Removing
1. Relieve residual fuel pressure (see chapter "fuel injection system").
2. Remove the battery.
Note: read the diagnostic code before disconnecting the battery.
3. (Models with manual transmission) Disconnect the clutch release cable.
4. (Models with automatic transmission) Disconnect the throttle control cable.
5. Drain the coolant.
6. Remove the heatsink assembly.
7. Drain gear oil (models with manual transmission) or automatic transmission fluid.
8. Remove the front wheels.
9. Remove the anti-roll bar (see chapter "Suspension").
10. Remove a forward reception pipe of system of release.
11. (4WD Models) Remove the cardan shaft.
12. Disconnect the drive shafts from the transmission side, (4WD models) remove the right drive shaft.
13. (Models with manual transmission) Remove the shift lever.
14. (Models with automatic transmission) Disconnect the transmission control cable.
15. Disconnect the tie rod ends.
16. Mark the steering shaft and remove the universal joint.
17. Using the special tool, disconnect the tie rod ends from the steering knuckle.
18. Remove the air conditioning compressor with an electromagnetic clutch.
Note:
- Do not disconnect the pipes from the compressor.
- Hang the compressor on a rope.
19. Disconnect the power steering expansion tank.
Note:
- Do not disconnect the hoses from the expansion tank.
- Hang the expansion tank on a rope.
20. Disconnect the accelerator cable.
21. Disconnect the speedometer drive cable from the transmission.
A) Press the tab on both sides as shown in the picture.
b) Remove the rope.
22. Remove the front subframe.
A) Disconnect the connectors from the electronic control unit, push them into the engine compartment and remove.
b) Disconnect the connectors and clamps, disconnect the wiring harness from the vehicle.
V) Disconnect all ground wires from the engine and transmission.
G) Install lifting eye #1 to lift the engine.
- Tightening torque - 24±5 Nm
d) Attach the tool securely to the jack.
e) Raise the jack until it contacts the front subframe.
Attention: to avoid damage to the holes, wrap the pin of the special tool with electrical tape.
Note: To install the pins of the special tool, use the holes for the anti-roll bar mounting bolts.
and) Turn out adjusting bolts and nuts of fastening of a forward stretcher.
h) Lower the jack with the engine and transmission assembly.
Note: Lower the jack slowly to avoid damage to hoses and connectors that have not been removed in time.
And) Hang the engine and transmission assembly using a pulley and chain.
To) Remove the power steering pump from the engine.
Note:
- Do not disconnect the pipes from the power steering pump.
- Hang the pump on a rope.
l) Turn away bolts and nuts, remove a forward subframe with the steering mechanism.
23. Remove automatic transmission.
A) Remove the three torque converter bolts and remove the torque converter drive plate.
b) Remove the torque converter and automatic transmission.
Disassembly, inspection, cleaning and repair of the cylinder block
The procedures for disassembling, checking, cleaning, repairing and assembling parts of the cylinder block are described in the chapter "Engine - General Repair Procedures".
Installation
1. Install the front engine mount bracket.
A) Temporarily tighten the bolt (A), shown in the figure.
b) Finally tighten the bolts (WITH), (IN), (D) And (A).
Removal and installation of the power unit (1)
1 - power steering pump drive belt,
2 - power steering pump,
3 - vacuum brake booster hose,
4 - fuel hose,
5 - heater hose No. 1,
6 - heater hose No. 2,
7 - radiator inlet hose,
8 - steering shaft seal,
9 - bracket for the rear engine mount,
10 - power steering pump bracket,
11 - expansion tank,
12 - front engine mount bracket,
13 - subframe,
14 - exhaust manifold rack.
2. Clean the bolt holes in the cylinder block and install the manual transmission.
3. (Models with automatic transmission) Install the torque converter.
A) Install the torque converter on the automatic transmission and verify that it is properly installed by measuring the distance (A) between the parting plane and the torque converter shown in the figure.
- Rated distance (A) - 29 mm
b) Apply grease to the torque converter axle.
4. Install automatic transmission (see chapter "Automatic transmission").
5. Install the rear engine mount bracket.
A) Temporarily tighten the bolt (A).
b) Tighten the bolts (WITH), (IN) And (D).
V) Finally tighten the bolt (A).
G) tighten bolt (E).
6. Install the front subframe.
A) Install the engine/transmission assembly to the front steering subframe assembly.
b) Install the power steering pump and power steering hose bracket to the engine.
V) Install the power steering pump drive belt and adjust its tension.
G) Securely fix the special tool on the rolling jack.
Removal and installation of the power unit (2).
1 - accelerator cable,
2 - air filter bracket,
3 - speedometer drive cable,
4 - manual transmission,
5 - transfer box (4WD),
6 - starter,
7 - automatic transmission,
8 - torque converter,
9 - compressor bracket,
10 - air conditioning compressor,
11 - air conditioning compressor drive belt,
12 - power steering pump bracket,
13 - stiffener,
14 - engine assembly.
d) Install the subframe on the special tool.
e) Install the subframe with the engine on the car.
and) Tighten the subframe mounting bolts.
h) Connect all wires, connectors and clamps.
And) Connect the connectors to the electronic control unit.
To) Connect ground to engine and transmission.
7. Install the exhaust manifold strut.
A) Temporarily tighten the bolt (1).
b) Finally tighten the bolts (2) And (1).
8. Install the accelerator cable.
Make sure pedal free play is correct.
- Free play - 1-5 mm
9. Install the A/C compressor.
10. Install the A/C compressor drive belt and adjust its tension.
11. Align the marks and install the universal steering joint.
12. Install drive shafts.
13. Install the anti-roll bar.
14. Establish a forward reception pipe exhaust system.
15. (Models with manual transmission) Install the shift lever.
16. (Models with automatic transmission) Connect the transmission control cable.
17. Install the front wheels.
18. Install a new gasket on the drain plug, fill with manual transmission oil or automatic transmission fluid.
19. Install the radiator.
20. (Models with manual transmission) Install the clutch release cable.
21. (Models with automatic transmission) Install the throttle control cable.
22. Fill in coolant.
23. Remove the engine lifting eye.
24. Install the battery.