Removal and installation of the engine

Remove the engine and transmission assembly by lowering it down from the engine compartment. This requires a lift to raise the front of the car higher. In garage conditions, in the absence of a lift, a jack will be required, as well as strong and high enough supports to install a raised front of the car on them, this will make it possible to remove the engine from under it, lowered to the garage floor.

GOOD ADVICE: The engine is very heavy, so we recommend removing it with help.

WARNING: When removing and installing an engine with a large mass, use only fully serviceable lifting mechanisms designed for the appropriate load, and especially carefully control the correctness and reliability of connecting cables, traverses, etc. to the transport eyes of the engine.

1. For convenience, remove the hood (cm. «Removal and installation of a cowl»).

2. Reduce the pressure in the supply system (cm. «Reducing the pressure in the power system»).

3. Disconnect the wires from the battery and remove it from the car (cm. «Removing and installing the battery»).



4. Remove the air supply sleeve (cm. «Removing and installing the air filter and intake silencer»).


5. Remove the air filter (cm. «Removing and installing the air filter and intake silencer»).



6. Remove the pipeline of the crankcase ventilation system (cm. «Cleaning the crankcase ventilation system»).



7. Remove the engine mudguard (cm. «Removal and installation of a mudguard of the engine»).

8. Drain the liquid from the cooling system (cm. «Coolant replacement»).

9. If you remove the engine for repair, drain the oil from the oil sump (cm. «Changing engine oil and oil filter»).



10. Remove the cover of the mounting block in the engine compartment (see «Mounting blocks») and disconnect the block of the engine wiring harness from the block connector.

NOTE: The engine harness remains on the engine and will be removed with the engine.

11. Disconnect the wire from the body «masses», by unscrewing the mounting bolt.



12. Remove battery tray (cm. «Removal and installation of the shelf of fastening of the rechargeable battery»).



13. Disconnect from the body bracket two «massive» wires by unscrewing the bolt of their fastening.




14. Remove the expansion tank of the cooling system from the body brackets, disconnect the liquid hose from it (cm. «Removal and installation of a broad tank») and take the expansion tank to the side.



15. Disconnect the power steering reservoir from the bracket by unscrewing the fastening bolt and move the reservoir aside.



16. Remove the front wheel drives (cm. «Removal and installation of front wheel drives»).


17. Remove the A/C compressor drive belt (cm. «Replacing the A/C Compressor Drive Belt»).

18. Remove the accessory drive belt (cm. «Accessory drive belt replacement»).



19. Remove the radiator of the cooling system (cm. «Replacing the cooling system radiator»).

NOTE: If the vehicle is not equipped with air conditioning, the radiator may not be removed. It is enough to disconnect the outlet hose from the lower radiator pipe.

Pic. 5.19. A/C compressor mounting

20. Turn out bolts of fastening of the compressor of the conditioner (see fig. 5.19). Without disconnecting the pipelines from the compressor, take it to the side and secure it in any way possible (e.g. tying with wire).

21. Disconnect the power steering pump from the engine (cm. «Power steering pump replacement»), and then, without disconnecting the pipelines from it, take it aside and fix it in the same way as you fixed the air conditioning compressor.



22. Squeezing the clamps, disconnect the fuel supply line 1 and the canister purge line 2.



23. Remove the collector (cm. «Removal, installation of the collector and replacement of its gasket»).



24. Disconnect the interior heater outlet hose by turning its retainer counterclockwise.



25. Squeezing the clamps with pliers and sliding them along the hoses, disconnect the steam outlet hose supplying the interior heater hose..



26.... and the radiator inlet hose from the outlet pipe of the water jacket located under the ignition coil.



27. Disconnect from an inlet pipe the pipeline of the vacuum amplifier of brakes.

NOTE: Throttle assembly removed for clarity. When removing the engine, it is not required to dismantle it.

28. Unfasten seven latches of a cover of a casing of the mechanism of a gear change..



29.... and remove the cover.



30. Disconnect the cable ends from the gearshift levers..



31.... and cable sheaths from gearbox brackets (cm. «Replacing the transmission control cables»).



32. Prying with a screwdriver..



33.... remove the spring retainer of the adapter of the working cylinder of the hydraulic clutch release..



34.... and disconnect the adapter from the clutch housing along with the hydraulic clutch release pipeline.



35. Remove the clutch release line hose holder from the bracket on the gearbox and move the line aside.



36. Place a secure support under the engine and remove the rear suspension support of the power unit (see «Replacing the suspension bearings of the power unit»).



37. Attach the slings of the lifting mechanism to the front..



38.... and rear transport eyes and tighten the straps.



39. Remove the gearbox crankcase ventilation breather from the flanging bracket of the left suspension support of the power unit.



40. Turn out a bolt of fastening of the left support of a suspension bracket of the power unit to an arm on a transmission.



41. Remove the right suspension bracket of the power unit (see «Replacing the suspension bearings of the power unit»).

42. Check again if all wires, hoses and attachments are disconnected from the power unit.

43. Remove the support from under the engine and lower the power unit down to the floor.

44. Hang the front of the car (raise the car on a lift) to a height sufficient to remove the power unit from under the vehicle, and place reliable supports under the body.

45. Remove the power unit from under the car.

46. Establish the engine, and also all removed knots and details in sequence, return to removal, taking into account the following:

• before installing the power unit, clean the threaded holes for fastening its supports with a tap from rust;
• be sure to replace the gasket of the collector with a new one;
• when connecting wires and pipelines, carefully monitor their correct location in the engine compartment, avoiding contact with heating and moving elements of the power unit.

After installing the engine, do the following.

1. Fill engine oil (cm. «Changing engine oil and oil filter»).

2. Fill the gearbox with oil (cm. «Changing the oil in the gearbox»).

3. Fill with coolant (cm. «Coolant replacement»).

4. Adjust the gearbox control actuator (cm. «Gearbox control drive adjustment»).

5. Remove air from the hydraulic clutch release (cm. «Bleeding the hydraulic clutch release»).

6. Start the engine and check for fuel, oil and coolant leaks. Check oil pressure. Listen to the engine: it should run smoothly, without extraneous noise and knocks.