Recommendations for removing the engine
Please read this section carefully before starting work.
If the engine is removed for repair, it is necessary to select a place for work, provide space for maintenance and storage of spare parts. Repairs are recommended to be carried out at a workshop or in a garage with a flat, horizontal floor with a clean hard surface.
Before removal clean from pollution, wash up the engine and a motor compartment. To remove, use a lifting device that allows you to safely lift the power package.
If you are removing the power unit for the first time, you must invite an experienced specialist. Some work should be done with an assistant.
All clamps and clamps that are damaged or cut when removing the engine are replaced with new ones when assembling the engine.
Depending on the year of manufacture and vehicle equipment, electrical wires, pipelines and hoses may be located in the engine compartment in different ways. Therefore, before disconnecting electrical connectors and disconnecting pipes or hoses, it is recommended to mark them with adhesive tape.
The engine is removed forward along with the gearbox.
Drained coolant must be collected and disposed of.
Removing
Place the car on a two post lift.
Open the hood to the service position and secure it with a bolt and nut system.
Drain the coolant.
Drain the gearbox oil.
Drain the engine oil from the engine.
Pic. 3.1. Location of units and assemblies in the engine compartment with the TU3JP engine: 1 - plastic cross member of the amplifier; 2 - plastic windshield deflector; 3 - supply tank with brake fluid; 4 - battery; 4 - air filter with air pipe and resonator; 6 - decorative cover of the fuse box
Pic. 3.2. Location of units and assemblies in the engine compartment with the TU5JP4 engine: 1 - plastic cross member of the amplifier; 2 - plastic windshield deflector; 3 - supply tank with brake fluid, 4 - battery; 5 - air filter with air pipe and resonator; 6 - decorative cover of the fuse box
Remove and move aside the supply tank 3 (pic. 3.1, 3.2) with brake fluid.
Remove the wiper arms.
Remove plastic windshield deflector 2.
Remove the decorative cover 6.
Remove the plastic cross member of the booster 1.
Remove the air filter assembly, air pipe and resonator 5.
Remove the right wheel arch mudguard.
Remove the battery 4 and its bracket.
Remove the front bumper.
Remove headlights.
Pic. 3.3. Front panel cross member location (1), cooling cassettes assy (2) together with the radiator and the lower cross member of the front panel (3)
Remove the front panel cross member 1 (pic. 3.3).
Remove the cooling cassette assembly 2 together with the radiator.
Set aside and secure the air conditioning radiator.
Remove the lower cross member of the front panel 3.
Don't let the horn hang on its wire.
Attention! Do not open the cooling circuit of the air conditioning system.
Depressurize the rail with the SCHRADER valve.
Disconnect the wiring harnesses and fuel supply pipe from the engine.
Remove the catalytic converter.
Remove the accessory drive belt.
Turn out bolts of fastening of the compressor of the conditioner and take away it aside, without disconnecting pipelines from it.
Remove the A/C compressor bracket.
Pic. 3.4. Bolt location (1) fastening the steering knuckle to the front suspension strut
Remove bolts 1 (pic. 3.4) attaching the steering knuckle to the front suspension strut.
Remove the front suspension ball joint trunnion from the steering knuckle.
Release the ABS sensor from the mounting brackets.
Move the wheel hub assembly away from the vehicle.
Remove the wheel drive shafts.
Reinstall and secure the wheel hub.
Pic. 3.5. Arrangement of bolts of fastening of the working cylinder (1) clutch and anti-shock booster (2) subframe
Turn out bolts and remove the working cylinder 1 (pic. 3.5) clutch.
Remove the shock-proof amplifier 2 of the sub-frame.
Pic. 3.6. Support location (1) linkage systems, pins (2) gear shifter and nuts (3) wire fasteners «masses»
Remove fingers 2 (pic. 3.6) gear shift mechanism.
Remove a support 1 of system of drafts.
Loosen the clamps and remove the coolant supply hoses to the heater core.
Loosen nut 3 and disconnect wire «masses» 3.
Release the engine wiring harnesses from the clips at the level of the computer and transmission.
Place a platform jack under the power package and secure the platform and engine mounts at the following points:
- in place of the anti-roll bar;
- in place of the catalytic converter mounting bolt on the engine block;
- on the air conditioner compressor bracket mounts;
- instead of the catalytic converter mounting bolt on the cylinder block.
Raise the platform jack so that the weight of the power package is supported by the jack.
Remove the right engine mount bracket.
Remove an elastic pillow of a suspension bracket of a transmission.
Make sure all electrical wires, hoses, fittings and pipes are disconnected from the engine.
Remove the power unit, being careful not to hook on the surrounding elements.
If necessary, disconnect the gearbox from the engine.
Installation
The engine is installed in the reverse order of removal, taking into account the following.
Replace with new self-locking nuts and bolts that have been tightened to a certain angle, as well as o-rings and gaskets.
Check for the presence of centering sleeves that determine the relative position of the engine and gearbox.
Pic. 3.7. Using mandrels (1 and 2) to replace differential seals
With mandrels 1 and 2 (pic. 3.7) replace the differential seals. Before installing sealing rings, fill the distance between the working edges of the ring with grease.
Pic. 3.8. Axis location (1) left engine mount that needs to be lightly coated with SPAGRAH grease
Apply to axle 1 (pic. 3.8) light coat of SPAGRAH grease on the left engine mount and reinstall the power unit.
Tighten the left engine mount nut to 65 Nm.
Install the right engine mount bracket.
Further installation of the engine is carried out in the reverse order of removal, taking into account the following.
Install the engine mount.
Install the accessory drive belt.
Install the wheel drive shafts.
Fill the gearbox and engine with oil.
Install the front bumper and headlights.
Fill with coolant and bleed air from it.
Connect the battery.