5.2. 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 necessary to make repairs of the engine 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 are performed with the assistant.
All clips and collars which at removal of the engine will be damaged or cut at assembly of the engine should be replaced with 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.

Fig. 3.3-24. Arrangement of screws of fastening of a casing of the engine



Unscrew screws and remove an engine casing (see fig. 3.3-24).

Fig. 3.3-1. 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. 3.3-1).
Uncover a broad tank.

Fig. 3.3-25. Arrangement of forward air ducts



Remove forward air ducts (see fig. 3.3-25).
Turn off a bolt of fastening of the fan of a radiator with the viscous coupling, holding from a provorachivaniye a fan axis other wrench.
Unscrew a radiator fan casing.
Remove the fan with the viscous coupling together with a casing.

Fig. 3.3-2. An arrangement of a clamp of a casing and the direction of turn at removal of the fan of a radiator with the electric drive



For removal of the fan of a radiator with the electric drive disconnect the electric socket from the fan, take a casing clamp, turn a casing in the direction of an arrow (fig. 3.3-2) and remove the fan.

Fig. 3.3-27. 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. 3.3-27).

Prevention
Using chalk, a 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.


Fig. 3.3-28. Arrangement of a bolt of fastening of a tension roller of a poliklinovy compressor belt of the conditioner



Weaken a bolt of fastening of a tension roller of a poliklinovy compressor belt of the conditioner and take off a belt from pulleys (see fig. 3.3-28).

Fig. 3.3-29. Weakening of a tension of the main poliklinovy belt



Face key turn counterclockwise the mechanism of a tension of the main poliklinovy belt therefore the belt tension will be weakened, fix in this situation the tension mechanism a pin (poz.1, see fig. 3.3-29) and take off a belt.

Fig. 3.3-3. Arrangement of bolts of fastening of a quencher of fluctuations



Turn out eight bolts and remove a quencher of fluctuations from a pulley of a bent shaft (fig. 3.3-3).

Fig. 3.3-4. An arrangement of bolts of fastening of the thermofilter over a turbocompressor



Turn out bolts (fig. 3.3-4) and remove the thermofilter over a turbocompressor.


Fig. 3.3-5. An arrangement of bolts of fastening of a reception exhaust pipe to a turbocompressor



Turn out bolts of fastening of a reception exhaust pipe to a turbocompressor (fig. 3.3-5).

Fig. 3.3-34. Arrangement of screws of fastening of a heater of an exhaust pipe and noise isolation of an additional heater



Turn out screws of fastening of a heater of an exhaust pipe and a noise isolation of an additional heater (see fig. 3.3-34).

Fig. 3.3-35. Arrangement of clamps of fastening of the lower mudguard of a motor compartment



Release clamps and remove the lower mudguards of a motor compartment consisting of two sections (see fig. 3.3-35).

Fig. 3.3-36. Arrangement of bolts of fastening of an arm of the lower mudguard of a motor compartment



Turn out two bolts and remove an arm of the lower mudguard of a motor compartment (see fig. 3.3-36)
Weaken collars and remove a forward exhaust pipe with catalytic converter.
Install under the engine the reception pallet for collecting cooling liquid.

Fig. 3.3-6. Arrangement of the crane of discharge of cooling liquid (1) and drainage bolt (2)



Merge cooling liquid, having turned on 90 ° the crane 1 (fig. 3.3-6) in the basis of a pipe and having turned out a drainage bolt 2.
Unscrew the conditioner compressor from an arm and, without disconnecting from it hoses, take him aside.
Turn out the torque compensator from the engine and a body.
Turn out an elastic support in the lower right part of a frame.

Fig. 3.3-7. Arrangement of bolts of fastening of a starter: 1 – nut; 2 – electric socket



Disconnect the electric socket from a starter, then unscrew a nut of 1 (fig. 3.3-7) and disconnect a positive wire from a starter.
Unscrew two bolts shown by shooters in fig. 3.3-7 and, being careful, remove a starter.

Fig. 3.3-8. Arrangement of a bolt of fastening of the hydrotransformer



Through the opening which opened after removal of a starter unscrew three bolts of fastening of the hydrotransformer (fig. 3.3-8). For access to each subsequent bolt it is necessary to turn a bent shaft of the engine in the direction of its working rotation on 1/3 turns.

Note
For a provorachivaniye of a bent shaft it is necessary to use a bolt of fastening of a pulley of a bent shaft.

Cars with the mechanical transmission
Unscrew and remove a casing from the right shaft of the drive.
In the right distributive block disconnect the electric socket and, having unscrewed a nut, remove a starter wire tip. Then unscrew a bolt of fastening of a clip of a wire and take a starter wire aside.
Disconnect the electric socket from the backing lamp switch.

All models
Unscrew and remove a casing from the left shaft of the drive.
Remove the thermofilter on the left side of the transmission.
Disconnect the electric socket from the speedometer sensor.

Fig. 3.3-9. Arrangement of the electric socket (1), sensor of a speedometer, sensor of frequency of rotation of the engine (2) and bolt (3) fastenings of the pipeline of the automatic transmission


In the presence of the sensor 2 (fig. 3.3-9) of frequency of rotation of the G28 engine, unscrew it. The sensor 2  is located in a forward left part of the transmission.
Unscrew a bolt 3 fastenings of the pipeline of the automatic transmission and move the pipeline aside.
Release from an arm and disconnect electric sockets of a plait of wires and the multipurpose switch.
Disconnect electric sockets on the left side of the engine.
Unscrew the lower bolts of fastening of the transmission to the engine.

Fig. 3.3-10. An arrangement of bolts (arrow) of fastening of the engine to the lower frame



Unscrew the lower bolts shown by shooters in fig. 3.3-10, fastenings of the engine to the lower frame.

Fig. 3.3-11. An arrangement of collars of fastening of hoses of the cooling system to heater unions on a partition of a motor compartment


Weaken collars (fig. 3.3-11) and disconnect the cooling system hoses going to a heater.
Remove a vacuum hose from the vacuum amplifier of brakes.
Weaken collars and disconnect cooling system hoses from the engine.

Fig. 3.3-12. An arrangement of the electric socket of the sensor (1) in a hose (2) air supply to an inlet collector



Disconnect the electric socket from the sensor of 1 air branch pipe (fig. 3.3-12).
Remove a hose 2 air supply to an inlet collector.

Fig. 3.3-21. An arrangement of bolts of fastening of a pulley of a poliklinovy belt of the pump of the amplifier of steering and the special tool for deduction of a pulley from a provorachivaniye



Unscrew bolts of fastening of a pulley of a poliklinovy belt of the pump of the amplifier of steering, holding a pulley from a provorachivaniye the special tool (see fig. 3.3-21).
Weaken collars and remove an air branch pipe from the air filter.

Fig. 3.3-13. An arrangement of the electric socket (1) of the sensor of the fan of a radiator and collars of fastening of hoses of the cooling system from the sensor (2) and an additional heater (3)



Disconnect the electric socket 1 and a hose of the cooling system from the sensor 2 (fig. 3.3-13) of the fan of the cooling system.
Weaken collars and disconnect cooling system hoses from an additional heater 3.
Disconnect fuel hoses from the fuel filter.
Uncover the air filter.

Fig. 3.3-14. Arrangement of the electric socket of a flowmeter of air



Disconnect the electric socket from a flowmeter of air (fig. 3.3-14) and release wires from clamps.
Disconnect electric sockets from the electromagnetic valve and the valve of recirculation of the fulfilled gases (EGR).
Disconnect vacuum hoses from a turbocompressor and mechanical valves of system of recirculation of the fulfilled gases and move hoses aside.

Fig. 3.3-15. Races position of screws and direction of removal of a casing of the control unit: 1 – direction of removal



Turn the left protection cover of the control unit in the direction of an arrow 1 (fig. 3.3-15) and turn out the back right screw.
Turn out the remained fastening screws shown by shooters in fig. 3.3-15.
Remove a control unit casing.
In the control unit disconnect electric sockets from control units of the engine and the transmission. Release fastening of the relay for what, using the screw-driver with a thin edge, wring out side clamps.
Disconnect the remained sockets and remove a plait of wires from the top part of the engine.
Unscrew the top bolts of fastening of the transmission to the engine, having left one bolt on the place.
On a back part of a turbocompressor weaken a bolt

Fig. 3.3-16. An arrangement of a bolt (A) of fastening of a rack (In) on a back part of a turbocompressor


And (fig. 3.3-16), turn a rack clockwise and again tighten a bolt.
Disconnect racks of support of a cowl from a cowl. Establish a cowl vertically and enshrine it in this provision.
Suspend on таль load-lifting capture 2024 and fix its captures on the engine.
Unscrew bolts of fastening of the transmission to the engine.
Check that all electric wires, hoses, branch pipes and pipelines were disconnected from the engine.

Cars with the automatic transmission

Fig. 3.3-17. Use of the big screw-driver for pressing of the hydrotransformer to the engine at removal of the engine



Before removal of the engine the big screw-driver press the hydrotransformer to the engine (fig. 3.3-17).
Being careful, raise the engine, then take away it from the transmission and take from a motor compartment up.

Cars with the automatic transmission
Fix the hydrotransformer on the engine.

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.
Before installation be convinced that the rack In (see fig. 3.3-16) on a back part of a turbocompressor is turned clockwise.
Before installation of the engine fix a motor compartment electric wires and hoses on each side in order that did not clamp them the engine.
At installation check existence of the aligning plugs defining a relative positioning of the engine and transmission.

Cars with the mechanical transmission
Clear vents of a power shaft and at reuse of a clutch plate remove from it corrosion traces. Grease drive 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 flywheel it is necessary to use bolts of an original design.

Fig. 3.3-18. Measurement of distance between a basic surface for bolts of fastening of the hydrotransformer and a basic surface of a case



Check correctness of installation of the hydrotransformer. If the distance between a basic surface for bolts of fastening of the hydrotransformer and a surface of a case makes 19 mm, so the hydrotransformer is installed correctly. At incorrectly installed hydrotransformer this distance makes about 14 mm (fig. 3.3-18). In this case the drive plate of the hydrotransformer and the pump of the automatic transmission collapses.

Install the engine into place and, shaking it here and there, provide the correct arrangement on support.
Install the compressor of the conditioner and the pump of the amplifier of steering.
Before a vvinchivaniye of bolts of fastening of the compressor of the conditioner be convinced that the aligning plugs of the compressor are in the place.
Establish a pulley of the pump of the amplifier of steering.
Establish poliklinovy a belt.
Install the radiator fan with the viscous coupling.
Install the compensator of torque and screw it on the engine and a body.
Fill in cooling liquid in the cooling system. Reuse of cooling liquid is not allowed if the head of the block of cylinders was removed or the block of cylinders was replaced.
Check that elements of system of release were correctly established on suspension brackets and did not concern a body at its 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 the first launch of the engine it is necessary to pump over fuel system, otherwise the fuel pump will be damaged.
Before launch of the engine check existence and level of oil in the engine.