4.2. Removal and engine installation
Recommendations about engine removal
Before the work beginning attentively familiarise with all section on engine removal.
If the engine remove for repair, it is necessary to choose a place for work, to provide space for service and storage of spare parts. It is recommended to carry out repairs on a car repair shop or in garage with an equal horizontal floor with a pure firm covering.
Before removal clear of pollution and wash up the engine and a motor compartment. For engine removal use the load-lifting mechanism allowing safely to lift the power unit.
If you remove the engine for the first time, it is necessary to invite the skilled expert. Some works should be carried out with the assistant.
All clips and collars which at engine removal will be damaged or cut, at engine assemblage replace with the new.
The engine acts in film forward without a transmission.
The merged cooling liquid is necessary for collecting and utilising.
Before an accumulator detachment find out, whether there is at you a code of inclusion of a radio receiver.
The storage battery is located under a luggage space floor.
Switch off ignition and disconnect a wire of "weight" from the storage battery.
Fig. 3.2–1. An arrangement of the screw of fastening of the left ventilating lattice
Turn out the screw of fastening of the left ventilating lattice of a bumper, the right lattice is thus released also. Remove lattices (fig. 3.2–1).
Fig. 3.2–2. An arrangement of screws of fastening of the bottom mudguard of a motor compartment
Turn out screws and remove the bottom mudguard of a motor compartment (fig. 3.2–2)
Remove the left and right party of a bumper.
Cars with washers of headlights
Disconnect a hose passing through an aperture in the bottom part of a bumper, from atomizers of washers.
Remove a forward bumper.
Establish under the engine the pallet for gathering of a cooling liquid.
Turn out a stopper in the bottom part of a radiator and merge cooling liquid.
Loosen the collars of fastening also remove the branch pipe of an air inlet connecting the air filter and the case of throttle knot.
Fig. 3.2–3. An arrangement of screws of fastening of a casing of the engine
Turn out screws and remove an engine casing (fig. 3.2–3).
Release a clip of fastening of a hose of system of cooling to the right casing of a gear belt.
Fig. 3.2–4. An arrangement of screws of fastening of a casing of the block of management
Turn out seven screws and remove a casing of the block of the management located in the left back part of a motor compartment (fig. 3.2–4).
Fig. 3.1–9. An arrangement of the block of engine management (1), the block of management of a drive (2) and electric sockets (3) on a partition of a motor compartment
Disconnect electric sockets from the block of 1 engine management (fig. 3.1–9 see) and the block of 2 managements of a drive, and also all electric sockets on a partition of a motor compartment.
Turn out screws of fastening of the block of management of system of the cruise-control with the relay and the block of safety locks (fig. 3.1–9 see).
Remove a sealant from the top part of the partition separating a motor compartment and the ventilating chamber.
Mark and disconnect from the engine electric wires.
Release two clips, крепящие a flexible isolating braid of wires.
Unscrew isolating braid of wires from a partition of a motor compartment, take out transitive 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 block of management of the cruise-control.
Disconnect an accelerator cable.
Fig. 3.1–16. An arrangement of collars of fastening of hoses of system of cooling to a broad tank (arrows on the right) and to heater unions (arrows at the left) on a partition of a motor compartment
Loosen the collars (arrows at the left, fig. 3.1–16 see) and disconnect hoses of system the coolings going to a heater.
Disconnect electric sockets of ljambda-gauges from the left and right party, release wires of gauges from clips and take wires aside.
Unscrew and uncover the air filter.
Disconnect an electric socket from air flowmeter.
Disconnect an electric socket from the ACF-valve.
Loosen the collars also remove a pipe of system of the cooling, connecting a broad tank and a radiator.
Remove bringing pipe to a broad tank, preliminary having removed a tank for a liquid of system of the amplifier of a steering.
Disconnect a vacuum pipe for switching of an inlet collector before the left headlight.
Fig. 3.2–5. An arrangement of electric sockets and elements of fastening of a fuel highway: 1, 5, 6, 10 – bolts of fastening of a fuel highway; 2, 4, 7, 9 – clips; 3, 8 – electric sockets of gauges of a detonation
Disconnect electric sockets 3 and 8 (fig. 3.2–5) from gauges of a detonation from the left and right party of a fuel highway.
Release four clips 2, 4, 7 and 9 fastenings of electric wires.
Disconnect electric sockets from fuel atomizers from the left and right party of the engine.
Turn out bolts 1, 5, 6 and 10 and, being careful, remove a fuel highway.
Close opened apertures 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. An arrangement of elements of fastening of a cross-section beam and elements of system of release: 1 – болтовой a connector; 2, 3 – fastening bolts catalytic neutralizer
Turn out bolts of fastening of the cross-section beam, shown by arrows on fig. 3.2–6.
Turn out bolts of a connector of 1 system of release.
Remove left каталитический neutralizer.
Release clamps of system of release and remove it.
Unscrew reception exhaust pipes from final collectors.
Unscrew an arm catalytic neutralizer with a spring and remove каталитический neutralizer together with a reception exhaust pipe.
Remove the heat resisting guard located under neutralizer.
Unscrew a heat resisting guard of a cable of the lever of the selector from the pallet трансмиссионного oils.
Fig. 3.2–7. An arrangement of a label and bolts of fastening of a flange of a shaft of a drive to a transmission
Put labels on flanges of a shaft of a drive and a transmission, turn out bolts and disconnect a shaft of a drive from a transmission (fig. 3.2–7 see).
Turn out bolts of fastening of a support of a shaft of a drive and establish under a shaft a support.
Unscrew a cable of the lever of the selector from an arm, disconnect it from a transmission and take aside.
Remove a casing closing electric connections.
Disconnect a starter wire in a distributive box and an arm.
Unscrew nuts, крепящие wires, disconnect wires and take them aside.
Disconnect fastening of an air line from the generator.
Disconnect a pipe to the heat exchanger трансмиссионного oils.
Unscrew a hose of a cooling liquid in the radiator basis.
Disconnect an electric socket of the gauge of temperature of the cooling liquid, located over a hose.
Fig. 3.2–8. An arrangement of bolts of fastening of the bottom lever
Turn out a bolt of fastening of the bottom lever, thus do not lose a lining (fig. 3.2–8).
Fig. 3.2–9. An arrangement of screws of fastening of an air line of a radiator and a socket of the gauge of pressure
Turn out screws of fastening of an air line of a radiator (fig. 3.2–9).
Disconnect an electric socket of the gauge of pressure (fig. 3.2–9 see).
Disconnect electric sockets from the left and right headlight.
Remove the left headlight.
Disconnect an electric socket from the temperature gauge catalytic neutralizer 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 away the bolts located under support of a cowl, thus keep the washers located under bolts.
Unscrew from two parties of a bumper elastic elements.
Remove a forward cross-beam together with a radiator.
Fig. 3.2–10. Installation of the adaptation 3204 for tension easing semi wedge a belt
Loosen the a tension semi wedge a belt, using the adaptation 3204, also remove a belt (fig. 3.2–10).
Chalk, marker or paint note a rotation direction semi wedge a belt. If at installation полиwedge the belt rotates in other party, it will lead to its destruction.
Unscrew a pulley semi wedge a belt on the pump of the amplifier of a steering, thus keep a lining located under a pulley as it is necessary for using at installation.
Fig. 3.2–11. An arrangement of bolts of fastening of the pump of the amplifier of a steering
Turn out bolts of fastening of the pump of the amplifier of a steering and, without disconnecting pipelines, take him aside (fig. 3.2–11).
Fig. 3.2–12. An 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 directing plugs of the compressor of the conditioner.
Establish the adaptation for lifting of transmission V.A.G 1383, lift the adaptation so that the transmission weight was perceived by the adaptation.
Fig. 3.2–13. An arrangement of bolts of fastening of the right and left support of a transmission
Turn out bolts of fastening of the left and right support of a transmission, remove an arm of fastening of a transmission and adaptation V.A.G 1383 (fig. 3.2–13).
Fig. 3.1–31. An arrangement of bolts of fastening of the engine to the bottom frame
Unscrew the bottom bolts of fastening of the engine to the bottom frame, shown by arrows on fig. 3.1–31.
Establish a cowl vertically and fix it in this position.
Screw holders V.A.G 3180 on the engine.
Be convinced that all electric wires, hoses, branch pipes and pipelines are disconnected from the engine.
Suspend on таль capture by load-carrying capacity not less than 500 kg and fix it for holders on the engine.
Being careful, raise the engine, take away it from a transmission and take forward from a motor compartment.
Installation is spent to sequences, return to removal taking into account the following.
At engine installation it is necessary to replace on new self-locking nuts and bolts which tightened доворачиванием on a certain corner, and also sealing rings and linings.
At installation check up presence of the directing plugs defining position of the compressor of the conditioner.
If from the engine the transmission acted in film, at installation check up presence of aligning plugs, engine and transmission interposition.
At connection of the engine with a transmission be careful – do not damage the gauge of frequency of rotation of the engine.
Cars with a mechanical transmission
Clear Slots a shaft of a drive and at a reuse of a disk of coupling remove from it corrosion traces. Grease Slots a shaft with a thin layer of greasing G 000 100.
Check up a condition of the bearing of deenergizing of coupling and if necessary replace it.
Using the mandrel, check up a centering of a disk of coupling.
Check up a condition of the needle bearing in an end face of a cranked shaft from outside a flywheel. If necessary replace the bearing.
Cars with an automatic transmission
For hydrotransformer fastening to a frictional overlay it is necessary to use bolts of an original design.
Check up correctness of installation of the hydrotransformer.
Establish the engine into place and, having shaken it here and there, provide a correct arrangement on support.
Fig. 3.2–14. Elements of a support of the engine
Establish an engine support, thus check up, that it has not been strained (fig. 3.2–14).
Establish полиwedge a belt.
Check up adjustment of a cable of an accelerator.
Fill in cooling liquid. The reuse of a cooling liquid is not supposed, if the head of the block of cylinders acted in film or the block of cylinders was replaced.
Fill in oil in system of the amplifier of a steering and remove from it air.
Be convinced that the system of release of the fulfilled gases is correctly established on suspension brackets and does not concern bodies at rocking.
Check up correctness of connection of electric sockets.
Connect "a weight" wire to the storage battery.
Lift glasses electric glass lifts upwards against the stop. Then press all switches стеклоподъемника once again, at least for 1 second, in position of closing for activation of the block of management glass lifts.
Establish time for hours.
Before engine start-up check up presence and oil level in the engine.
Fig. 3.2–15. An arrangement and numbering of bolts of fastening of a mechanical transmission to the engine: And – an installation site of the aligning plug