Pic. 2-3. Removing the engine screen:
1 - front bracket;
2 - engine screen;
3 - screen mounting support;
4 - right bracket;
5 - rear bracket.
Remove the air filter:
- loosen the clamp securing the intake pipe hose to the spacer and disconnect the hose from the spacer;
- disconnect the wiring harness connector from the mass air flow sensor;
- unscrew the four bolts securing the front and rear air filter brackets to the car body and remove the air filter with the mass air flow sensor and the intake pipe hose assembly.
Drain the coolant from the radiator, cylinder block and heater, to do this, move the heater valve control lever to the right, unscrew the plugs on the left side of the cylinder block and on the right tank of the radiator, screw in the drain hose fittings instead of them and remove the plug from the expansion tank.
Loosen the clamps and disconnect the coolant inlet and outlet hoses from the radiator and from the engine.
Disconnect the expansion tank hose from the radiator.
Remove facing of a radiator of system of cooling.
Disconnect the plug from the sound device and remove the sound device.
Remove the air conditioning condenser as required in section "Ventilation, air conditioning and interior heating".
Disconnect the ignition harness from the fans.
Turn away four bolts and remove casings 10 and 12 of a radiator 11.
Remove two bolts, remove brackets 9 and remove the engine cooling system radiator assembly with fans.
Disconnect electrical wires:
- disconnect the battery harness terminal from the generator;
- disconnect wire from engine "masses";
- disconnect the plug connectors of the ignition wiring harness from the injector wiring harness, from the ignition coil, oxygen sensors, temperature, detonation, idle speed control, throttle position and crankshaft position sensors;
- Disconnect plugs of wires from gauges of the index of temperature of a cooling liquid and pressure of oil.
Disconnect the suction hose from the receiver to the vacuum brake booster.
Disconnect the canister purge hose from the throttle body.
Loosen the fastening clamps and disconnect the inlet and outlet hoses of the heater radiator from the engine.
Disconnect the discharge line and low pressure line from the compressor.
Disconnect hoses 10 and 11 (pic. 2-4-a) from fuel pipes 5 and 6 respectively or hose 2 (pic. 2-4-b) from the fuel line. Install process plugs in the openings of hoses and pipelines to prevent the ingress of dust particles from the air.
Pic. 2-4. Fuel equipment details:
A) for ECM with MP7.0 controller:
1 - bracket;
2 - electric fuel pump;
3 - filling pipe;
4 - fuel tank assembly;
5 - outlet fuel tube;
6 - fuel supply pipe;
7 - fuel rail;
8 - fuel filter;
9 - bracket for fastening the fuel filter;
10 - outlet hose;
11 - supply hose.
b) for ECM with M7.9.7 controller:
1 - fuel tank assembly;
2 - fuel pipeline hose;
3 - fuel rail;
4 - electric fuel pump;
5 - tube of the fuel filter and fuel pipeline;
6 - fuel filter;
7 - a tube of an electric fuel pump and a fuel filter.
Disconnect cable 2 (pic. 2-5) accelerator drive from sector 1 on the throttle pipe, from bracket 4 on the receiver and from the brackets on the cylinder head cover.
Pic. 2-5. Removing the accelerator drive:
1 - sector with a throttle control lever;
2 - throttle control cable;
3 - cable braid;
4 - bracket;
5 - throttle control pedal;
6 - spring cups;
7 - pedal pad;
8 - spring;
9 - latch.
Loosen the three clamps, unscrew the bolt securing the spacer to the cylinder head cover and remove the hose 1 and 4 (pic. 2-6) intake pipe assembly by disconnecting them from the throttle pipe 6, the mass air flow sensor 9 and the crankcase ventilation hose 3.
Unscrew the bolts securing the air filter brackets to the car body and remove the air filter 10 assembly with the mass air flow sensor 9, with the brackets and the air intake.
Disconnect the hose 8 of the vacuum brake booster from the receiver.
Disconnect the canister purge hose from the throttle body.
Drain the oil from the power steering reservoir. Disconnect the inlet hose and high pressure hose from the power steering pump and plug them.
Loosen the nuts securing the muffler intake pipe to the exhaust manifold. Disconnect the downpipe from the bracket on the gearbox and lower it down.
Pic. 2-6. Removing components and parts of the air supply system:
1 and 4 - inlet pipe hoses;
2 - crankcase ventilation tube;
3 - crankcase ventilation hose;
5 - hoses for heating the throttle pipe;
6 - throttle pipe;
7 - receiver;
8 - vacuum booster hose;
9 - mass air flow sensor;
10 - air filter;
11 - air filter support;
12 - bracket.
Using a socket wrench, unscrew the bolts securing the starter to the clutch housing, disconnect the wires from the starter and remove the starter. Loosen the bolts securing the clutch housing cover to the bottom of the clutch housing. Using a socket wrench, remove the bolts securing the clutch housing to the cylinder block.
Install the hydraulic traverse 67.7820-9550 on the hoist or on the crane and insert the hooks of the lifting device into the eyelet on the right side of the engine, mounted on the front exhaust manifold mounting stud, and behind the clutch housing mounting hole on the left side.
Slightly tighten the hoist chain, unscrew the nuts 7 (pic. 2-7) fastening pillows 8 of the front engine mount to the side brackets.
Install a transmission jack under the gearbox.
Remove the engine from the engine compartment by first lifting it up to remove the suspension mount bolts from the bracket holes, and then moving it forward to drive the end of the transmission input shaft out of the bearing located in the crankshaft flange. Loosen the clutch mounting bolts and remove it.
Install the engine to the vehicle in the reverse order of removal. When installing the clutch, use drift A.70081 to center the clutch disc.
Pic. 2-7. Removing the power unit:
1 - right engine mount bracket with a pillow;
2 - eyes for slinging;
3 - cross member of the rear engine mount;
4 - remote bushing;
5 - support for the rear engine mount;
6 - hairpin;
7 - nut;
8 - pillow;
9 - left engine mount bracket.