Warning! Do not forget that gasoline is a highly flammable liquid! Observe all applicable fire safety precautions when working on power system components. Do not smoke, do not approach the work area with an open flame or an unprotected carrier. Do not service the system in a room equipped with natural gas-fired, pilot flame-equipped heaters (such as water heaters and clothes dryers). Do not forget that gasoline is one of the carcinogenic substances that contribute to the development of cancer. Try to prevent fuel from getting into open areas of the body - use protective rubber gloves, in case of accidental unforeseen contact, thoroughly wash your hands with warm water and soap. Clean up spilled fuel immediately and do not store fuel-soaked rags near open flames. Remember that the fuel injection system of models equipped with fuel injection is constantly under pressure. Relieve any residual pressure in the system before attempting to disconnect fuel lines. Wear safety goggles when servicing power system components. Keep a class B fire extinguisher handy at all times!
The air conditioning system path is also constantly under pressure, and therefore, before disconnecting the refrigeration lines, it is necessary to discharge the system in a specialized workshop.
The cars of this model are equipped with an SRS system, the main component of which is airbags. Always turn off the system before doing any work near the location of the SRS directional g-force sensors, in the area of the steering column or instrument panel, to prevent accidental deployment of airbags, which is fraught with serious injury.
Withdrawal
Note. The compilers of this Guide recommend removing the engine assembly with the transmission. The assembly of the unit is lowered down and removed from under the car, so you should take care of ways to securely fix the vehicle in a raised position.
1. Depressurize the supply system and remove the air cleaner assembly with air sleeves (see chapter Power and exhaust systems).
2. Disconnect from the battery at first a negative wire, then positive.
Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!
Disconnect the battery wires from the fuse/relay box in the engine compartment. Having disconnected the electrical wiring from the mounting block, unscrew the fixing bolts and remove the spacer bar of the suspension strut supports. On V6 models, remove the battery, battery base, and mounting bracket.
3. Cover the fenders and the air baffle under the windshield of the car with special protective covers, or just old blankets. Remove the hood (see chapter Body).
4. Remove the alternator, ignition distributor and BB spark plug wires (see chapter Engine electrical equipment).
5. Remove the oil filter, drain the cooling system, drain the engine and transmission oil and remove the drive belts (see chapter Settings and ongoing maintenance).
6. Clearly label and disconnect all vacuum lines, emission control hoses, electrical wiring connectors, grounding bars and fuel lines from the engine. Marking electrical wiring, lines and hoses is best done with adhesive tape. It will also be useful to draw up a scheme for laying communications, or to take a series of photographs.
Note. The procedure for disconnecting the wiring from the PCM is described in Chapter Engine management.
7. Remove the fan (s) cooling systems and radiator (see chapter Cooling, heating systems).
8. After removing the filler cap, release the residual pressure in the fuel tank, then give the fuel lines from the engine to the chassis (see chapter Power and exhaust systems). Seal all open pipes and fittings immediately.
9. Disconnect the accelerator rod from the engine, and, if the vehicle is equipped accordingly, also the tempostat drive cable (see chapter Power and exhaust systems).
10. Unbolt the steering pump and move it to the side without disconnecting the hydraulic lines (see chapter Suspension and steering). Make sure that the pump is fixed strictly vertically, if necessary, remove it completely.
11. Remove bottom splash screens. On models equipped with air conditioning (K/V), unbolt and move the compressor to the side, - do not disconnect the refrigeration lines (see chapter Cooling, heating systems).
Note. Securely fasten the removed compressor with wire, not allowing it to hang on the hoses.
12. Disconnect electrical wiring from oxygen sensors. Separate the exhaust pipe from the exhaust manifold (ov) (see chapter Power and exhaust systems) and catalytic converter flange and remove it from under the vehicle.
13. Remove drive shafts (see chapter Clutch and drive shafts). Disconnect the wiring and shift/speedometer cables from the transmission (or VSS sensor) (see chapter Gear box). On models with a manual transmission, remove the clutch slave cylinder from the gearbox (see chapter Clutch and drive shafts). On models with AT, disconnect the ATF cooling lines from the transmission case (see chapter Gear box).
14. Attach slings to power unit lifting eyes. Raise the vehicle off the ground, leaving enough space below to remove the unit. Move winch/A-frame beams into working position (on the vertical axis of the engine compartment). Take up the slack of the lines, achieving their slight tension.
15. Make sure nothing else is connecting the power unit to the vehicle. If necessary, disconnect forgotten communication lines, having previously clearly marked them.
16. Turn out fixture of support of a suspension bracket of the power unit. Paint mark the position of the subframe relative to the chassis, then give the mounting bolts, lower the subframe and remove it from under the car (see chapter Gear box).
17. Slowly lower the power unit assembly a few centimeters and check again that no communication lines remain connected. Continue lowering the implement until it rests on the floor or on the load platform of the cart jack. Remove the power unit assembly from under the vehicle.
18. On models with АТ turn out bolts of fastening of the converter of rotation to a driving disk. Give bolts of fastening of the engine to transmission and dismember assembly.
19. Remove the flywheel/drive plate and place the engine on a mounting stand.
Installation
1. Check the condition of the power unit suspension mounts. Replace defective components.
Note. For a description of the procedures for checking the correct functioning of the system for active adjustment of hydraulic supports, see the relevant Sections of this Chapter.
2. On models with manual transmission, check the condition of the clutch components (it will be correct to replace the entire assembly) (see chapter Clutch and drive shafts) and lubricate the guide bearing with high temperature grease. Install the flywheel and clutch assembly components to the engine (see chapter Clutch and drive shafts).
3. On models with AT, check the condition of the seals and bushings of the rotation converter, lightly grease the nose of the converter and the lips of the seals with thick grease. Install the drive disk.
4. Carefully connect the transmission to the engine, screw in and tighten the mounting bolts with the required force (see chapter Gear box). On models with АТ screw and tighten bolts of fastening of the converter of rotation.
5. Raise the car above the ground to a sufficient height and get the power unit assembly under it. Move the winch/A-frame beams to the working position and connect the slings to the engine/transmission lifting eyes, after passing them through the opening of the engine compartment.
6. Raise the assembly of the power unit to its original position and install the brackets of its suspension supports. Insert rubber cushions into the supports and screw through the bolts / nuts of the studs of their fastening.
7. Install the subframe, aligning it with the chassis in accordance with the landing marks made during the dismantling process. Wrap the fastener and tighten it with the required force (see Specifications to Chapter Gear box).
8. Finally tighten the through bolts/nuts of the studs securing the support pads.
Note. Failure to comply with the required tightening forces for the fasteners of the suspension supports of the power unit leads to the development of increased vibrations during engine operation.
9. Disconnect the slings from the lifting eyes.
10. Reinstall the remaining components in the reverse order of removal.
11. Add coolant and engine oil to the engine, refuel the transmission (see chapter Settings and ongoing maintenance).
12. Start the engine and check for proper operation and signs of leaks. Switch off the ignition and check the fluid levels. Reinstall the hood. Carry out a road test of the vehicle. On models equipped with A/C, evacuate and charge the air conditioning system in a specialized workshop.