Removal and installation of the engine

Withdrawal

1. Disconnect ground wire from battery.

2. Remove the hood.

3. Drain the cooling system (see subsection 3.2.1.11).

4. Disconnect the air supply line to the turbocharger, the crankcase ventilation flex pipe from the cylinder head cover, and the air supply line between the air filter and the radiator shroud (the pipeline is dressed on fastening tips).

5. Disconnect all elastic pipes of the cooling system from the engine.

6. Disconnect the coolant pipes from the cylinder head and from the thermostat cover connected to the expansion tank of the cooling system.

7. Cut the clamps of the oil pressure sensor electrical wire.

8. Disconnect the accelerator pedal cable from the fuel pump lever and from the bracket.

9. Disconnect the fuel supply lines from the filter and fuel pump, and then the return line from the fuel pump.

10. Disconnect vacuum line from vacuum pump.

11. Disconnect the electrical connectors from the following items: alternator, coolant temperature sensor, oil pressure sensor, radiator fan thermal switch, engine shutdown solenoid valve (STOP valve), a cold engine fuel injection advance corrector, and a cold engine fast idle automatic thermal switch.

12. Cut the wire harness clips to the left engine mount bracket and move the wire harness away from the engine.

13. Disconnect the electrical connector from the radiator fan.

14. Remove the radiator fan together with the radiator shroud.

15. Unscrew the upper right bolts connecting the engine to the gearbox.


16. Remove the clamps securing the front suspension stabilizer bushing to the body (four bolts).

17. Disconnect the exhaust pipe from the turbocharger.

18. Disconnect the bracket holding the front exhaust pipe from the transaxle cross member.

19. Disconnect the electrical connectors from the starter.

20. Remove starter.

21. Unscrew from the engine mount beam one nut each of the left and right elastic support of the engine mount.

22. Disconnect the electrical connector from the reversing light sensor, and then remove the reversing light switch electrical wire clip.

23. Unscrew the bolts securing the clutch housing plate.

24. Disconnect the end of the clutch cable from the clutch release forks.

25. Unscrew all other bolts connecting the engine to the gearbox.

26. Support the gearbox with a jack.

27. Using a hoist, hang the engine on the lifting brackets, disconnect the engine from the gearbox (before the appearance of the end of the input shaft) and remove the engine from above from the engine compartment of the car.

Installation

Attention! Replace all self-locking nuts with new ones.

1. Lightly oil the end of the gearbox input shaft.

2. Carefully lower the engine into the engine compartment of the car, insert the gearbox input shaft into the clutch disc hub. Using two bolts securing the clutch housing to the engine (located as far apart as possible), connect the engine and gearbox.

3. Lower the engine slightly and insert the engine mount strut bolts into the holes in the engine mount cross member.


4. Move the hoist on which the engine was suspended, and the jack supporting the gearbox from below.

5. Insert and torque-tighten the bolts connecting the engine to the gearbox. Connect the ground wire and attach the clip to the reverse light switch wire.

6. Install the clutch housing plate by tightening the mounting bolts.

7. Connect the electrical connector to the reversing light switch.

8. Attach two elastic engine mounts to the engine mount cross member.

9. Install starter with bracket.

10. Connect the electrical connectors to the starter.

11. Connect the end of the control cable to the clutch release forks.

12. Screw exhaust pipe onto turbocharger flange.

13. Screw the bracket that supports the front exhaust pipe to the transaxle cross member.

14. Install the clamps securing the front suspension stabilizer bushing to the body (four bolts).

15. Install the radiator fan with the radiator shroud.

16. Connect the radiator fan motor electrical connector.

17. Connect all electrical wire connectors and use the latch to secure the harness to the left engine mount bracket.

18. Connect the vacuum line to the vacuum pump.

19. Connect fuel lines to fuel filter and fuel pump with new copper washers.

20. Connect the accelerator pedal cable to the fuel pump.

21. Connect the flexible pipes of the vehicle interior heating system to the cylinder head and to the oil cooler.

22. Connect the flexible pipe from the expansion tank of the cooling system to the cylinder head and to the thermostat cover.


23. Fasten the electrical wire of the oil pressure sensor to the flexible pipe with a clip.

24. Connect the two lower flexible pipes from the radiator to the coolant pump and oil cooler.

25. Insert the pipe between the air filter and the upper radiator casing; connect the air supply lines to the turbocharger and the engine ventilation lines.

26. Connect the vehicle ground wire to the battery.

27. Pour the correct amount of oil into the engine.

28. Fill the engine cooling system.

29. Remove air from the fuel system.

30. Remove air from the cooling system.

31. Install the hood.

32. Check the maximum RPM and idle speed of the engine. Adjust them if necessary.

33. Check the tightness of the connections of the fuel system and the cooling system.