Attention.
- Use protective coatings to prevent damage to painted surfaces.
- Disconnect connectors carefully while holding the connector with your hand to avoid damage.
Note: Tag all hoses to wires and avoid 200 rpm or more use errors when reconnecting.
1. Remove the cover (A) engine.
2. Remove engine protection (A).
3. Remove the drain plug (A) radiator and drain the engine coolant. Remove the radiator cap to speed up the drain.
4. Remove the air filter assembly.
(1) Remove the duct (A).
(2) Disconnect connector (IN) mass air flow sensor (AFS).
(3) Disconnect the hose (WITH) breather.
(4) Disconnect the hose (D) air intake and remove the air filter assembly (E).
Note:
Torque:
- Clamps: 2.9-4.9 Nm
- Bolts: 7.8-9.8 Nm
5. Disconnect the terminals (A) battery and remove the battery (IN).
Note:
Torque:
- (-) output: 4.0-6.0 Nm.
- (+) output: 7.8-11.8 Nm.
Bracket bolt: 9.8-11.8 Nm.
6. Remove battery tray (A).
Note: Tightening torque: 9.8-11.8 Nm.
7. Disconnect connector (A) intake air temperature sensor and disconnect the intake (IN) and graduation (WITH) pipe and intercooler hose.
Note:
Torque:
- Clamps: 4.9-6.9 N.m.
- Bolt: 9.8-11.8 N.m.
Standard power
Disconnect connector (A) boost pressure sensor (BPS) and disconnect the intake (IN) and graduation (WITH) pipe and intercooler hose.
Reduced power
8. Remove the top (A) and bottom (IN) radiator hoses.
9. Disconnect the engine harness connectors and remove the harness clamps from the cylinder head cover and intake manifold.
(1) Disconnect connector (A) differential pressure sensor. (With particulate filter).
(2) Disconnect connector (IN) exhaust gas temperature sensor. (With particulate filter).
(3) Disconnect connector (WITH) oxygen sensor.
(4) Disconnect connector (A) camshaft position sensor (CMPS).
(5) Disconnect connector (IN) fuel rail pressure sensor.
(6) Disconnect connector (WITH) glow plugs.
(7) Disconnect connector (D) fuel pressure regulator.
(8) Disconnect connector (E) boost pressure sensor (BPS). (Only for engines of standard power).
(9) Disconnect connector (F) oil pressure sensor.
(10) Disconnect connector (G) crankshaft position sensor (CKPS).
(11) Disconnect connector (H) exhaust gas cooling valve (EGR).
(12) Disconnect connector (I) fuel temperature sensor.
(13) Disconnect connector (J) fuel rail pressure regulator.
(14) Disconnect the injector connectors (TO).
(15) Disconnect connector (L) air control valve.
Standard power
Reduced power
(16) Disconnect connector (A) drive for changing the geometry of the intake manifold.
(17) Disconnect connector (IN) coolant temperature sensor (ECTS).
(18) Disconnect connector (WITH) variable geometry turbocharger electric drive (VGT).
(19) Disconnect connector (D) exhaust gas recirculation drive (EGR).
(20) Disconnect connector (A) generator and wire (IN).
(21) Disconnect connector (WITH) starter and wire (D).
(22) Disconnect connector (E) air compressor switch.
10. Disconnect harness connectors, shift cable and wire «masses».
11. Remove protection (A) wiring harness.
12. Disconnect the wire (A) «masses» engine.
13. Disconnect fuel hoses (A).
Standard power
Reduced power
14. Disconnect the vacuum hose (A).
15. Disconnect the hoses (A) heater.
16. Disconnect the oil hose (A) power steering. (HPS only)
17. Drain the refrigerant, disconnect the fittings (A) high and low pressure air compressor.
18. Remove cardan shaft (A).
19. Remove the front muffler (A).
Note: Tightening torque: 39.2-58.8 Nm.
20. Remove the bolt (A) mounting of the universal joint of the steering shaft.
21. Remove the front wheels.
22. Remove shock absorbers, stabilizer links, ball joints of lower arms and tie rod ends.
23. Remove the drive shaft from the hub.
24. Support the subframe with a jack, then unscrew the bolt (A) fastening of an arm of a back roller emphasis, bolts (IN) subframe fasteners, unscrew the nuts (WITH) and remove the subframe (D).
Note: Tightening torque:
- Bolt (A): 107.9-127.5 Nm.
- bolts (IN), nuts (WITH): 156.9-176.5 Nm.
25. Support the engine with a jack.
Note:
- Make sure that the power unit is supported with a jack, otherwise, after unscrewing the bracket mounting bolts, the power unit may fall.
- Before removing the power unit, make sure that all hoses and connectors are disconnected from it.
26.Remove the bracket (A) engine mounts.
Note: Tightening torque: Bolts (IN), nuts (WITH): 63.7 - 83.4 Nm.
27. Remove the bolts (A) gearbox support bracket.
Note: Tightening torque: 88.3-107.9 Nm.
28. Remove the power unit (A), by lifting the car.
Attention. When removing the engine and transmission assembly, be careful not to damage surrounding components and the bodywork.