2.3.1. Removal of the engine

NOTE The engine is removed forward at the removed radiator frame. At a stanovka install all fasteners of cables removed or which are cut off during dismantling on former places again. For utilization or reuse cooling liquid should be merged in pure capacity.

With the automatic transmission install the selector in situation "N" in cars.

Fig. 2.43. Mass cable of joint stock bank

Disconnect a mass cable from joint stock bank at the switched-off ignition (fig. 2.43).

ATTENTION When opening the broad tank can come out hot steam or hot cooling liquid, wrap up a cover rags and carefully open a tank.

Open a cover of a broad tank of the cooling system.

Remove forward wheels.

Fig. 2.44. Bolts of an exhaust pipe of an independent additional heater

In cars with an additional heater unscrew bolts of an exhaust pipe of an independent additional heater from the noise-insulating screen (fig. 2.44).

Fig. 2.45. Fastening of a forward noise isolation

Weaken quick disconnect couplings 1 and 2 and remove a forward noise isolation (fig. 2.45).

Where are available, weaken quick disconnect couplings 3 and remove the back noise-insulating screen.

Fig. 2.46. Holder of the noise-insulating crane

Turn off the holder of the noise-insulating screen (fig. 2.46).

Establish a casing of a front bumper.

Fig. 2.47. Air duct of the left intercooler

Remove air ducts of the right and left intercoolers (fig. 2.47).

Substitute the pallet for service cranes or the pallet under the engine.

Fig. 2.48. A drain bolt on a water hose

Open a drain bolt on a water hose from below at the left and merge OZh (fig. 2.48).

Fig. 2.49. Collar of the lower hose of the cooling system

Remove the lower hose of the cooling system from a radiator (fig. 2.49).

Fig. 2.50. An air duct hose to the intercooler and a pipeline arm with coolant

Disconnect a hose of an air duct 1 to the intercooler at the left below (fig. 2.50).

ATTENTION It is forbidden to open a contour of air conditioning system of climatic installation.

Disconnect the pipeline with coolant from an arm 2.

Disconnect вохдуховод 1 to a turbocharger on the right below.

Fig. 2.51. Air ducts to the intercooler and to a turbocharger

Disconnect an air duct 2 to the intercooler from a frame of a radiator (fig. 2.51).

Fig. 2.52. Perezhatiye of hoses of a coil of the drive of the hydraulic booster

Press hoses to the cooling coil of the drive of the hydraulic booster by means of clips for hoses (fig. 2.52).

Put the device for oil pumping.

Disconnect hydraulic actuator hoses.

Put the device for pumping of oil under the transmission.

Fig. 2.53. Tubes of ATF and an arm of highways for ATF on the engine

Disconnect tubes for ATF 2 and 3 on the place of division (fig. 2.53).

Turn off fastening of an arm of 1 highways for ATF on the engine.

Fig. 2.54. Engine casing

Remove a casing of the engine (fig. 2.54).

Unscrew bolts.

Fig. 2.2. Air duct

Remove an air duct of 1 and 2 (fig. 2.2).

Remove the top hose of the cooling system 1 from a radiator.

Fig. 2.55. The top hose of the cooling system and electric shtekerny connection of the left and right sensors of safety cushions on a radiator frame

Turn off electric shtekerny connection 2 of the left and right sensors of safety cushions on a frame of a radiator (fig. 2.55).

Fig. 2.56. Electric shtekerny connection of a headlight

Disconnect electric shtekerny connection of headlights on the left and right parties of the car (fig. 2.56).

Fig. 2.57. Electric sockets

Remove electric sockets 1 and 2 from the holder and disconnect (fig. 2.57).

Put electric cables aside.

Fig. 2.58. Shtekerny sockets of sound signals

Disconnect shtekerny sockets of 3 sound signals of 2 (fig. 2.58) at the left and on the right.

NOTE Poses. 1 do not take into account.

Remove a bumper.

Fig. 2.59. Protection of a bumper

Fig. 2.60. Fastening of the left air duct

Turn off fastening of air ducts at the left and on the right on a radiator (fig. 2.60).

Take the sensor of external temperature 2 of the holder.

Fig. 2.61. The sensor of external temperature and the cooling coil of the drive of the hydraulic booster

Unscrew bolts 3 and 4 and remove the cooling coil of the drive of the hydraulic booster (fig. 2.61).

Disconnect electric shtekerny connection 1 on the sensor of high pressure.

ATTENTION It is forbidden to open a contour of air conditioning system of climatic installation.

Unscrew fixing bolts of the condenser.

NOTE To avoid damages of the condenser, and also pipelines and hoses of a contour of air conditioning system, it is necessary to watch that lines and hoses were laid without tightness, excesses and breaks.

Turn the condenser with the connected highways down.

Unscrew bolts at the left and on the right on a radiator frame.

Disconnect the hummock drive from the cowl lock.

Fig. 2.62. Fastening of a sealant of a motor compartment on a radiator frame

Remove a sealant of a motor compartment on a frame of a radiator and on connecting edges of wings (fig. 2.62).

Fig. 2.63. Fastening of the energopoglashchayushchy buffer

Unscrew bolts from the energopoglashchayushchy buffer (fig. 2.63) at the left and on the right.

NOTE The assistant is necessary for removal of a frame of a radiator.

Remove a frame of a radiator and put in a steady position.

NOTE Before removal of a poliklinovy belt mark the direction of the course with chalk or a felt-tip pen. Change of the direction of the course of earlier operated belt can lead to its damage

Fig. 2.64. Weakening of a poliklinovy belt

For weakening of a poliklinovy belt turn a tension damper in the direction of an arrow (fig. 2.64).

Record a tension element by means of a clamp.

Take off a poliklinovy belt.

Fig. 2.65. Electric socket of the sensor of level and temperature of oil

Disconnect the electric socket from the sensor of level and temperature of oil (fig. 2.65).

Fig. 2.66. Air conditioning system contour tube arm

Remove air conditioning system contour tube arm from the oil pallet (fig. 2.66).

Fig. 2.67. Fastening of the compressor of the conditioner and shtekerny socket of a wire

Disconnect the shtekerny socket of 1 wire going to the electromagnetic coupling of the compressor of the conditioner (fig. 2.67).

ATTENTION It is forbidden to open a contour of air conditioning system of climatic installation.

Turn off the conditioner compressor from an arm.

NOTE To avoid damages of the condenser, and also pipelines and hoses of a contour of air conditioning system, it is necessary you watch that lines and hoses were laid without tightness, excesses and breaks.

You will hang out the compressor of the conditioner and the condenser with the connected pipelines on the right on a body.

Disconnect a wire of weight 1.

Disconnect the vacuum tube going to the amplifier of brakes from a motor board 2.

Fig. 2.68. Weight wire, motor guard and hose of an absorber

Disconnect a hose of an absorber of 3 (fig. 2.68).

Fig. 2.69. Water hoses and fastening of a broad tank of the cooling system

Disconnect water hoses 1 and 2 and turn off fastening of a broad tank of the cooling system (fig. 2.69).

Disconnect the shtekerny socket going to the sensor of a signaling device of the OZh low level below on a broad tank of the cooling system.

Disconnect the electric socket from the sensor of pressure of pressurization 1.

Fig. 2.70. Electric socket of the sensor of pressure of pressurization and left hose of nadduvochny air

Disconnect the left hose for nadduvochny air 2 (fig. 2.70).

Fig. 2.71. Right hose of nadduvochny air

Disconnect the right hose for nadduvochny air 1 (fig. 2.71).

Disconnect electric sockets 1 lambda probe after the catalyst and the heater a lambda probe 1 after the catalyst (the brown socket) from an arm.

Fig. 2.72. Electric sockets lambda probes

Disconnect electric sockets 2 a lambda probe and the heater a lambda probe (the black socket) from an arm (fig. 2.72).

ATTENTION Pressure of fuel has to be taken off before opening of any knot of high pressure.

Fig. 2.73. Connecting union of a fuel-supply line

Disconnect a fuel-supply line (the following fuel collect and immediately close all open openings) (fig. 2.73).

Disconnect behind on the engine the water hoses going to the heater heat exchanger.

Remove screen wiper levers.

Remove the deflector.

Fig. 2.74. Cover of the switching block

Uncover the switching block in the water taking away box, having turned off screws (fig. 2.74).

Fig. 2.75. Fixing of levers

Fix levers by a yoke by means of a treshchetka (fig. 2.75).

Turn off an electric cable 1.

Fig. 2.76. An electric cable and sockets in the switching block

Disconnect electric sockets 2.4 in the switching block (fig. 2.76).

Fig. 2.77. Unblocking of the block of safety locks

Unblock the block of safety locks (fig. 2.77).

Release a plait of wires and put it with the connected engine control unit on the engine.

Fig. 2.78. Bolt connections of the lamellar pump

Turn off bolt connections of 1 lamellar pump through openings in a pulley for a poliklinovy belt (fig. 2.78).

Fig. 2.79. The threaded connection on the back party of the lamellar pump

Turn off the threaded connection on the back party of the lamellar pump (fig. 2.79).

Disconnect electric sockets 1 and 2 and release a cable.

Fig. 2.80. Inlet hose of the air filter / turbocharger and electric sockets

Disconnect an inlet hose 3 air filters / turbochargers (fig. 2.80).

Fig. 2.81. Electric socket of a flowmeter of air

Disconnect the electric socket 1 from a flowmeter of air (fig. 2.81).

Release a plait of wires on the case of the air filter and remove the case.

Fig. 2.82. Fastening of a mass wire

Turn off a mass wire from the right longeron (fig. 2.82).

Fig. 2.83. Heat-shielding screen of the right driveshaft

Turn off the heat-shielding screen of 1 right driveshaft (fig. 2.83).

NOTE It is impossible to bend a demountable element of system of release more than on 10 °.

Fig. 2.84. Tightening collar

Weaken tightening a collar and shift (fig. 2.84) back.

Separate a reception pipe and the catalyst.

Fig. 2.85. Reception pipe of the catalyst

Turn off a bolt 1 on an arm of a reception pipe and remove a pipe (fig. 2.85).

Fig. 2.86. Electric socket of the switch of lamps of a backing

Disconnect the electric socket from the switch of lamps of a backing and release a cable of a plait of wires (fig. 2.86).

Fig. 2.87. Threaded connections of the engine / check point

Turn off threaded connections engine / KPP 1-3 and 7-11 (fig. 2.87) available from below.

Remove a starter and shift aside.

Disconnect shtekerny connection 3.

Turn off a nut of 1 collar.

Fig. 2.88. Removal of a starter

Turn off a nut 2 and remove electric wires (fig. 2.88).

Remove a starter.

Mark the adjusting provision of connections 1 and the fixing plugs 2 from below on the right and left pillows of the engine.

NOTE Various fixing openings are intended for various engines.

Fig. 2.89. Fastening of the right pillow of the engine

Unscrew nuts 1 from below of the left and right pillows of the engine (fig. 2.89).

Fig. 2.90. Fastening of the left pillow of the engine

Weaken on several turns the top nut on the left pillow of the engine (fig. 2.90).

Fig. 2.91. Posting of the power unit

Suspend the device for posting for the engine and to the crane for service as it is represented in the figure 2.91.

NOTE For alignment of a center of gravity position of the power unit of a level of hooks have to be inserted, as shown in the figure 2.91.

ATTENTION Hooks and lock pins of device for posting have to be recorded by pins.

Turn off the last connecting bolt of the engine and transmission.

NOTE Check whether all hoses and wires between the engine and a body are disconnected.

Lift the engine so that hairpins of pillows of the engine were released.

Lift a jack to a transmission prileganiye.

Separate the engine and the transmission and lift the engine from a motor compartment forward.

NOTE At installation replace самоконтрящиеся nuts and bolts/screws. Replace the bolts/screws tightened on a certain corner, and also sealing rings, manzhetny consolidations and sealing rings of round section. Hoses and hose unions of system of pressurization of air have to be cleared before Ustanovka of oils and lubricant.

For fastening of all connections of hoses use collars of the corresponding series.

At the return Ustanovkaye establish all cable couplers where they were established initially.

At installation of a new clutch plate in connection with an old SAC press clutch plate (the disk self-regulating press) it is necessary to turn an adjusting ring of a press disk against the stop. Otherwise press the disk will work with the reduced clip pressure (coupling slips).

NOTE If the clutch plate does not change, it is not necessary to turn an adjusting ring.

New SAC press disks are already previously adjusted and do not demand adjustment.

And at earlier использовавшемя a clutch plate gear gearing of a nave clear gear gearing of a power shaft of dirt and corrosion and to apply a superthin layer of lubricant on gear gearing. Do not grease the directing plug.

If necessary check centering of the conducted clutch plate.

Check the bearing of switching off of coupling for wear, if necessary replace.

At leaky landing of a plastic ring of the bearing of switching off paste a plastic ring of the bearing of switching off by means of AMV 195 KD1 01 glue to a ring of a podshinik.

Fig. 2.92. Rectangular ledges of a plastic ring of the bearing

Three rectangular ledges of a plastic ring will get to grooves of a ring of the bearing (fig. 2.92).

If grooves are deeper than 0,5 mm – replace a podshinik of switching off of coupling.

The needle bearing in the crankshaft has to be installed in engines of cars with the mechanical transmission. If necessary install the bearing.

Clear vents of main shaft KP and a damper of a flywheel of dirt and a rust and to apply on them very thin film of lubricant. Surely remove excess of lubricant.

Check existence in the block of cylinders of adjusting plugs for centering of the engine/transmission, if necessary insert plugs.

Fig. 2.93. Check of installation of a flange

Check that on a flange the intermediate guard is suspended, and adjusting plugs are got (fig. 2.93).

Install an intermediate guard on centering plugs between the engine and the check point.

Priflantsuyte the engine to the transmission also twirl one bolt by hand.

Lower the engine and at the same time establish a carving bolt of a pillow of the engine and console of a pillow of the engine.

NOTE The given moments of an inhaling are right for slightly greased, fosfatirovanny or oxidized nuts and bolts. Use of additional lubricants, for example engine or gearbox oils, except grafitsoderzhashchy is allowed. Do not use the fat-free details. The admission of the moments of an inhaling makes ±15%.

Fig. 2.94. Fastening of the engine to the mechanical transmission

Watch fig. 2.94.

Fig. 2.95. Fastening multitronic engine/transmission

Watch fig. 2.95.

Further installation is carried out in the return sequence.

Install and fix system of release of OG without mechanical tension.

Install the conditioner compressor.

Install the pump of the hydraulic booster.

Establish a poliklinovy belt.

Establish a radiator frame with hinged details.

Fig. 2.96. Fastening of the rubber buffer

Lower a support emphasis against a provorachivaniye at the expense of a body weight on the rubber buffer and tighten nuts (fig. 2.96).

Establish a casing of a front bumper.

Fix pipelines for gearbox oil.

Follow rules of connection of the rechargeable battery.

ATTENTION For start of the engine do not use the charger. There is a danger of damage of control units to the car.

Check oil level.

Fill in cooling liquid.

NOTE It is allowed to reuse the merged cooling liquid only if the head of the block of cylinders or the block of cylinders was not replaced. The polluted cooling liquid is forbidden to be used further.

Check oil level in a tank of the hydraulic booster of the steering mechanism.

Check the ATF level.

Check adjustment of headlights.