1. Remove the negative cable from the battery.
2. Remove the crankcase protection and mudguard.
3. Remove grille.
4. Disconnect the hood release cable from the hood closing mechanism and remove from the clips.
5. Remove the hood, having previously marked the position of the hinges, to facilitate reinstallation and disconnecting the windshield washer tube.
6. Drain the coolant from the cooling system by placing an appropriate container under the radiator drain plug and opening the drain plug located at the bottom of the radiator. To speed up the draining of the coolant, open the cap of the expansion tank. To drain the coolant from the cylinder block, unscrew the drain bolts located on both sides at the rear of the cylinder block.
7. Loosen the clamps and remove the pipes and hoses of the cooling system:
- upper and lower radiator pipes;
- expansion tank hoses;
- interior heating hoses;
- water pump hoses.
8. Unscrew the four bolts securing the upper front cross member, two bolts from both sides at the top and the two lower bolts securing the cross member support and remove it together with the radiator.
9. Disconnect the exhaust pipe from the exhaust manifold. On a turbocharged engine, disconnect the front exhaust pipe from the turbocharger.
10. Disconnect the brake booster vacuum pipe from the vacuum pump.
11. Disconnect the fuel supply and return pipes from the high pressure fuel pump. On a turbocharged engine, remove the fuel filter from the bracket.
12. Disconnect electrical wires and remove connectors from the following units and sensors:
- generator;
- starter;
- ground bus;
- temperature sensor;
- temperature excess sensor;
- oil pressure sensor;
- solenoid valve on the high pressure fuel pump;
- electromagnetic fan clutch;
- radiator temperature sensor.
13. Remove the accelerator cable from the high pressure fuel pump.
14. Install the engine lifting shackle at the rear of the cylinder head.
15. Remove all drive belts, after loosening their tension.
16. Remove the radiator fan by first unscrewing the central fastening nut.
17. Remove starter.
18. Remove the crankshaft pulley. To prevent turning of the crankshaft when unscrewing the pulley mounting bolt, fix the flywheel ring gear through the hole for installing the starter.
19. Remove the alternator and water pump drive belt tensioner.
20. Remove the power steering pump without disconnecting the hoses from it, and fix it to the body using a soft wire.
21. Remove the gear lever by first unscrewing the tip of the lever and removing the plastic casing with the frame and corrugated collar and unscrewing the lever.
22. Unscrew the stabilizer clamps and remove the stabilizer.
23. Remove the clutch cable from the clutch release lever.
24. Unscrew the nuts securing the engine brackets to the cross member pads.
25. Unscrew the lower clutch plate from the bottom of the car, lift the gearbox with a jack and unscrew it from the body. Unscrew the bolts securing the clutch housing to the engine, for which lower the gearbox slightly.
26. Using a hoist, carefully lift the engine and separate the gearbox from it.
27. Lifting the engine at the same time move it forward and turn it in a horizontal plane to remove it up.
Installation
The engine is installed in the reverse order of removal. In this case, it is necessary to pay attention to some features:
- when installing the clutch on the flywheel, it is necessary to center the clutch disc with a centering mandrel;
- If, when connecting the gearbox to the engine, the input shaft of the gearbox does not enter the clutch disc, it is necessary to turn the crankshaft of the engine a little.
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