1. Remove the negative cable from the battery.
2. Remove the crankcase guard and mudguard.
3. Remove the radiator grille.
4. Disconnect the hood release cable from the hood closing mechanism and remove it from the clips.
5. Remove the bonnet, first marking the position of the hinges to facilitate reinstallation and disconnecting the windscreen washer pipe.
6. Drain the coolant from the cooling system by placing a suitable 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 expansion tank plug. 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 cooling system pipes and hoses:
- upper and lower radiator hoses;
- expansion tank hoses;
- interior heating system hoses;
- hoses from the water pump.
8. Unscrew the four bolts securing the upper front crossmember, two bolts on both sides at the top and two lower bolts securing the crossmember support and remove it together with the radiator.
9. Disconnect the exhaust pipe from the exhaust manifold. On a turbocharged engine, disconnect the exhaust pipe from the turbocharger.
10. Disconnect the brake booster vacuum line 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;
- electromagnetic 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 an engine lift cleat at the rear of the cylinder head.
15. Remove all drive belts, first loosening their tension.
16. Remove the radiator fan, having first unscrewed the central mounting nut.
17. Remove the starter.
18. Remove the crankshaft pulley. To prevent the crankshaft from turning when unscrewing the pulley mounting bolt, secure the flywheel ring gear through the starter mounting hole.
19. Remove the generator and water pump drive belt tensioner.
20. Remove the power steering pump without disconnecting the hoses from it and secure it to the body using soft wire.
21. Remove the gear shift lever, having first unscrewed the tip of the lever and removed the plastic casing with the frame and corrugated cuff and unscrewed the lever.
22. Unscrew the stabilizer mounting 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 beam cushions.
25. From underneath the car, unscrew the lower clutch shield, use a jack to lift the gearbox and unscrew it from the body. Unscrew the bolts securing the clutch housing to the engine, for which you need to lower the gearbox a little.
26. Using a lifting mechanism, carefully lift the engine and separate the gearbox from it.
27. While lifting the engine, simultaneously move it forward and, turning it in a horizontal plane, remove it upwards.
Installation
The engine is installed in the reverse order of removal. 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 engine crankshaft slightly.