Removing the power unit: methods and safety precautions
If it is decided to remove the engine for overhaul or
repair of the main components, then it is necessary to carry out certain preparatory measures.
It is extremely important to determine the place where the work will be performed. Undoubtedly, the best place for this is the workshop. It is very important to have an equipped working platform, as well as a place to store the car. If there is no workshop or garage, then a flat, smooth concrete or asphalt platform will be required.
Flushing the engine compartment and engine before removal will keep the tool clean and in constant working condition.
You will also need a lift or hoist. Make sure that these devices have enough capacity and are able to lift the engine with all attachments. Safety is paramount, as lifting the engine from the vehicle is a potentially hazardous operation.
If work on removing the engine is carried out by an inexperienced person, then an assistant is needed. Consult and ask for help from those who have experience in performing such work. There are many ways to work on lifting the engine from the engine compartment that preclude them from doing it alone.
Plan your activities ahead of time. Get all the necessary tools and equipment before you start work.
Some of the tools that provide safety during removal and installation of the engine, as well as reduce labor costs, include (besides the lift) sturdy stands, a full set of wrenches and mandrels, wooden blocks, rags and solvent to clean up the inevitable puddles of spilled operating fluids. If you intend to rent a lift, then agree on this in advance and perform all work that does not require this mechanism. This will save money and time.
Keep in mind that you may not be able to use the car for a long time. To perform some work not available in «domestic» conditions (due to the lack of special equipment), you will have to contact the services of a service station or a specialized workshop. These facilities are working according to plan, so it is advisable to consult there before removing the engine in order to accurately estimate the time spent on repairs and remanufacturing of parts.
When removing the engine, always be very careful. Careless actions and haste can cause serious injury. Think ahead about your actions. Do not spare time for this, because the main thing is work without injuries.
Vehicles with 1.1 and 1.3 liter engines
Removal and installation of the power unit
Note. When removing the power unit, make sure that the jacks and stands are installed correctly, as well as the correct slinging of the engine.
Attention! Take measures to prevent the vehicle from rolling and falling off the stands while working under the vehicle.
Open the hood, disconnect the wires from the battery and remove it.
Remove the windshield wiper arms along with the brushes.
Remove the air intake cover of the vehicle interior ventilation system.
Remove the wiper motor assembly with rods.
Remove the bottom protective cover.
Disconnect the electronic engine control harness electrical connectors and reversing light electrical connector.
On vehicles with a five-speed manual transmission, remove the clutch slave cylinder.
Disconnect the electrical connectors for the oxygen concentration sensor and the oil pressure warning light sensor.
Disconnect the electrical connectors for the rear oxygen concentration sensor and the ignition coil.
Disconnect the electrical connectors of the coolant temperature sensor and the TDC sensor of the piston of the first cylinder.
Disconnect jumpers from engine (tires) connections with «weight» body.
Disconnect the suction hose from the union on the housing of the vacuum brake booster.
Disconnect the supply and drain fuel lines from the engine.
Disconnect the crankcase ventilation hoses from the engine.
Note. Before disconnecting the fuel lines, first relieve the pressure in the engine power supply system.
Drain the liquid from the cooling system.
Disconnect the hoses from the automatic transmission oil cooler (if the car has an automatic transmission) (only on vehicles with 1.3 liter engines).
Note.
- Before disconnecting the hoses, mark them so as not to confuse them during installation.
- Make sure that fluids and oil do not spill out of the detachable hoses. Plug openings to protect against contamination.
Disconnect the radiator inlet and outlet hoses from the engine, then remove the radiator assembly with hoses.
Disconnect heater hoses from engine (inlet and outlet).
Disconnect the throttle control cable from the engine.
On vehicles with a manual transmission, disconnect the shift cable.
On vehicles with automatic transmission, disconnect the control cable from the transmission (only on vehicles with 1.3 liter engines).
Disconnect the flexible speedometer drive shaft from the gearbox.
Remove the A/C compressor mounting bolts and remove it from the mounting bracket.
Remove the steering gear dust cover, unscrew the steering shaft terminal connection bolt and remove the steering gear.
Note. Preliminarily mark the relative position of the terminal connection and the steering gear.
Raise the car with a jack and remove the wheel.
Disconnect the brake mechanism from the steering knuckle and hang it on a wire hook to the suspension strut.
Having unscrewed the mounting bolts, disconnect the suspension strut from the steering knuckle.
Remove the wheel speed sensor from the steering knuckle (with anti-lock braking system).
Disconnect the muffler intake pipe from the exhaust manifold.
Note. For the duration of the work, hang the exhaust pipe of the mufflers on a hook made of strong wire to the body.
Hang the engine on chains or cables.
Using a hoist, slightly raise the power unit (to a height that allows you to perform further operations).
Loosen the bolts securing the suspension bracket to the engine.
Raise the power unit slowly (to take the load off the suspension brackets) and temporarily leave it in that position.
Note. First make sure that all cables, hoses, wires, electrical connectors, etc. are disconnected from the engine.
Remove the plugs located on the right fender liner, and unscrew the bolts securing the gearbox suspension bracket.
Turn away bolts and nuts of fastening of a crossbar.
Remove the power unit from the engine compartment by tilting it with the gearbox down.
Install the power unit in the reverse order of removal.
After connecting the throttle actuator, adjust it as described in subsection «Supply system».
Vehicles with 1.5 and 1.6 liter engines
Removing the power unit
Note. When removing the power unit, make sure that the jacks and stands are installed correctly, as well as the correct slinging of the engine.
Attention! Take measures to prevent the vehicle from rolling and falling off the stands while working under the vehicle.
Open the hood, disconnect the wires from the battery and remove it.
Remove the windshield wiper arms along with the brushes.
Remove the air intake cover of the vehicle interior ventilation system.
Remove the wiper motor assembly with rods.
Remove the bottom protective cover.
Disconnect the electrical connectors of the electronic engine control harness.
Disconnect the electrical connector of the generator and the oil pressure sensor in the engine lubrication system.
Disconnect the suction hose from the union on the housing of the vacuum brake booster.
Disconnect the supply and drain fuel lines from the engine.
Disconnect the crankcase ventilation hoses from the engine.
Disconnect the hoses from the automatic transmission oil cooler (if the car has an automatic transmission).
Note.
- Before disconnecting the hoses, mark them so as not to confuse them during installation.
- Make sure that fluids and oil do not spill out of the detachable hoses. Plug openings to protect against contamination.
Drain the liquid from the cooling system.
Disconnect the radiator inlet and outlet hoses from the engine, then remove the radiator assembly with hoses.
Disconnect jumpers from engine (tires) connections with «weight» body.
Disconnect heater hoses from engine (inlet and outlet).
Disconnect the throttle control cable from the engine.
On vehicles with automatic transmission, disconnect the control cable from the transmission.
Disconnect the electrical connector of the switch and the fuel cutoff solenoid valve.
Remove the A/C compressor mounting bolts and remove it from the mounting bracket.
Raise the vehicle.
Disconnect the muffler intake pipe from the exhaust manifold.
Note. For the duration of the work, hang the exhaust pipe of the mufflers on a hook made of strong wire to the body.
Disconnect the steering knuckle from the front suspension strut.
Disconnect the brake mechanism from the steering knuckle and hang it on a wire hook to the suspension strut.
Remove the wheel speed sensor from the steering knuckle (with anti-lock braking system).
Hang the engine on chains or cables. Using a hoist, slightly raise the power unit (to a height that allows you to perform subsequent operations).
Turn away a bolt of terminal connection of a shaft of a steering.
Loosen the bolts securing the suspension bracket to the engine.
Raise the power unit slowly (to take the load off the suspension brackets) and temporarily leave it in that position.
Note. First make sure that all cables, hoses, wires, electrical connectors, etc. are disconnected from the engine.
Remove the plugs located on the right fender liner, and unscrew the bolts securing the gearbox suspension bracket.
Turn away bolts and nuts of fastening of a crossbar.
Remove the power unit from the engine compartment by tilting it with the gearbox down.
Install the power unit in the reverse order of removal.
After connecting the throttle actuator, adjust it as described in subsection «Supply system».