Attention.
- The vehicle must be parked on a level surface.
- Install wheel chocks in front of and behind the rear wheels.
- If there are no lifting eyes on the engine, install them on the engine using bolts, the parameters of which are given in the spare parts catalog.
- When working, observe safety precautions, do not apply excessive force and strictly follow the instructions in this manual.
- Do not start work until the engine cooling system and exhaust system have cooled to a safe temperature.
- Use only designated lifting points to lift and support the engine.
- Depending on your preference, you can use a two-post or four-post lift. If the use of a two-post lift is unavoidable, adopt a hydraulic strut under the rear axle to prevent the center of gravity from shifting back when the engine is removed.
General review
Remove the engine and transmission assembly from the vehicle down. Disconnect engine and gearbox.
Preparation
1. Relieve fuel pressure.
2. Drain the coolant from the radiator.
Attention.
- Pull out the coolant drain only after the engine has completely cooled down.
- Do not allow coolant to come into contact with the drive belt.
3. Remove the following parts:
- Protective pallet of the engine.
- Engine cover.
- Right and left front fenders.
- Front wheels with tires.
- Rechargeable battery with a shelf.
- Air intake with air filter housing.
- Upper and lower radiator hoses and cooling fan.
- Front exhaust pipe.
Engine compartment on the left
1. Disconnect all engine wiring harness connectors around the left mounting pad, and then temporarily fix the wiring harness to the side of the engine.
Note. Put plastic bags over the wire connectors to prevent dust or foreign material from getting on them when removing the engine.
2. Disconnect the fuel supply hose from the engine side.
3. Disconnect heater hoses.
4. Disconnect the control rods from the gearbox.
5. To remove a cable of weight from outside a transmission.
Motor edema on the right
1. Disconnect the vacuum hose from the intake manifold.
2. Modifications with air conditioning system: remove the air conditioning compressor without disconnecting the pipelines from it, and hang it on a rope or wire.
3. Disconnect the expansion tank hoses.
Under the car
1. Remove the left and right ABS wheel sensors from the steering knuckles.
2. Remove the brake caliper assembly with connected brake hoses from the steering knuckles. Hang the calipers on the car body with a rope or wire to take the load off the brake lines.
3. Disconnect the outer sockets of the tie rod ends from the steering knuckles.
4. Remove the rear engine torsion bar.
5. Remove drive shafts (left and right).
6. Modification 4WD: remove the propeller shaft.
7. Remove the anti-roll bars.
8. Remove the front suspension subframe.
9. Remove the front suspension arms.
10. Prepare the gearbox for disconnection: unscrew the gearbox connecting bolts located at the rear on the underside of the upper oil pan.
Removing
1. Using a lift truck or similar (e.g. transmission jack), securely support the bottom of the engine and gearbox assembly.
Note. Use wooden blocks to achieve the most stable position of the power unit.
2. Remove motor mounting bracket (1) and right engine mount (2).
1. Motor mount.
2. Right motor mounting insulator.
3. Left motor mounting insulator.
3. Loosen the nut (A) engine mounting bolt.
4. Carefully lower the jack or raise the vehicle with a jack to remove the engine/gearbox assembly. When performing the procedure, strictly observe the precautions.
Attention.
- Make sure that the parts of the engine and gearbox do not cling to the car body.
- Before lowering the engine with gearbox, once again make sure that all wires and hoses are disconnected.
- It is necessary to remember about the forthcoming shift of the center of gravity. If necessary, support the rear of the vehicle with jacks at the lifting points to prevent the vehicle from falling off the lift.
- If necessary, support the vehicle at the rear with a jack or suitable device.
Disconnection
1. Install the lifting eyes on the engine front cover on the front left side, and on the cylinder head on the right side at the rear.
The arrow indicates the side of the front of the engine
Note.
Tightening torque of the lifting eye bolts:
- From the side of the front cover of the engine: 32.9 Nm.
- From the side of the cylinder head: 25.0 Nm.
2. Remove the starter.
3. Using a garage winch, drive and disconnect the engine from the transmission assembly.