Removing the vehicle engine by lowering it together with the gearbox out of the engine compartment.
For the task a lift is required to raise the front part of the vehicle high enough.
If the work is carried out in garage conditions, in the absence of a lift, a jack and sturdy high supports are needed to place the raised front part of the vehicle on them, which will make it possible to withdraw the engine from underneath.
Tools required: 10, 13, 16, 18 spanners, 16, 18 mm sockets, set of screwdrivers, coolant container, hydraulic support.
Depressurise the fuel system as described in the article – «Replacing the additional fuel filter».
Remove the electronic engine control unit.
Remove the engine undertray (article – Removing the engine undertray, wheel arch liners and mudflaps).
Drain the coolant from the cooling system.
If the engine is being removed for repair, drain the oil from the engine sump.
Remove the front suspension subframe (article – Removing the vehicle subframe).
Remove the air filter (article – Removal and installation of the air intake and resonator).
On the K4M engine, disconnect the cable from the throttle body.
Withdraw the cable from the receiver bracket and move it aside.
Press the clip of the brake servo hose.
Disconnect the hose from the receiver union.
Disconnect the canister purge valve hose from the throttle body union.
Press the clip of the wiring harness connector of the throttle position sensor.
Disconnect the connector from the socket.
Press the clip of the injector wiring connector.
Separate the connectors.
Press the clip and disconnect the wiring connector from the camshaft position sensor.
Disconnect the fuel line hose from the fuel rail union.
Press the clip of the wiring connector of the dephaser solenoid valve.
Disconnect the connector from the dephaser solenoid valve.
Disconnect the wiring connectors from the ignition coils.
Press the clip of the wiring connector of the manifold absolute pressure sensor in the receiver.
Disconnect the connector from the sensor.
Press the clip of the wiring connector of the canister purge valve.
Disconnect the connector from the valve.
Press the clip of the wiring connector of the intake air temperature sensor in the receiver.
Disconnect the connector from the temperature sensor.
Press the clip of the wiring harness connector of the knock sensor.
Disconnect the connector from the sensor.
Press the clip of the wiring harness connector of the oil pressure sensor.
Disconnect the connector from the sensor.
Undo the nut of the alternator power cable.
Disconnect the power cable from the alternator terminal.
Press the clip of the wiring harness connector.
Disconnect the connector from the alternator.
Press the clip of the wiring connector of the air conditioning system pressure sensor.
Disconnect the connector from the sensor.
Prise up the wiring harness retaining clip.
Fold back the clip and move the wiring harness aside.
Compress the bent tabs of the clamp securing the heater outlet hose.
Disconnect the stub from the cooling system hose union.
Also disconnect the radiator outlet stub from the cooling system hose union.
Also disconnect the radiator inlet stub.
Disconnect the heater inlet hose from the water distributor.
Disconnect the heater hoses from the brackets.
Press the clip of the wiring connector of the coolant temperature sensor.
Disconnect the connector from the sensor.
Press the clip and disconnect the wiring connector from the crankshaft position sensor.
Undo the bolt securing the earth cable.
Disconnect the earth cable from the gearbox housing.
Press the clip and disconnect the pipe from the clutch slave cylinder.
Plug the pipe with the cap of the slave cylinder union for bleeding.
Disconnect the downpipe from the exhaust manifold.
Press the clip of the wiring connector of the critical oil level drop sensor.
Disconnect the connector from the sensor.
Remove the front wheel driveshafts.
Press the clip of the wiring connector of the reverse light switch.
And disconnect the connector from the sensor.
Press the clip of the wiring connector of the control oxygen sensor.
And separate the connectors.
Undo the nut securing the earth cable.
Undo the nut of the starter power cable and move the cables aside.
Remove the air conditioning compressor without disconnecting the pipes and secure it with wire.
Disconnect the gearbox control cables from the selector and gearshift levers and withdraw them from the bracket.
Move the wiring harness aside.
Install supports under the powertrain.
Undo the five bolts securing the right-hand engine mounting.
Undo the three bolts securing the mounting to the gearbox.
Check once more that all cables and hoses are disconnected from the engine.
Lower the engine on the supports, holding it to prevent it from falling.
If it is not possible to lower the engine on the supports, suspend the front part of the vehicle (raise the vehicle on a lift) to a height sufficient to withdraw the powertrain from underneath, and install reliable supports under the body.
Refit the engine as well as all the removed assemblies and parts in the reverse order of removal, taking into account the following:
- before fitting the powertrain, clean the threaded holes securing its mountings of rust with a tap;
- be sure to replace the downpipe gasket with a new one;
- when connecting the cables and pipes, carefully monitor their correct layout in the engine compartment, avoiding contact with the heating and moving elements of the powertrain.
After fitting the engine, carry out the following.
Add the oil.
Add the coolant.
Start the engine and check for leaks of fuel, oil and coolant.
Check the oil pressure.
Listen to the engine: it must run evenly, without extraneous noises and knocks.
