Contents: Removal ⇩ Installation ⇩
Removal
Caution: Install plugs on disconnected pipes.
1. Place the vehicle horizontally and apply the parking brake.
2. Disconnect the battery.
3. Remove the hood (see section "Body").
4. If air conditioning is installed, remove the right side panel of the footrest and disconnect the wiring connector from the relay.
5. Disconnect the two motor wiring connectors on the left side of the footrest panel.
6. Remove the rubber plug from the engine compartment bulkhead and pull the wires into the engine compartment.
7. Disconnect the battery cable from the retaining clip on the suspension strut.
8. Remove the radiator (see section "Cooling system").
9. Evacuate the air conditioning system (see section "Air conditioner"). Disconnect both tubes from the compressor.
10. Remove the valve cover insulator.
11. Disconnect the centrifugal air cleaner hose from the air filter hose.
12. Disconnect the compressor air hose.
13. Disconnect the hoses/pipes from the turbocharger and charge air cooler.
14. Disconnect the heater hoses from the cylinder head.
15. Disconnect the gearbox ventilation tube clips from the cylinder head and move the tubes to the side.
16. Disconnect the power steering pump hoses.
17. Disconnect the thermostat bypass hose.
18. Release the bypass hose clips on the front timing belt cover.
19. Disconnect the accelerator cable from the fuel injection pump.
20. Press on the tabs of the accelerator cable adjusting nut and remove the cable from the fuel injection pump bracket.
21. If an automatic transmission is installed, disconnect the kick-down cable from the fuel injection pump.
22. Disconnect the supply and return fuel lines from the fuel injection pump.
23. Disconnect the fuel lines from the booster pump.
24. Disconnect the hose from the vacuum pump.
25. Unscrew the three nuts securing the exhaust system's inlet pipe.
26. Disconnect the oil cooler pipes from the oil filter housing.
27. Automatic transmission: disconnect the fluid cooling pipes from the radiator. Remove the coolant tube support bracket from the left side of the block.
28. Place a support under the gearbox.
29. Disconnect the ground wire from the starter.
30. Automatic transmission: remove the fastening fasteners and remove the plate and the gearbox housing gasket to access the torque converter drive clutch mounting bolts.
31. Mark the relative position of the torque converter drive coupling halves.
32. Turning the crankshaft, one by one, unscrew the four half-coupling mounting bolts.
33. Attach an engine lifting eye to the two rear cylinder head bolts.
34. Secure the slings to the lift and engine.
35. On both sides, unscrew the four bolts securing the front engine mount to the block.
36. On both sides, unscrew the two bolts securing the rear engine mounts to the clutch housing (torque converter).
37. Remove the nuts and washers securing the front support to the frame and remove the support from the vehicle.
38. Remove the clutch housing fasteners. The starter does not need to be removed.
39. Raise the engine and disconnect it from the gearbox.
40. Check that all wires and tubes are disconnected.
41. Remove the engine.
Installation
42. Apply Hylomar sealant to the mating surfaces of the block and clutch housing. Lubricate the splines of the gearbox input shaft with Rocol MV3. Automatic transmission: apply Loctite 290 locking adhesive to the threads of the coupling half bolts. Tightening torque of the bolts is 39 N·m.
43. Lower the engine into the engine compartment. Manual transmission: insert the input shaft into the clutch splines, clutch housing, install it with the guide pin. Tighten the fasteners:
- clutch housing with a torque of 40 Nm
- torque converter housing with a torque of 46 Nm.
The article is based on information from the website (www.LRman.ru)
44. Install the engine mounts.
45. Remove the temporary gearbox support.
46. Tighten the support fastenings to the frame to a torque of 45 N·m.
47. Reinstall the removed parts in reverse order (items 1-37).
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