Attention: Please read the entire section, including the message at the beginning section 3, before you begin removing the engine. This section describes how to remove the engine separately from the transmission through the top of the engine compartment.
Removal
1. Disconnect the negative battery cable.
2. Contact Chapter 1 for details and drain the coolant and engine oil. Reinstall the oil pan drain plug when finished to prevent any remaining oil from escaping from the engine.
3. Contact Chapter 11 for details and remove the hood. Place it in a safe place where it will remain undamaged.
4. Contact Chapter 4 and remove the air filter.
5. Release the retaining clips and separate the coolant hoses from the thermostat housing, the lower hose from the radiator and water pump, the heater hoses from the engine and the bulkhead. Please note that coolant will spill when separating the hoses. After marking the direction of the hoses, set them aside.
6. After disconnecting the hoses, unscrew the two screws and remove the expansion tank of the cooling system.
7. Contact Chapter 11, remove the front grille and front bumper.
8. Contact Chapter 3 and remove the radiator together with the upper support cross member.
9. On engines with an exhaust gas recirculation system, remove the exhaust manifold as described in Chapter 4, which will increase the free space when lifting and removing the engine.
10. After unscrewing the lock nuts, separate the exhaust distribution pipe from the manifold flange.
11. On vehicles with power steering (refer to Chapter 1) remove the power steering pump drive belt. Remove the pump mounting bracket from the cylinder block and set it aside from the engine.
12. On cars with air conditioning (refer to Chapter 1) remove the air conditioning compressor drive belt. Separate the compressor from the engine and set it aside. Do not disconnect the air conditioning system hoses.
13. Disconnect the accelerator cable from the fuel pump and support bracket.
14. Disconnect the fuel pressure pipes in the fuel filter and the fuel drain pipe in the high pressure fuel pump.
15. Disconnect the fuel supply hose from the fuel pump. When using quick-release couplings on fuel hoses, release the clamps on the couplings, squeeze them together, and gently pull toward you to remove the coupling. Use a rag to soak up any spilled fuel. Plug the hose to prevent fuel from spilling and dirt from getting inside.
16. Depending on the type of alternator, either disconnect the multi-pin plug or remove the plastic cover and unscrew the terminal nuts. Disconnect the alternator wires, noting their location.
17. Loosen the union nut and separate the vacuum pipe from the rear of the brake vacuum pump located on the alternator.
18. Noting their location, disconnect the plug connectors from the following components (see figure 4.18):
Figure 4.18. Disconnect the wires from the following components:1. Coolant temperature gauge sensor; 2. Cylinder block ground wire; 3. Oil pressure contact sensor; 4. Fuel filter water separator; 5. Cold start device of the fuel pump; 6. Bosch high-pressure fuel pump cold start accelerator; 7. Fuel pump shut-off valve.
19. Remove the starter as described in Chapter 5.
20. Apply the parking brake, then raise the front of the vehicle and support it on stands.
21. Once under the vehicle, separate the rubber boot of the clutch release lever from the clutch housing and slide it up the cable.
22. Pull the cable out of the groove on the release lever and separate the cable sheath from the clutch housing. Remove the rubber boot from the cable.
23. Unscrew the two bolts and remove the lower clutch housing cover.
24. On vehicles with a manual transmission MT75, disconnect the wires from the reverse light switch on the transmission.
25. On models with automatic transmission, remove the bolt and separate the engine and transmission retaining bracket. Working through the hole created by removing the starter, unscrew the four nuts holding the drive plate to the torque converter. If necessary, the engine crankshaft can be turned using a wrench to bring the torque converter mounting nuts into an accessible position.
26. On vehicles with an automatic clutch, disconnect the electrical wire from the speed sensor on the gearbox. Disconnect the electrical wire from the speed sensor and the crankshaft position sensor (see paragraph 18, Section 5).
27. Unscrew the lower nut and washer on each of the engine mounts.
28. Unscrew the lower bolts connecting the clutch housing to the engine, which are only accessible from below, then lower the car to the ground.
29. Secure the engine to a suitable lift. If possible, fabricate lifting eyes to connect the hoist to the engine, making sure they are strong enough, and connect them to the front and rear of the engine at diagonally opposite points.
30. Place a suitable jack under the transmission and jack it up slightly without lifting it.
31. Remove the remaining bolts connecting the engine to the transmission, noting that on later models the top bolts also secure the fuel line support bracket. Separate the fuel line clamps from the support bracket (see Figure 4.31).
Figure 4.31. Remove the fuel lines from the bracket on top of the gearbox.
32. Check again that all relevant components and devices are disconnected and put aside.
33. With the help of an assistant, move the engine forward and away from the transmission while lifting it. Once the engine is separated from the transmission, carefully guide it upward and remove it from the engine bay (see Figure 4.33). Do not allow the engine to hang on the transmission input shaft during removal (or installations) engine. On models with automatic transmission, ensure the torque converter remains engaged with the transmission. Once the engine tray is separated from the vehicle, move the power unit to the side and lower it onto a dolly. If the trolley is not in use, the vehicle must be moved backwards and then the engine must be lowered. In this case, make sure the gearbox is well supported while moving the vehicle.
Figure 4.33. Removing the engine.
34. After removing the engine, check the mounts and replace them with new ones if they are worn or damaged. Also check the condition of all hoses and tubes (see Chapter 1). Components that are usually hidden can now be properly checked and replaced at the slightest doubt regarding their condition. Also, don't forget about the possibility of a major clutch overhaul (see Chapter 6). It is considered beneficial to replace the clutch with a new one whenever a major engine overhaul is carried out. Also check the condition of all components damaged during removal (type of seals) and replace those that are damaged or worn with new ones.
37. Tighten all connections to the recommended torques.
38. After installing the engine on the supports, check that equal play exists on both sides between the lower corners of the rubber mount and the installed chassis bracket.
39. Check that the mating surfaces are clean, then connect the exhaust pipe using new self-locking nuts and gasket.
40. Make sure all connections are properly and securely fastened.
41. Remove temporary plugs or caps from fuel lines before connecting them properly and securely.
42. Connect and adjust the accelerator cable as described in Chapter 4. Details of installation of intake manifold and air filter are also given in this Chapter.
43. Replace the coolant hoses with new ones (or fixing clamps), if they are in bad condition.
44. Contact Chapter 6 for details when connecting the clutch cable.
45. On vehicles with power steering and air conditioning, install and adjust the drive belt(s) as described in Chapter 1.
46. Once the engine is completely installed, make sure all hoses are connected, then add engine oil and coolant (see Chapter 1).
47. Once completed, start the engine in accordance with section 23.