Attention.
- The vehicle must be parked on a level, solid surface.
- Install wheel chocks in front of and behind the rear wheels.
- 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 preference, you can use a two-post or four-post lift. If the use of a two-post lift is unavoidable, install a hydraulic jack under the rear axle to prevent the center of gravity from shifting backwards when the engine is removed.
General description
The engine is removed through the bottom of the car. After removing the engine and gearbox assembly, they must be separated.
Preparation
1. Drain the coolant from the radiator.
Attention.
- Drain the coolant only after the engine has completely cooled down.
- Do not allow coolant to come into contact with the drive belt.
2. Remove the following parts:
- Protective pallet of the engine.
- Engine cover.
- Front wheel with tires.
- Front fenders (left and right).
- Rechargeable battery with a shelf.
- Intake ducts and air hoses.
- Air intake and air filter assembly.
- Radiator Hoses (upper and lower) and cooling fan assembly.
- Front exhaust pipe.
Left side of the engine compartment
1. Remove engine ECU (1) with bracket (2) assembled.
2. Remove bracket (A) from the left engine mounting insulator.
3. Disconnect all engine wiring harness connectors around the left engine mounting insulator and temporarily secure the wiring harness to the engine.
Note. Put plastic bags over the wire connectors to prevent dust or foreign material from getting on them during engine removal.
4. Disconnect the fuel hoses from the fuel pump.
5. Disconnect the heater hoses and install plugs to prevent coolant from escaping.
6. Disconnect control cables (modifications with automatic transmission) or selector and shift cables (modifications with a manual transmission) from the gearbox.
7. Remove the ground cable from the gearbox side.
8. Disconnect the vacuum hose from the brake booster.
Right side of the engine compartment
1. Remove the fuel filter.
2. Remove ground cable.
3. Disconnect the bottom hose of the expansion tank from the intake pipe of the cooling system.
4. Remove the generator.
5. Modifications with air conditioning system: remove the air conditioning compressor without disconnecting the pipelines from it, and hang it on a rope or wire.
Under the car
1. Remove the front wheel speed sensors (left and right) from rotary knuckles.
2. Remove the brake caliper assembly with connected brake lines 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. To turn away two bolts connecting rotary fists with racks.
4. Remove the rear engine tie rod.
5. Modification 4WD: remove the cardan shaft.
6. Remove drive shafts (left and right).
7. Unscrew the fastening nuts with caps from the side of the rack (right and left).
8. Disconnect the intermediate steering shaft assembly.
9. Remove the turbocharger cooling pump with bracket assembly.
10. Remove the exhaust gas pressure drop sensor with bracket assembly.
11. Disconnect the clutch hydraulic lines.
12. Remove the front suspension subframe.
13. Unscrew the transmission connecting bolts located 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 the upper engine tie rod (1).
The arrow points towards the front of the engine.
3. Unscrew the three mounting bolts (A) right engine mounting insulator (2).
4. Unscrew the two mounting bolts (IN) left engine mounting insulator (3).
5. Carefully lower the jack or raise the vehicle with a jack to remove the engine and transmission 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.
Disconnection
1. Hook the winch to the rear engine rigging eyes (1) and front (2).
2. Remove the starter from the engine.
3. Using a garage winch, lift and disconnect the engine from the transmission assembly.