Attention! The procedure is given using the example of cars with DK5ATE engine.
1. Drain the coolant.
2. Drain the transmission oil.
3. Drain the engine oil if necessary.
4. Remove the upper front cross member.
5. Press the fasteners 1 that hold the top of the radiator (see illustration).
6.5 Press the clamps 1
6. Disconnect the air conditioner radiator from the coolant radiator, remove the cooling system radiator (see arrows in illustration 6.5). Move the air conditioner radiator to the side without disconnecting the refrigerant circulation pipes from it.
7. Remove the cooling radiator.
Attention! All work related to the air conditioner should be entrusted to a specialized workshop. Do not open the refrigerant circulation system yourself - risk of frostbite!
8. Remove the front bumper.
9. Disconnect both drive shafts from the gearbox and secure them to the body so that they do not sag, see the relevant chapter.
10. Remove the left and right mudguards.
11. Remove the accessory drive belt, see the relevant chapter.
12. Clamp hose 2 with a suitable clamp, for example clamp "a" 1512 (see illustration).
6.12 Clamp hose 2 with a suitable clamp, for example clamp "a" 1512
13. Disconnect the brake hose.
14. Plug the wheel cylinder inlet.
15. Remove the battery and its tray.
16. Move power steering pump 3 away from the work area (see illustration).
6.16 Move power steering pump 3 away from the work area
17. Cars with air conditioning (engine serial number starting from 91000000). Move the condenser 4 and compressor 5 of the air conditioner away from the work area (see illustration 6.16).
18. Remove the engine control unit.
19. Remove the clutch slave cylinder 5 (see arrows in the illustration).
6.19 Remove the clutch slave cylinder 6 (see arrows)
20. Fasten the protective cap "a" (see arrows in the illustration) to avoid damage to the clutch slave cylinder 6.
6.20 Fasten the protective cap "a" (see arrows) to avoid damage to the clutch slave cylinder 6
21. Install a support beam on the front to raise the engine and relieve the load on the power unit supports, or raise the power unit using a crane or hoist (see illustration).
6.21 Lift the power unit using a crane
22. Remove the upper support 7, and then the lower support 8 of the engine mount (see illustration).
6.22 Remove the upper support 7 and then the lower support 8 of the engine mount.
Tightening torques:
- central bolt 13 support - 50 Nm. Tightening of the bolt is performed with a socket head bolts 20 - 20 Nm.
- nut 10 - 65 Nm;
- bolts 9-50 Nm;
- bolts 21 - 110 Nm;
- bolts 22 -60 Nm;
- bolts 23 - 70 Nm
23. Unscrew the bolts 9 (see illustration 6.22).
24. Unscrew the central nut 10 of the fastening and remove the support 11, remove the bushing 12 (see illustration 6.22).
25. Unscrew the central bolt 13 of the support using the socket head "a" 0317-AB (see illustration).
6.25 Unscrew the central bolt 13 of the support using the socket head "a"
26. Remove the head 14 of the gearshift lever and the upper trim 15 of the rear part of the center console (see illustration).
6.26 Remove the gearshift lever head 14 and the upper trim 15 of the rear part of the center console
27. Unscrew the nuts 16 (see illustration).
6.27 Unscrew the nuts 16
28. Remove the intake pipe 17 (see illustration).
6.28 Remove the exhaust pipe 17
29. Release the gear shift lever housing 18 from its fasteners (see illustration 6.28).
30. Disconnect all wires, hoses and pipes secured to the power unit housing.
31. Carefully remove the power unit (see illustration).
6.31 Carefully remove the power unit
The power unit is installed in the reverse order of removal.
32. The tightening torque of the power steering pump mounting bolts is 20 Nm.
33. The tightening torque of the wheel hub nut is 345 Nm, the wheel bolts are tightened with a force of 85 Nm.