed units and parts on the engine compartment plan.
When performing installation work on the cooling system, replace the band clamps with screw clamps.
The engine should be removed from the vehicle upwards, with the gearbox disconnected and the hood fixed with the "51.2.170" device, in the following order.
Take readings from the diagnostic SR, turn off the ignition, disconnect the "–" terminal of the battery and remove the heater partition in the engine compartment. Turn the latches (Fig. 4.26) of the soundproof casing 90° counterclockwise and remove the casing.
Remove the corrugated boot from the throttle shaft. Remove the air filter housing together with the air flow meter and the windshield washer fluid reservoir.
Disconnect the clamp (1, Fig. 4.27) hose fastenings and disconnect the brake booster hose (2).
Relieve pressure in the fuel lines, disconnect the supply line from the distribution line and plug the openings of the hoses/pipes with plugs or clamps ("13.5.281" and "13.5.282"),
Remove the front engine accessory protection panel. Loosen the mounting bolts at the front of the stiffener plate (behind the bumper), then the bolts at the rear, and remove the stiffening plate (Fig. 4.28).
Drain and dispose of the coolant. Remove the alternator drive belt and the power steering pump, which must be secured to the body with a wire clip. Leave the pipes connected.
Evacuate the air conditioner and remove the lines between the air conditioner compressor and the condenser. Remove the suction line from the air conditioner compressor, move it to the side and secure it. The air conditioner compressor remains on the engine.
Disconnect the oil lines from the automatic transmission heat exchanger, remove the heat exchanger. Remove the automatic transmission and the heat-insulating screen from the starter. Disconnect the cable connections and starter fasteners and remove it.
Remove the automatic transmission heat exchanger from the cooling system radiator and remove the engine cooling system radiator. Loosen the clamps (Fig. 4.29) and disconnect the hoses from the engine cooling system manifold, generator and thermostat housing.
Disconnect the hoses from the interior heating system and the HS (1, Fig. 4.30) from the heater valve block.
Remove the heater valve block (2) complete with hoses.
Press the lock (1, Fig. 4.31) and disconnect the hose (2) from the fuel tank ventilation valve.
Disconnect the engine wiring harness branch in the control electronics compartment, disconnect the "+" cable from the battery terminal and disconnect the automatic transmission wiring harness branch in the control electronics compartment.
Secure the disconnected wiring harnesses to the engine and in the engine compartment.
Disconnect the plug connectors (PC) from the oxygen sensors in the exhaust gas and pull the wire harnesses upward, securing them to the engine. Remove the expansion tank of the engine cooling system.
Open the tank lid (1, Fig. 4.32) power steering fluid, pump out the working fluid and send it for disposal.
Close the lid and unscrew the tank mount from the support beam. Leave the pipes connected.
Disconnect the jumper (2) connecting to the ground from the oil filter housing. Unscrew the oil filter housing (3) from the bracket, unhook it from the support beam and secure it to the engine with a wire clamp. Leave the pipes connected. Again, temporarily install the power steering pump reservoir.
Caution! After removing the swivel support and front axle output shafts, the engine tilts forward.
Support the engine with a wooden block (1, Fig. 4.33) on the front axle beam, securing it with a bandage.
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Remove the left and right swivel bearings, wheel drive output shafts, front propeller shaft and bulkhead (3, Fig. 4.34) in the engine compartment, for which it is necessary:
- release the hose and wire harness from the clamps;
- disconnect the SS (1);
- remove the wiring harness (2);
- unscrew the nut and bolts (arrows) and remove the partition.
This will allow the engine to pass through with the exhaust manifold installed.
Disconnect the ground ribbon wire from the right front side member. Unscrew the upper nuts (9, see Fig. 4.146) left and right engine mounts.
Install the "11.0.000" device (Fig. 4.35) on the engine lifting devices and lightly tighten the chains with a hoist.
Disconnect the exhaust pipes from the engine exhaust manifolds.
Make sure all hoses, lines and wiring harnesses connecting the engine to the body compartment are disconnected, paying particular attention to:
- pipeline on the cylinder head cover;
- air conditioning compressor and its pipelines;
- air conditioner condenser;
- exhaust manifold;
- front axle gearbox;
- steering shaft.
Gently lift the engine with a hoist (crane) and remove it from the compartment, taking care not to damage adjacent structures if they are accidentally touched.
Attention! The engine must be kept in a vertical position at all times, which ensures the safety of the oil in the hydraulic tappet cylinders. If it is necessary to turn the engine over, the hydraulic tappets must first be removed or the engine must be turned for no more than 5-7 minutes.
When disconnecting hydraulic drive components, air may enter the system. After assembling the system, it is necessary to bleed it to remove air. The engine should be installed in the reverse order, while it is necessary to check 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 centering bushings for connecting the engine to the automatic transmission and smoothly lower the engine onto its supports.
Install new self-locking nuts on the engine mounts by hand, but do not tighten them. The car is standing on its wheels. Using strong shaking movements, align the engine and tighten the engine mount nuts to the body to a torque of 42 N·m (4.2 kgf·m). Tighten the bolts connecting the exhaust manifolds to the exhaust system to a torque of 15 N·m (1.5 kgf·m). Replace the O-ring of the cylinder block drain plug and tighten the plug (M14x1.5) to a torque of 25 N·m (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.
Attention! Connect the battery only when the ignition is off.
Start and warm up the engine, check the tightness of the systems. Recheck the oil and antifreeze levels.
Check the engine crankshaft speed in idle mode and the CO content in the exhaust gas.
Install the engine bay stiffening plate. Be sure to install the spacer washers. The tightening torque for new bolts and nuts consists of two steps – 56 N·m (5.6 kgf·m) + 90°.