Helpful Hint: The engine is very heavy, so we recommend removing it with an assistant using special equipment (lift, hoist, etc.).
Warning: When removing and installing a power unit assembly that has a large mass, use only fully functional lifting mechanisms designed for the corresponding load, and especially carefully check the correctness and reliability of the connection of cables, crossbars, etc. to the engine transport eyes.
You will need: wrenches "10", "12", "14", "17", pliers, a flat-blade screwdriver.
1. For ease of work, remove the hood (see "Removal and installation the hood").
2. Reduce the pressure in the fuel system (see "Reducing pressure in the fuel system").
3. Remove the battery (see "Removal and installation the battery").
4. Drain the cooling system (see "Replacing the coolant").
5. If you remove the engine for repair, drain the oil from the oil pan (see "Changing engine oil and oil filter").
6. Unscrew the fastening nut...
7. ...and disconnect the power wire from the contact bolt of the starter solenoid relay.
8. Unscrew the control wire mounting nut...
9. ...and disconnect the wire from the contact bolt of the traction relay.
10. Unscrew the nut...
11. ...and remove the ground wire harnesses from the stud.
12. Unscrew the fastening nut and disconnect the wire from the generator contact bolt.
13. Disconnect the wiring harness connector from the voltage regulator.
14. Use a screwdriver to pry...
15. ... remove the spring clip...
16. ...and remove the clutch release hydraulic drive hose adapter from the end of the intermediate pipe.
17. Disconnect the wiring harness connector from the throttle body connector (see "Removal and installation the throttle assembly").
18. Loosen the clamp...
19. ...and remove the air supply hose from the throttle body neck (see "Removal and installation the air filter housing and intake noise muffler").
20. Press the lock and disconnect the wiring harness connector from the throttle assembly.
21. Release the clamps and disconnect the wiring harness connectors from the ignition coil...
22. ...and from the exhaust gas recirculation valve.
23. Use a screwdriver to pry up the spring clip...
24. ...and disconnect the wiring harness connector from the camshaft position sensor.
25. Press the latch...
26. ...and disconnect the wiring harness connector from the intake manifold vacuum sensor.
27. Disconnect the wiring harness connectors from the injectors...
28. ...and from the temperature sensor of the incoming air into the intake pipe.
29. Squeeze the clamps and disconnect the fuel supply line from the fuel rail.
30. Disconnect the wiring harness connector from the reverse light switch...
31. ...from the speed sensor...
32. ...and from the oil pressure drop warning light sensor.
33. Disconnect the knock sensor wiring harness connector.
34. Disconnect the hoses of the intake manifold length adjustment system and the brake booster vacuum hose from the fittings.
35. Remove the exhaust pipe (see "Replacing the inlet pipe").
36. Remove the catalytic converter (see "Removal and installation the catalytic converter").
37. Remove the accessory drive belt (see "Replacement of auxiliary drive belt").
38. Loosen the two nuts securing the power steering pump by turning the pulley until the hole in it aligns with the nuts...
39. ...unscrew the nut securing the high-pressure line bracket of the power steering pump, remove the pump and move it to the side.
40. Release the clips and disconnect the wiring harness connector from the air conditioning compressor.
41. Remove the two lower mounting bolts...
42. ...and the two upper air conditioning compressor mounting bolts. Move the air conditioning compressor to the side without disconnecting the pipes from it, and secure it to the body using any available method (for example, tie it with wire).
43. Loosen the clamp securing the radiator outlet hose of the cooling system by squeezing its bent ears, slide the clamp along the hose.
44. ...and remove the outlet hose from the thermostat housing pipe.
45. Loosen the clamp securing the radiator supply hose of the cooling system by squeezing its bent ears, slide the clamp along the hose...
46. ...and remove the supply hose from the water distribution pipe.
47. Loosen the clamp securing the heater radiator outlet hose by squeezing its bent tabs, slide the clamp along the hose...
48. ...and disconnect the outlet hose from the heater radiator pipe. Disconnect the inlet hose in the same way.
49. Loosen the transmission control drive terminal clamp bolt...
50. ...and disconnect the rod and gear shift lever.
51. Remove the front wheel drives (see "Removal and installation front wheel drives").
Note: The front wheel drives do not have to be disconnected from the gearbox. In this case, secure the drives disconnected from the hubs to the power unit using any available method (for example, tie it with wire).
52. Attach the lifting gear slings to the front and rear transport eyes and tighten the slings.
53. Place a secure support under the engine.
54. While holding the bolts securing the rear support cushion of the power unit from turning, use the second wrench to unscrew the nuts...
55. ...unscrew the three support bracket mounting bolts...
56. ...and remove the pillow.
57. Remove one bolt and one nut securing the power unit to the left support.
Note: Fuse box and battery tray removed for clarity.
58. Remove the right powertrain suspension support (see "Replacing the powertrain suspension mounts").
59. Check again that all wires, hoses and attachments are disconnected from the power unit.
60. Remove the support from under the engine and lower the power unit down to the floor.
61. Raise the front of the car (raise the car on a lift) to a height sufficient to remove the power unit from under the vehicle, and install reliable supports under the body.
62. Remove the power unit from under the vehicle.
63. Install the power unit, as well as all removed components and parts, in the reverse order of removal, taking into account the following:
- before installing the power unit, use a tap to clean the threaded holes for mounting its supports from rust;
- be sure to replace the intake manifold and neutralizer gaskets with new ones;
- when connecting wires and pipes, carefully ensure that they are correctly positioned in the engine compartment, avoiding contact with heating and moving elements of the power unit.
After installing the engine, do the following.
1. Fill the engine with oil (see "Changing engine oil and oil filter").
2. Fill with coolant (see "Replacing the coolant").
3. Remove air from the clutch release hydraulic drive (see "Bleeding the clutch release hydraulic drive").
4. Start the engine and check for fuel, oil and coolant leaks. Check the oil pressure. Listen to the engine: it should run smoothly, without any extraneous noise or knocking.