Removing
1. Disconnect a wire from the negative plug of the storage battery.
2. Remove the fuel pressure in the power supply system.
3. Remove the hood.
4. Drain the coolant from the engine cooling system.
5. Remove a transmission.
6. Remove the radiator.
Pic. 3.64. Connecting connectors and hoses to a DOHC engine: 1 - bolt, 3.0 Nm; 2 - central cover; 3 - connectors of the ignition coil; 4 – a socket of the gauge of temperature of a cooling liquid (pointer); 5 – a socket of the gauge of temperature of a cooling liquid; 6 - bolt, 10 Nm; 7 – accelerator pedal cable connection; 8 - annular sealing gasket; 9 – connection of a fuel hose of a high pressure; 10 – a socket of the gauge of malfunction of system of ignition; 11 – a socket of the gauge-switch of pressure of oil; 12 – connection of a vacuum hose of the amplifier of brakes; 13 - connection of the fuel return hose; 14 – a socket of a regulator of frequency of rotation of idling; 15 - throttle position sensor connector (TPS); 16 - connection of hoses of the cooling system; 17 - knock sensor connector; 18 – connection of heater hoses; 19 – connection of vacuum hoses; 20 - injector connectors; 21 – a socket of the gauge of provision of a cranked shaft; 22 – a socket of the gauge of provision of a camshaft
7. Turn away bolts and disconnect a cable 7 (pic. 3.64) accelerator pedals.
8. Disconnect throttle position sensor connectors (TPS) 15, idle speed control 14, knock sensor 1, oil pressure switch 11, ignition system malfunction sensor 10, coolant temperature sensor 5, coolant temperature sensor (pointer) 4 and 20 nozzles.
9. Turn away bolts and remove the central cover 2.
10. Disconnect the connectors of the ignition coil 3, the camshaft position sensor 22 and the crankshaft position sensor 21.
11. Loosen the clamp and remove the fuel return hose 13.
12. Turn away bolts and disconnect a fuel hose 9 of a high pressure and an annular sealing lining 8.
13. Disconnect the vacuum hose 12 of the brake booster.
14. Disconnect the vacuum hoses 19.
15. Loosen the clamps and disconnect the coolant hoses 16.
16. Loosen the clamps and disconnect the heater hoses 18.
Pic. 3.65. DOHC Engine: 1 - bolt; 2 – an arm of a support of the engine; 3 - bolt, 62 Nm; 4* - nut, 118 Nm; 5 - sensor connector (switch) fluid pressure in the hydraulic system of the power steering; 6 – fastening of the pump of the hydraulic booster of a steering; 7 – a socket of the compressor of the conditioner; 8 – fastening of the compressor of the conditioner; 9 – a belt of a drive of the pump of the hydraulic booster of a steering and the conditioner compressor; 10 - bolt, 49 Nm; 11 – a reception pipe of system of release of the fulfilled gases; 12 - bolt, 50 Nm; 13 - gasket; 14 - generator connector; 15 - engine assembly
17. Disconnect the sensor connectors (switch) pressure 5 (pic. 3.65) fluids in the hydraulic system of the power steering, compressor 7 of the air conditioner and generator 14.
Attention! Mounting points marked with the icon (*), you must first pre-tighten, and after lowering the car to the ground (in unloaded state) tighten it completely.
18. Loosen the tension and remove the belt 9 for the drive of the power steering pump and the air conditioning compressor.
19. Turn out bolts of fastening 6 and remove the pump of the hydraulic booster of a steering together with the hoses connected to it.
Attention! Removed power steering pump assembly with bracket and hoses tie with wire and place so that it does not interfere with the removal and installation of the engine assembly.
20. Disconnect the air conditioning compressor wire connector and remove the compressor from the bracket along with the connected hoses.
Attention! Tie the removed compressor with wire and place it in a place where it will not interfere with the removal and installation of the engine.
21. Turn away nuts and disconnect a reception pipe 11 of system of release of the fulfilled gases and remove a lining.
22. Remove bolts 1.
23. Install a rolling hydraulic jack under the engine.
24. Remove the special tool from the engine that was used to remove the transmission.
25. Fasten the engine to the yoke and hang it from a hoist or similar device.
26. Insert a piece of wood between the jack foot and the engine sump and raise the engine slightly to unload the support; then remove the engine mount bracket.
27. Check that all wires are disconnected from the engine (electrical connectors), hoses, etc., and then slowly lift the engine out of the engine compartment.
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
1. When installing the engine, carefully check that the wires, hoses and wire connectors are not pinched.
2. Install a rolling hydraulic jack under the engine (by inserting a block of wood between the jack foot and the engine sump) and install the engine support bracket while adjusting the engine position with a jack.
3. While supporting the engine with a jack, disconnect the hoist.
Pic. 3.44. High pressure fuel hose installation: 1 - place of lubrication with engine oil; 2 - high pressure fuel hose; 3 - ring gasket
4. When installing the high pressure fuel hose, lubricate the O-ring with a small amount of clean engine oil (see fig. 3.44).
Attention! Do not allow oil to enter the fuel rail.
5. Slightly turning the fuel hose flange to the right and left, carefully insert it into the fuel rail so as not to damage the O-ring. After installation, check that the hose turns smoothly in the fuel rail.
6. If the hose flange sticks when turning, the O-ring may be damaged. Detach the flange (complete with hose) from the fuel rail and inspect the gasket for damage, then reinsert it and check for smooth turning.
7. Tighten the mounting bolts.
8. Install the heatsink.
9. Install the gearbox.
10. Adjust the accelerator pedal cable.
11. Fill in cooling liquid in the cooling system.
12. Adjust drive belt tension.
13. Install the hood.