Removal and installation of the engine

Removing

Note. Removal and installation of the engine and gearbox in the final drive unit is carried out from below the vehicle.

Remove the following items:

• battery cover, battery box, battery bracket, battery and battery tray;
• front wheels;
• bottom cover and mudguards;
• air duct, air hose and air filter assembly;
• accelerator cable and bracket;
• drive belt.
• Drain the following liquids:
• working fluid for an automatic transmission or gearbox oil in a block with a final drive;
• engine coolant;
• power steering fluid.

Disconnect the purge valve hose.

Disconnect the power steering return hose from the power steering oil pump.

Disconnect the power steering pressure pipe from the steering gear.

Disconnect the power steering return hose from the power steering reservoir.

Remove the following items:

• front cross member, front stabilizer, lower control arm, steering gear and engine mount #1;
• drive shaft;
• power steering reservoir with hose;
• expansion tank of the cooling system with a hose;
• cooling fan assembly;
• automatic transmission fluid hose, gear selection cable and wiring harness (models with automatic transmission);
• gear selection cable and shift cable (models with manual transmission);
• clutch slave cylinder with tube (models with manual transmission);
• Earth (engine mount #3);
• air conditioning compressor with tubes.

Note. Secure the air conditioning compressor with a wire or rope so that it does not interfere with operation.

Disconnect the following items:

• vacuum brake booster hose;
• fuel supply hose;
• heater radiator hose;
• upper and lower radiator hose;
• main muffler.

Attention! Do not tighten the #1 engine mount bolt before installing the #3 engine mount.

Check and adjust if necessary the following:

• front wheel alignment angles.
• pulley and belt.
• leakage of engine oil, engine coolant, automatic transmission fluid, manual transmission oil and fuel.
• setting the ignition timing and idle speed. Check CO, CH value.
• operation of auxiliary equipment driven by the engine.

Note. If the vehicle is fitted with an overhauled engine, test drive it to make sure everything is working properly.

Removing the main fuse block connector

Release the tongue as shown in Figure 2.282.

Raise the locking lever and remove the connector.

Removing engine mounts #3 and #4

Secure the engine and transmission to the final drive using an engine jack and accessory (pic. 2.283).

Removing the engine mount and #4

Secure the engine and transmission to the final drive using an engine jack and accessory.

Installing the engine mount and #4

Install engine mounts #1 and #4.

Note. Do not tighten the #1 and #4 engine mount bolt and nut when performing this operation.

Tighten a bolt of fastening of a support of the engine No. 4 shown in drawing 2.284.

Tightening torque: 66.6 - 93.1 Nm.



Tighten a bolt and a nut of fastening of a support of the engine No. 4 and an arm of the platform of the accumulator battery in the order shown in drawing 2.285.


Torque:

• 1 - 44–61 N·m;
• 2 - 6.9–9.8 Nm.

Installing engine mount #3

Tighten the #3 engine mount studs.

Tightening torque: 7–13 Nm.

Install the #3 engine mount and temporarily tighten the mounting bolts and nuts.

Tighten the #3 engine mount bolts.

Remove the engine jack and accessory.



Tighten the #1 engine mount bolts (pic. 2.286).

Tightening torque: 93.1 - 116.6 Nm.