4.2. Removal and installation of the engine

Recommendations about removal of the engine
Before work attentively study all section on removal of the engine.
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. It is recommended to make repairs 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.
Replace all clips and collars which at removal of the engine will be damaged or cut at assembly of the engine with new.
The engine is removed without transmission forward.
The merged cooling liquid needs to be collected and utilized.
Before a detachment of the accumulator find out whether you have a code of turning on of the radio receiver.

Removal
The rechargeable battery is located under half of the luggage compartment.
Switch off ignition and disconnect a wire of "weight" from the rechargeable battery.

Fig. 3.2-1. Arrangement of the screw of fastening of the left ventilating grate



Turn out the screw of fastening of the left ventilating grate of a bumper, at the same time also the right lattice is released. Remove lattices (fig. 3.2-1).

Fig. 3.2-2. Arrangement of screws of fastening of the lower mudguard of a motor compartment



Turn out screws and remove the lower mudguard of a motor compartment (fig. 3.2-2)
Remove the left and right side of a bumper.

Cars with washers of headlights
Disconnect the hose passing through an opening in the lower part of a bumper from nozzles of washers.
Remove a front bumper.
Install under the engine the pallet for collecting cooling liquid.
Turn out a stopper in the lower part of a radiator and merge cooling liquid.
Weaken collars of fastening and remove the air inlet branch pipe connecting the air filter and the case of throttle knot.

Fig. 3.2-3. Arrangement of screws of fastening of a casing of the engine



Turn out screws and remove a casing of the engine (fig. 3.2-3).
Release a clip of fastening of a hose of the cooling system to the right casing of a gear belt.

Fig. 3.2-4. Arrangement of screws of fastening of a casing of the control unit



Turn out seven screws and remove a casing of the control unit located in the left back part of a motor compartment (fig. 3.2-4).

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 block of 1 engine management (see fig. 3.1-9) and the block 2 controls of the drive, and also all electric sockets on a partition of a motor compartment.
Turn out screws of fastening of the control unit of system a cruise control with the relay and the block of safety locks (see fig. 3.1-9).
Remove a sealant from the top part of the partition separating a motor compartment and the air-ventilation chamber.
Mark and disconnect electric wires from the engine.
Release two clips fixing the flexible isolating braid of wires.
Unscrew the isolating braid of wires from a partition of a motor compartment, take out transitional plugs from a motor compartment, take wires from a partition and take them aside.
Disconnect a hose from a servomotor.
Disconnect a vacuum pipe from the control unit a cruise control.
Disconnect an accelerator cable.

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 (arrows at the left, see fig. 3.1-16) and disconnect the cooling system hoses going to a heater.
Disconnect electric sockets a lambda sensors from the left and right side, release wires of sensors from clips and take wires aside.
Unscrew and uncover the air filter.
Disconnect the electric socket from an air flowmeter.
Disconnect the electric socket from the ACF valve.
Weaken collars and remove the cooling system pipe connecting a broad tank and a radiator.
Remove the bringing pipe to a broad tank, previously having removed a tank for liquid of system of the amplifier of steering.
Disconnect a vacuum pipe for switching of an inlet collector before a left headlight.

Fig. 3.2-5. Arrangement of electric sockets and elements of fastening of the fuel highway: 1, 5, 6, 10 – bolts of fastening of the fuel highway; 2, 4, 7, 9 – clips; 3, 8 – electric sockets of sensors of a detonation



Disconnect electric sockets 3 and 8 (fig. 3.2-5) from detonation sensors from the left and right side of the fuel highway.
Release four clips 2, 4, 7 and 9 fastenings of electric wires.
Disconnect electric sockets from fuel nozzles from the left and right side of the engine.
Turn out bolts 1, 5, 6 and 10 and, being careful, remove the fuel highway.
Close the opened openings on the engine pure rags.
Turn out forward bolts of fastening of the left and right final collector (on one bolt).

Fig. 3.2-6. Arrangement of elements of fastening of a cross beam and elements of system of release: 1 – bolted connector; 2, 3 – bolts of fastening of catalytic converter



Turn out the bolts of fastening of a cross beam shown by shooters in fig. 3.2-6.
Turn out bolts of a connector of 1 system of release.
Remove the left catalytic converter.
Release clamps of system of release and remove it.
Unscrew reception exhaust pipes from final collectors.
Unscrew an arm of catalytic converter with a spring and remove catalytic converter together with a reception exhaust pipe.
Remove the heat-resistant guard located under converter.
Unscrew a heat-resistant guard of a cable of the lever of the selector from the pallet of gearbox oil.

Fig. 3.2-7. An arrangement of a tag and bolts of fastening of a flange of a shaft of the drive to the transmission



Apply tags on flanges of a shaft of the drive and transmission, turn out bolts and disconnect a drive shaft from the transmission (see fig. 3.2-7).
Turn out bolts of fastening of a support of a shaft of the drive and establish a support under a shaft.
Unscrew a selector lever cable from an arm, disconnect it from the transmission and take aside.
Remove the casing closing electric connections.
Disconnect a starter wire in a distributive box and an arm.
Unscrew nuts, the fixing wires, disconnect wires and take them aside.
Disconnect fastening of an air duct from the generator.
Disconnect a pipe to the heat exchanger of gearbox oil.
Unscrew a hose of cooling liquid in the radiator basis.
Disconnect the electric socket of the sensor of temperature of cooling liquid located over a hose.

Fig. 3.2-8. Arrangement of bolts of fastening of the lower lever



Turn out a bolt of fastening of the lower lever, at the same time do not lose laying (fig. 3.2-8).

Fig. 3.2-9. Arrangement of screws of fastening of an air duct of a radiator and socket of the sensor of pressure



Turn out screws of fastening of an air duct of a radiator (fig. 3.2-9).
Disconnect the electric socket of the sensor of pressure (see fig. 3.2-9).
Disconnect electric sockets from the left and right headlight.
Remove a left headlight.
Disconnect the electric socket from the sensor of temperature of catalytic converter and take him aside.
Unscrew the heat exchanger and take away it from a radiator.
Disconnect electric sockets of the fan of a radiator, release wires from clips and take them aside.
Remove cowl support in both forward wings.
Turn off the bolts located under cowl support, at the same time keep the washers located under bolts.
Unscrew elastic elements from two parties of a bumper.
Remove a forward cross-piece together with a radiator.

Fig. 3.2-10. Installation of device 3204 for weakening of a tension of a poliklinovy belt



Weaken a tension of a poliklinovy belt, using adaptation 3204, and take off a belt (fig. 3.2-10).

Prevention
Chalk, marker or paint note the direction of rotation of a poliklinovy belt. If at installation poliklinovy the belt rotates in other party, it will lead to its destruction.

Unscrew a pulley of a poliklinovy belt on the pump of the amplifier of steering, at the same time keep the laying located under a pulley as it needs to be used at installation.

Fig. 3.2-11. Arrangement of bolts of fastening of the pump of the amplifier of steering



Turn out bolts of fastening of the pump of the amplifier of steering and, without disconnecting pipelines, take him aside (fig. 3.2-11).

Fig. 3.2-12. Arrangement of bolts of fastening of the compressor of the conditioner



Turn out bolts of fastening of the compressor of the conditioner and take the compressor aside, without disconnecting from it pipelines (fig. 3.2-12).
Keep the directing conditioner compressor plugs.
Install the device for raising of the V.A.G 1383 transmission, lift adaptation so that the weight of the transmission was perceived by adaptation.

Fig. 3.2-13. Arrangement of bolts of fastening of the right and left support of the transmission



Turn out bolts of fastening of the left and right support of the transmission, remove an arm of fastening of the transmission and V.A.G 1383 adaptation (fig. 3.2-13).

Fig. 3.1-31. An arrangement of bolts of fastening of the engine to the lower frame



Unscrew the lower bolts of fastening of the engine to the lower frame shown by shooters in fig. 3.1-31.
Establish a cowl vertically and enshrine it in this provision.
Screw holders of V.A.G 3180 on the engine.
Make sure that all electric wires, hoses, branch pipes and pipelines are disconnected from the engine.
Suspend on таль capture with a loading capacity not less than 500 kg and fix it for holders on the engine.
Being careful, raise the engine, take away it from the transmission and take from a motor compartment forward.

Installation
Installation is carried out to the sequences, the return to removal taking into account the following.
At installation of the engine it is necessary to replace with new samokontryashchiyesya of a nut and bolts which tightened a dovorachivaniye on a certain corner, and also sealing rings and laying.
At installation check existence of the directing plugs defining position of the compressor of the conditioner.
If from the engine the transmission was removed, at installation check existence of the aligning plugs, interposition of the engine and transmission.
At connection of the engine with the transmission be careful – do not damage the sensor of frequency of rotation of the engine.

Cars with the mechanical transmission
Clear vents of a shaft of the drive and at reuse of a clutch plate remove from it corrosion traces. Grease shaft vents with a thin layer of G 000 100 lubricant.
Check a condition of the bearing of switching off of coupling and if necessary replace it.
Using a mandrel, check centering of a clutch plate.
Check a condition of the needle bearing in an end face of a bent shaft from a flywheel. If necessary replace the bearing.

Cars with the automatic transmission
For fastening of the hydrotransformer to a frictional slip it is necessary to use bolts of an original design.
Check correctness of installation of the hydrotransformer.
Install the engine into place and, having shaken it here and there, provide the correct arrangement on support.

Fig. 3.2-14. Engine support elements



Establish an engine support, at the same time check that it was not strained (fig. 3.2-14).
Establish poliklinovy a belt.
Check adjustment of a cable of an accelerator.
Fill in cooling liquid. Reuse of cooling liquid is not allowed if the head of the block of cylinders was removed or the block of cylinders was replaced.
Fill in oil in system of the amplifier of steering and remove from it air.
Fill in engine oil in the engine.
Make sure that the system of production of the fulfilled gases is correctly installed on suspension brackets and does not concern a body when rocking.
Check correctness of connection of electric sockets.
Connect a wire of "weight" to the rechargeable battery.
Turn on the radio receiver and enter into it a code.
Lift glasses power windows up to an emphasis. Then press all switches of a window regulator once again, at least for 1 second, in the provision of closing for activation of the control unit of window regulators.
Determine time on hours.
Before launch of the engine check existence and level of oil in the engine.

Fig. 3.2-15. An arrangement and numbering of bolts of fastening of the mechanical transmission to the engine: And – an installation site of the aligning plug