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3.2. Removal and installation of the engine

Recommendations about removal of the engine
Before work attentively study this section.
If the engine is removed for repair, it is necessary to choose the place for work, to provide space for service and storage of spare parts. Repairs are recommended to be made at car repair shop or in a garage with an equal horizontal floor with a pure hard coating.
Before removal clear of pollution and wash up the engine and a motor compartment. For removal of the engine use the load-lifting mechanism allowing to lift safely the power unit.
If you remove the engine for the first time, it is necessary to invite the skilled expert. Some works should be performed with the assistant.
All clips and collars which at removal of the engine will be damaged or cut at assembly of the engine replace new.
The engine is removed without transmission forward.
The merged cooling liquid needs to be collected and utilized.
Before a detachment of the rechargeable battery find out whether you have a code of turning on of the radio receiver.

Removal
Switch off ignition and disconnect a wire of "weight" from the rechargeable battery.
Uncover a broad tank.
Fig. 3.1-1. Arrangement of clamps of fastening of the lower mudguard of a motor compartment

Release the clamps shown by shooters in fig. 3.1-1 and remove the lower mudguard of a motor compartment.
Fig. 3.1-2. Arrangement of bolts of fastening of an arm of the lower mudguard of a motor compartment

Turn off two bolts and remove an arm of the lower mudguard of a motor compartment (fig. 3.1-2)
Install under the engine the pallet for collecting cooling liquid.
Fig. 3.1-3. Arrangement of an air duct (1) and collars (2 and 3) of fastening of hoses of the cooling system

Weaken a collar of 3 (fig. 3.1-3), remove a hose and merge cooling liquid in the pallet.
Weaken a collar 2, remove a hose, move it down and merge cooling liquid from a radiator.
Disconnect fastening of an air duct 1 from the generator.
Fig. 3.1-4. Arrangement of an oil filter and oil heat exchanger: 1 – hose; 2 – oil filter; 3 – oil heat exchanger

Disconnect an additional hose of the cooling system in the lower part of the oil heat exchanger and merge cooling liquid in the pallet. In fig. 3.1-4 the arrow showed a collar of fastening of an additional hose of the cooling system to the oil heat exchanger.
Fig. 3.1-5. An arrangement of a stopper of discharge of cooling liquid from the block of cylinders of the engine

Turn out the carving stopper of discharge of cooling liquid shown in fig. 3.1-5 by an arrow from the block of cylinders of the engine.
At installation of a stopper it is necessary to use a new sealing ring.
Fig. 3.1-41. Arrangement of screws of fastening of a casing of the engine

Turn out four screws and remove an engine casing (see fig. 3.1-41).
Fig. 3.1-42. An arrangement of collars of fastening of an air branch pipe of a flowmeter of air and the soaking-up pipeline: 1 – fuel supply pipeline; 2 – fuel supply hose

Weaken collars and remove the air branch pipe which is connecting the measuring instrument of a consumption of air and soaking up the pipeline (see fig. 3.1-42).

Prevention
The fuel system is under pressure. Before separation of elements of fuel system it is necessary to take off pressure in system. For this purpose close the place of separation of fuel system pure rags and, being careful, smoothly unscrew a connecting nut.
Unscrew nuts and disconnect a fuel feeding hose from the pipeline (see fig. 3.1-42).
Fig. 3.1-6. An arrangement of hoses in the top part of the engine: 1 – hose of ventilation of a case; 2, 4, 6, 7 – vacuum hoses; 3 – the valve for switching of the soaking-up pipeline; 5 – connection of a vacuum hose with the vacuum amplifier of brakes; 8 – screws of fastening of an air branch pipe of throttle knot

Disconnect a hose of system of ventilation of a case from the right cover of a head of the block of cylinders (fig. 3.1-6).
Turn out the valve 3 for switching of the soaking-up pipeline and take him together with the pipeline aside.
Being careful, remove a vacuum hose 6.
Turn out screws 8 and remove an air branch pipe from the case of throttle knot.
Disconnect a hose of system of ventilation of a case from the left cover of a head of the block of cylinders.
Remove a hose of the vacuum amplifier of brakes from a connector and take a connector from an arm.
Fig. 3.1-7. An arrangement of protection covers (1-4) in a back part of a motor compartment

Remove protection covers 1-4 in a back part of a motor compartment (fig. 3.1-7).
Fig. 3.1-8. Arrangement of screws and direction of removal (1) of a casing of the control unit

Turn the left casing closing the control unit in the direction specified by an arrow (1, fig. 3.1-8), and turn out the back right screw.
Turn out the remained fastening screws shown by shooters in fig. 3.1-8.
Remove a control unit casing.
Fig. 3.1-9. An arrangement of the control unit of the engine (1), the control unit of the drive (2) and electric sockets (3) on a partition of a motor compartment



Disconnect electric sockets from the control unit of the engine 1 (fig. 3.1-9) and the control unit of the drive 2, and also all electric sockets on a partition of a motor compartment. Shooters specified an arrangement of screws of fastening of the case of safety locks.
Disconnect the electric socket from the GRA control unit.
Take the sealing plate located between a motor compartment and a tank of a radiator.
Release from clips an electrical wiring in a motor compartment.
Unscrew plugs of fastening of an electrical wiring to a partition of a motor compartment and move an electrical wiring aside.
Fig. 3.1-10. An arrangement of an air branch pipe (1) and an air inlet (2) about a forward cross-piece of the engine

Separate an air inlet of 2 (fig. 3.1-10) from a forward cross-piece and remove it together with an air branch pipe 1.
Fig. 3.1-11. Arrangement of screws of fastening of the top part of the case of the air filter

Turn out four screws shown by shooters in fig. 3.1-11, fastenings of the top part of the case of the air filter, at the same time disconnect electric sockets 1-3 and take them aside.
Fig. 3.1-12. Arrangement of a connecting nut of fastening of the delivery pipeline of the hydraulic pump

Unscrew a connecting nut and disconnect the delivery pipeline of the hydraulic pump (fig. 3.1-12).
Fig. 3.1-13. An arrangement of a collar of fastening of a vacuum hose to the AKF valve

Weaken a collar and disconnect a vacuum hose from the AKF valve (fig. 3.1-13).

Cars with GRA
Fig. 3.1-14. Arrangement of draft of management (1), nut of fastening (2) of the vacuum block and vacuum hose (3)

Disconnect draft of management 1 (fig. 3.1-14) from the vacuum block.
Remove from the vacuum block a vacuum hose 3.
Unscrew a nut 2 and remove the vacuum block.

All cars
Fig. 3.1-15. Places of fastening of a cable of an accelerator to a butterfly valve and accelerator cable covers to an arm

Disconnect an accelerator cable from a butterfly valve, take a cover of a cable from an arm (fig. 3.1-15).
Fig. 3.1-16. An arrangement of collars of fastening of hoses of the cooling system to a broad tank (shooters on the right) and to heater unions (shooters at the left) on a partition of a motor compartment

Weaken collars and disconnect the hoses connecting an average pipe of the cooling system and a broad tank (arrows on the right in fig. 3.1-16).
Weaken collars (arrows at the left) and disconnect the cooling system hoses going to a heater.
Move hoses to the right lower part of a motor compartment.
Fig. 3.1-17. Direction of movement of a clamp of the electric socket

Disconnect all electric sockets on a forward wall for what move a clamp in the direction of an arrow (fig. 3.1-17).
Disconnect electric sockets a lambda sensors and take from wire clamps, going to a lambda sensors.
Release all electric conducting of the engine from clamps.

Cars with the mechanical transmission
Disconnect the electric socket from the speedometer sensor (an arrow A in fig. 3.1-18).
Fig. 3.1-18. An arrangement of electric sockets of the sensor of a speedometer (A) and the switch of a backing (In)

Disconnect the electric socket from the backing switch – the multipurpose sensor (arrow B).

All cars
Unscrew nuts of fastening of a final collector and a reception exhaust pipe available from above.
Turn out, but not completely, the top bolts of fastening of the transmission to the engine.
Fig. 3.1-19. Elements of fastening of an average pipe of the cooling system: 1, 3 – collars; 2, 5 – bolts; 4 – hose

Remove an average pipe of the cooling system for what weaken collars of 1 and 3 (fig. 3.1-19), turn out bolts of fastening 2 and 5 and disconnect from it a hose 4.

Cars with the electric fan of a radiator
Turn out screws, remove the electric fan of a radiator and take him together with the connected wires aside.

Cars with the radiator fan with the viscous coupling
Unscrew a casing of the fan and remove it.
Fig. 3.1-40. Reversing of a bolt of fastening of the fan of a radiator

Holding a radiator fan pulley from a provorachivaniye a special key 3212, a usual key unscrew a bolt of fastening of a pulley. As the bolt has the left carving, for unscrewing it is necessary to rotate it clockwise (see fig. 3.1-40).
Lift the fan of a radiator up and remove it from the car.

All cars
Fig. 3.1-43. Arrangement of screws of fastening of a casing of a poliklinovy belt

Turn out screws and remove a casing of a poliklinovy belt (see fig. 3.1-43