Special tool
 | Engine lift tool 303-122 (21068A) |
 | Radiator hose clamp remover and installer 303-397 (24-003) |
General equipment:
- Technological plugs
- Assembly stand:
- Fixing clamp
- Repair shop crane
Installation
All cars
1. General notes:
- Use special tool 303-397 to install and remove coolant hoses and vent hoses, if necessary.
- The location of the engine mounts in the description is indicated based on the view from the gearbox towards the engine.
2.
CAUTION: Make sure the two guide bushings are installed.
Connect the engine and gearbox.
3. Install the left flange bolts.
4. Install the right flange bolts. Connect the shift cable bracket.
5. Install the engine assembly with gearbox on the assembly stand. Support the gearbox with wooden blocks and secure it with a clamp.
6. Disconnect the special tool.
7. Connect the vehicle speed sensor connector (VSS).
8. Connect the reversing light switch connector.
9. Raise the vehicle. Refer to Section 100-02 for more information.
10. Put the engine assembly with gearbox on the assembly stand under the car.
11. Lower the vehicle and guide the engine and transmission assembly into the engine compartment.
12. Install the rear engine mount.
- Tighten the middle nut.
- Tighten the engine mount nuts.
13. Install the front engine mount.
14. Remove the fixing collar.
15. Raise the car. See Section 100-02 for more information. Remove the assembly stand from under the engine assembly with the gearbox.
16. Connect the clutch master cylinder line.
17.
CAUTION: The inner hinge must not be tilted more than 18 degrees. External hinge - at an angle exceeding 45 degrees.
Install the left front axle shaft into the gearbox. Remove the technological plugs from the gearbox openings.
18.
NOTE: Replace clip and nuts on intermediate bearing.
NOTE: Insert the countershaft into the transmission so that the countershaft bearing rests against the rib of the countershaft bracket.
Establish a forward semiaxle with an intermediate shaft. Remove the technological plugs from the gearbox openings.
19. Install the engine roll limiter.
Vehicles with air conditioning
20. Connect the power steering pump bracket to the drive belt tensioner.
All cars
21. Connect the ball joints of the lower suspension arms on both sides.
22. Install the shift cable and gear selection cable.
23. Connect the heated oxygen sensor connector (HO2S).
24. Dock the plug connector of the crankshaft position sensor (SKR sensor).
25. Connect the plug connector of the oil pressure switch.
26. Connect an exhaust manifold to a reception exhaust pipe.
- Connect the exhaust manifold to the cylinder head.
- Use new gaskets.
27. Remove the flexible exhaust pipe temporary support.
28. Install starter ground cable.
Vehicles without air conditioning
29. Connect the power steering pump to the base plate. Remove the clamp.
30. Connect the power steering hydraulic line bracket.
Vehicles with air conditioning
31. Connect the air conditioning compressor.
32. Install the power steering high pressure pipe bracket.
All cars
33. Install the drive belt and tension it.
34. Install the drive belt cover.
35. Lower the car.
36. Install the coolant hose.
37. Connect the carbon filter vacuum line.
38. Connect the coolant and heating hoses.
- 1.Coolant bottle hose
- 2.Heater hose
- 3.Coolant hose
Vehicles without air conditioning
39. Connect the plug connector and connect the wire.
- 1.Connect the electrical wiring to the generator.
- 2.Install the power steering pump connector.
Vehicles with air conditioning
40. Connect the electrical wiring to the generator.
All cars
41. Connect the heater hose.
42. Connect the hoses and dock the plug connector.
- 1.Vacuum hose - fuel pressure control
- 2.Vacuum hose for brake booster
43. Dock the engine wiring harness connector. Secure the shift cables.
44. Connect the plug connector.
- 1.Ignition coil (EI)
- 2.Condenser
45.
NOTE: Use a new exhaust manifold gasket.
Connect the exhaust manifold (shown from below).
46. Connect the exhaust manifold heat shield and engine ground cable.
- 1.Exhaust manifold heat shield
- 2. Engine ground cable
47. Connect fuel lines.
48. Connect the plug connector of the engine wiring harness and the plug connector of the camshaft position sensor (SMR).
49. Connect the accelerator cable.
- 1.Fix the clamp.
- 2.Fix the cable in the bracket.
50. Install the inlet pipeline.
51. Install the air filter with air intake hose.
- 1.Air intake hose
- 2.Connect the plug connector of the mass air flow sensor (MAF).
- Connect the PCV hose to the cylinder head.
52. Fix a reservoir of the amplifier of a steering.
53. Tighten the nuts of the upper supports of the left and right suspension struts.
54. Install the battery shelf.
- 1.Fix and connect the plug connector.
- 2.Tighten the bolts.
- 3.Fix the wiring harness.
55. Install a new oil filter.
56. Fill in engine oil according to specification.
57. Standard final operations:
- Refill coolant. Refer to Section 303-03 for more information.
- Bleed the hydraulic clutch system. Refer to Section 308-00 for more information.
- Check engine oil level.
- Install battery. Refer to Section 414-01 for more information.
- If necessary, secure the cable using cable ties.
- Check fluid levels again and correct if necessary.
Visitor comments