1. Engine mount bracket
2. Engine support cushion
3. Gearbox support bracket
4. Front support of the power unit
5. Rear support of the power unit
6. Front subframe beam
Withdrawal
Note: In order not to damage the paintwork of the body, cover the fenders with a suitable material. Tag all fittings and connectors before disconnecting them.
1. Disconnect the wires from the battery terminals (1).
2. Remove the battery.
3. Drain the coolant. To speed up the drain, remove the radiator cap.
4. Turn off screws and remove a decorative cover of the engine. Tightening torque: 8-12 Nm.
5. Remove the engine mudguard (2). Tightening torque: 4-6 Nm.
6. Disconnect the air flow sensor connector (3). Disconnect the vacuum hose (4) from the inlet (6). Remove the inlet pipe (6) and air filter cover (5).
7. Disconnect the engine control unit connectors (7 and 8). Remove the filter element and remove the air filter housing (9). Tightening torque: 8-10 Nm.
8. Remove battery tray (10).
9. Remove the top (11) and bottom (12) radiator pipes. Remove the transmission fluid cooler pipes (13) (models with automatic transmission).
10. Disconnect heater hoses (14) and fuel hose (15).
11. Disconnect the accelerator cable (16), by loosening the locknut and disconnecting the cable from the lever. Disconnect throttle position sensor connectors (17) and absolute air pressure sensor (18) (if installed).
Only for 1.4L engines
12. Disconnect front oxygen sensor connectors (19) and crankshaft position sensor (20).
13. Disconnect the ignition coil connector (21), noise suppression capacitor (22), camshaft position sensor, coolant temperature sensor and wire «masses».
Only for 1.6L engines
14. Disconnect rear oxygen sensor connectors (26), compressor switch (27),knock sensor (28) and injector wiring harness (29 and 30).
15. Remove the engine wiring harness guide (31). Disconnect the idle speed control connector (32).
16. Disconnect front oxygen sensor connectors (33), crankshaft position sensor (34) and oil valve timing phase adjustment (35).
17. Disconnect ignition coil connectors (36), noise suppression capacitor (37), camshaft position sensor (38) and wire «masses» (39). Remove the wiring harness bracket (40).
18. Disconnect the wire «masses» (41) between engine mount (42) and bodywork.
19. Remove wire «masses» (43) between gearbox and body.
Only for models with automatic transmission
20. Disconnect the connectors of the selector position sensor (44), solenoid valves (45) and transmission fluid temperature sensor (46).
21. Disconnect the speedometer sensor connectors (47), downshift switch (48), speed sensors input (49) and weekend (50) shafts.
22. Unscrew the nut (51) and disconnect the automatic transmission selector cable (52).
Only for models with manual gearbox
23. Disconnect the speedometer sensor connectors (53), sensor «neutral» (54) and reversing light switch (55).
24. Remove the cables (56) gear selection and engagement.
For all models
25. Pull the disconnected wiring harnesses towards the fuse box so as not to pinch or damage them when removing the engine.
26. Disconnect the canister purge hose (57) and brake booster vacuum hose (58).
27. Remove the refrigerant from the air conditioning circuits and remove the high and low pressure pipes
28. Remove supply hose (59) power steering pump and drain the fluid.
29. Remove return hose (60) power steering pump.
30. Loosen nuts (61 and 62), screw (63) and remove the motor bracket (64). Tightening torques:
- screw (61): 69-93 Nm;
- bolt (63): 49-64 Nm;
- screw (62): 49-64 Nm.
Only for models with automatic transmission
31. Remove the wiring harness cover (65) from the bracket. Remove the gearbox bracket (66), by unscrewing 2 screws (67). Tightening torque for bracket fastening screws: 69-93 Nm.
Only for models with manual gearbox
32. Remove the clutch slave cylinder hose (68) from the bracket. Remove gearbox bracket (69). Tightening torque: 69-93 Nm.
For all models
33. Disconnect the connector (70) and wire terminals «IN» (71) generator.
34. Remove the front wheels.
35. Remove the wheel speed sensor (72).
36. Remove the brake caliper (73).
37. Tie up the brake caliper (74) wire to the front suspension strut spring.
38. Unscrew the nuts and remove the bolts (75) rotary knuckles.
39. Remove the bolt (75) steering shaft joint.
40. Remove front muffler heat shield (76). Remove the front muffler (77). Tightening torque: 29-39 Nm.
41. Install a lift under the car, supporting the engine with the gearbox
Note: Mount the engine securely on a hoist so that it does not fall when removed. Before lowering the engine, make sure that all connectors and hoses are disconnected.
42. Loosen the screws (78) and nuts (79) subframe mountings. Tightening torque: 93-117 Nm.
43. Remove the engine from a transmission, having lifted the car.
Installation
44. Installation is carried out in reverse order.
45. After installing the engine, perform the following procedures:
- adjust the automatic transmission selector cable;
- adjust the accelerator cable;
- fill the engine with engine oil;
- fill the gearbox with gear oil;
- fill the engine cooling system with coolant;
- fill the power steering system with working fluid;
- check for leaks.