Note. The engine can be removed from the vehicle only as part of the power unit.
The power unit is removed using a hydraulic lift or hoist, lifting it from the engine compartment (then the car is rolled back and the power unit is lowered onto the cart). In this case, the tips of the front wheel drive shafts are disconnected from the power unit and remain on the vehicle.
Note. Below is only the procedure for removing and installing the power unit, a detailed description of each of the operations is given in the relevant sections of the manual.
Removing
Remove the power unit in the following order:
1. Relieve pressure in the fuel supply system. To do this, do the following:
- disconnect the electric fuel pump wiring harness connector from the injection system wiring harness;
- start the engine and let it stop;
- turn on the starter for 3 s to equalize the pressure in the pipelines.
2. Put the car on a lift and brake it with the parking brake drive lever. Chock the rear wheels, jack up the front wheels and open the hood.
3. Raise the car on a lift and remove the engine mudguard by unscrewing the bolts of its fastening to the body.
4. Drain the coolant by unscrewing the drain plugs of the cylinder block and radiator with the expansion tank cap removed and the heater valve open.
5. On models with manual transmission:
- drain the oil from the gearbox by unscrewing the drain plug;
- disconnect the clutch cable from the gearbox;
- disconnect the gear lever drive rod from the gear selector rod;
- Disconnect the tire from the gearbox that connects it to «weight» body.
6. On models with automatic transmission:
- disconnect the control cable from the automatic transmission;
- drain the gearbox oil;
- Disconnect the electrical connector from the automatic transmission:
- Disconnect the tire from the gearbox that connects it to «weight» body.
7. Disconnect the wire from «negative» battery outlet.
8. Remove the battery tray.
9. Remove the air filter housing along with air ducts.
10. Remove the alternator drive belt.
11. Remove the radiator and expansion tank.
12. On models with power steering, remove the power steering pump from the bracket and move it aside without disconnecting the inlet and outlet hoses.
13. On models equipped with air conditioning, disconnect the electrical connector from the air conditioning compressor, unscrew the fastening bolts and nuts and move the compressor to the side without disconnecting the inlet and outlet hoses, fix the compressor in this position.
14. Remove the generator.
15. Disconnect the accelerator cable from the throttle body and the bracket holding the cable sheath.
16. Disconnect the vacuum brake booster hose from the intake manifold.
17. Disconnect the exhaust pipe from the exhaust manifold by unscrewing the three nuts on the bolts tightening the flanges and remove the gasket.
18. Remove the bracket and mounting plate of the electronic control unit of the engine management system, disconnect the block of the wiring harness going to the engine from the control unit, and fix the wiring harness to the engine.
19. Disconnect the hoses from the inlet and outlet pipes of the heater radiator on the front panel.
20. Disconnect the front wheel drive shafts from the gearbox.
21. Disconnect the engine wiring harness connector at the left front of the engine compartment by turning the union nut counterclockwise.
22. Remove the cover from the relay and fuse box and disconnect the engine wiring harness block from the box panel. Attach the engine wiring harness to the engine.
23. Disconnect the fuel lines from the engine and plug them.
24. If the engine is removed using a hoist, then hook the engine on the eyelets mounted on the cylinder head and gearbox, and hang the engine.
25. Disconnect the rear suspension bracket from the engine by unscrewing the nuts and removing the bolts.
26. Remove the left engine mount. To do this, do the following:
- unscrew the central nut of the silent block and the bolts of the silent block to the base plate of the left suspension;
- remove the silent block from the base plate;
- unscrew the bolts securing the base plate of the left suspension to the body (the base plate must be dismantled, as otherwise it will prevent the removal of the power unit).
27. Turn away nuts and remove a spacer level of an arm of the right suspension bracket of the engine.
Pic. 3.1. Power unit suspension: 1 - bolt; 2 - rubber cushion; 3 - upper bracket of the right support; 4 - stamped bracket; 5 - right support bracket; 6 - bolts; 7 - nut; 8 - rubber cushion; 9 - left support bracket; 10 - plate; 11 - bolt
28. On parts of cars, a silent block can be installed on the bracket of the right engine mount. If it is installed, remove it, then remove the right suspension bracket by unscrewing the nuts securing the bracket to the bracket on the cylinder block (see fig. 3.1). Remove the wiring harness from the bracket.
29. After disconnecting the engine mounts from the body, make sure that all parts, wires and hoses that may interfere with the removal of the engine are disconnected, removed or laid aside and securely fastened.
30. Raise the power unit while tilting it so as not to touch the body, and remove it from the engine compartment. Make sure that the crankshaft pulley does not touch the air conditioning pipes or the condenser (if necessary, cover the condenser with a sheet of strong cardboard or plywood).
31. Raise the power unit to a sufficient height, move it away from the vehicle or roll the vehicle out from under the power unit and lower it onto the cart.
Installation
Install the power unit in the reverse order of removal. When installing the power steering pump, you must first tighten the lower pump mounting bolt, after coating its threaded part with Loctite Frenetanch, then tighten the front mounting bolts (from the side of the pump drive pulley). Lastly, the rear pump mounting bolts are tightened. After attaching the throttle cable to the throttle body, adjust it as described in subsection «Supply system». Also adjust the clutch release drive according to the instructions in subsection «Clutch».