4.7.2. Removal, separation and installation of the engine

Removal

During the work in a motive compartment it must be kept in mind that the fan of a radiator can independently turn on at the switched-off engine and the included ignition (position "II" of the ignition key). Owing to the processes of the heat sink taking place in a motive compartment, it can repeatedly occur. Therefore, whenever possible, during the work in a motive compartment it is necessary to switch off ignition.

It is worth to remember that fuel is flammable liquid in the highest measure! During the work with components of a power supply system observe all taken measures of fire safety. You do not smoke, do not approach the venue of works with naked flame or the carrying unprotected by the lamp shade. You do not make service of system in the room equipped with the heating devices using natural gas and equipped with a control torch (such as vodogre and dryers for clothes). Do not forget that fuel is among the cancerogenic substances promoting development of cancer. Try not to allow hits of fuel on open parts of the body, - use protective rubber gloves, at casual unforeseen contact carefully wash out hands warm water with soap. Immediately collect the spilled fuel and do not put the rags impregnated with fuel and lubricants near sources of naked flame. Remember that the power supply system of the models equipped with injection of fuel constantly is under pressure. Before starting a detachment of fuel lines, dump residual pressure in system (for more details see the Head of the Power supply system, release and decrease in toxicity of the fulfilled gases). At service of components of a power supply system put on goggles. Constantly hold near at hand the class B fire extinguisher!

The path of the air conditioning system also constantly is under pressure, and therefore before a rassoyedineniye of refrigerator lines it is necessary to make a system discharge in the conditions of a specialized workshop.

The SRS system which main components are safety cushions is included in a basic equipment of all modern cars. Before starting performance of any works near an arrangement of sensors of the directed SRS overloads, around a steering column or the dashboard, without fail disconnect system in order to avoid the casual operation of safety cushions fraught with receiving serious injuries.

Authors of the present manual recommend to make removal of the engine assembled with transmission. Assembly of the unit falls down and is taken from under the car in view of what it is necessary to take care of ways of reliable fixing of the vehicle in the lifted situation.

Depending on year of release and the equipment vacuum hoses and hoses of the cooling system can have various routes of laying. It is recommended to mark before dismantling of connections them an adhesive tape. Further removal of the C14SE engine is described. Operations with other engines are made similarly.


 PERFORMANCE ORDER

  1. Tire out the car on the flat horizontal platform with rather hard coating. Remove a cowl (see the Head Kuzov). Bring forward wheels into rectilinear situation, take a key from the lock of ignition and block a steering column.
  2. Remove the rechargeable battery (page. Head Sistemy of electric equipment of the engine).

Owing to shutdown of the rechargeable battery information from memory, for example, DTC or a code of the audio system is erased. Switch-off the battery only at the switched-off ignition. Otherwise it is possible to damage the control unit of injection.

  1. Remove the air filter with the giving hose (see the Head of the Power supply system, release and decrease in toxicity of the fulfilled gases).
  2. Merge cooling liquid in pure capacity.
  3. Disconnect all hoses of the cooling system from a radiator. Previously weaken collars and displace them back.
  4. Separate the socket of the electric motor of the fan and disconnect an electrical wiring plait from an air inlet sleeve.
  5. Turn out fixing bolts of a sleeve of an air inlet and, having taken out it upward from the holder, remove from a radiator.
  6. Remove a cable of a butterfly valve from the case of a butterfly valve and take him aside (see the Head of the Power supply system, release and decrease in toxicity of the fulfilled gases).
  7. Remove all vacuum hoses from a branch pipe of a butterfly valve.
  8. Remove a vacuum hose from the amplifier of brakes.

Detachment of a vacuum hose from the amplifier of brakes

  1. Separate sockets of injectors and take an electrical wiring plait aside.
  2. Disconnect hoses of cooling liquid from a broad tank and remove it.
  3. Disconnect heater hoses from branch pipes on a partition of a motive compartment.

Fastening of hoses of a heater

  1. Remove a bracket from a cable of the drive of coupling and disconnect a cable from a clutch lever.

Fastening of a cable of the drive of coupling and socket of the switch of a lamp of a backing

  1. Separate the backing lamp switch socket (the shooter at the left on an illustration).
  2. Mark the giving and returnable fuel hoses not to mix them in places at assembly. Press hoses clips. Disconnect the holder of fuel hoses at the inlet pipeline and remove them. Collect the following fuel by rags.

Fastening of the holder of fuel hoses

  1. Disconnect a speedometer from the transmission.
  2. Mark with a tape all electrical wiring going to the engine and disconnect it.
  3. At a car complete set the GUR system weaken a tension of a V-shaped belt and remove it (see the Head Nastroyki and routine maintenance of the car).
  4. At the corresponding complete set turn out bolts of fastening and remove the pump GUR from the holder on the block of cylinders and, without disconnecting hoses from the pump, tie up it a wire so that it did not prevent further dismantling and that hoses were not tense.

Pump GUR fixture

  1. Mark the provision of the corresponding forward wheel concerning its nave that then it was possible to establish the balanced wheel in its former situation. Weaken bolts of fastening of a wheel at the car standing on the earth. To Poddomkratta a car front, establish it on props and remove a forward wheel.
  2. Remove the gear shifting lever from a rod on the transmission. For this purpose weaken a collar on the lever. Previously mark both parts so that at assembly they could be established in former situation.

Collar on the gear shifting lever

  1. Disconnect an electrical wiring from the generator and a starter (see the Head Sistemy of electric equipment of the engine).
  2. Disconnect a reception pipe from a final collector, remove it from holders and incline aside.
  3. Take out from rotary fists spherical support on the right and at the left. Previously turn out tightening bolts.
  4. Disconnect forward cross levers from a body.
  5. Give bolts of fastening and remove the holder of draft of a forward suspension bracket from a cross beam of a forward stretcher together with draft and the stabilizer of cross stability.

Bolts of fastening of the holder of draft of a forward suspension bracket

  1. Beat out both power shafts from the transmission case.
  2. Install the elevator under the engine and slightly raise the power unit. It is also possible to use the lifting device, having hooked on it for lifting eyes of the engine. Raise the engine so that to unload both of its top support.
  3. Give bolts of fastening and remove blocks of depreciation of the engine from a longitudinal beam of a forward frame and from the engine. On an accompanying illustration the forward left block of depreciation on cars without the GUR or K/V systems is shown.

Bolts of fastening of the forward left block of depreciation

  1. Check that all hoses, an electrical wiring and other lines were disconnected from the engine.
  2. Carefully lower the engine with the transmission from a motive compartment.
  3. Disconnect the transmission from the engine (see the Head the Manual 5-staged box of gear shifting or Automatic 4-staged transmission).

Installation

 PERFORMANCE ORDER

  1. Check engine support, cooling system hoses, oil and fuel hoses for existence of cracks or other damages and if necessary replace the corresponding parts. Carefully pass a tap a carving in openings of a beam of a forward frame to remove the sealant remains.
  2. Check thickness of the conducted clutch plate, and also a condition of frictional slips. At considerable wear or a big run replace the conducted disk in a set. If the bearing of switching off of coupling when pressing a pedal of coupling publishes noise, replace the bearing.
  3. Clear the bearing of switching off of coupling and grease vents with a thin layer of MoS2 lubricant.
  4. Connect the transmission to the engine (see the Head the Manual 5-staged box of gear shifting or Automatic 4-staged transmission).
  5. By means of the lifting equipment carefully enter the engine with the transmission into a motive compartment. Level the engine with support and tighten fastening bolts.
  6. Shake the engine in different directions.
  7. Previously having cleared a brush a carving of fixing bolts of the block of depreciation of the engine and having greased it with OPEL-90 sealant 167 347/15 10, tighten them with the required efforts.
  8. Insert both power shafts into the transmission case against the stop.
  9. Install into place cross levers, drafts and the stabilizer (see the Head Podvesk and steering).
  10. Connect an electrical wiring of the generator and a starter (see the Head Sistemy of electric equipment of the engine).
  11. Install system of production of the fulfilled gases in rubber support and fix by bolts with effort 25 Nanometers to a final collector.

Use new laying.

  1. Put on the gear shifting lever a rod and level the tags put at removal.
  2. Check adjustment of the mechanism of gear shifting (see the Head the Manual 5-staged box of gear shifting or Automatic 4-staged transmission).
  3. Establish into place forward wheels and level the tags put at removal. Screw bolts of fastening of wheels. Lower the car on the earth and tighten bolts cross-wise with effort of 110 Nanometers.
  4. Fix a speedometer shaft on the transmission.
  5. Attach a coupling drive cable, establish brackets.
  6. Connect a backing lamp electrical wiring.
  7. Put on heater hoses unions on a partition of a motive compartment and record hoses collars.
  8. Connect fuel hoses according to the marking put earlier and fix them by collars. The hose of supply of fuel should be put on the corresponding pipe rather far. You watch that collars did not concern adjacent elements. Fix fuel hoses on holders at a final collector.
  9. Put on a vacuum hose on the amplifier of brakes and check reliability of connection.
  10. Fix the tank of cooling liquid on a partition of a motive compartment. Connect hoses of the cooling system and fix them by collars.
  11. Connect engine electrical wiring plait sockets.
  12. Connect sensors of temperature and pressure of motive oil.
  13. Connect sockets of injectors and fix an electrical wiring plait.
  14. Attach the drive of a butterfly valve to the case of a throttle and check its adjustment (see the Head of the Power supply system, release and decrease in toxicity of the fulfilled gases).
  15. Fix a reception funnel of air in holders on a radiator.
  16. Connect the socket of the electric motor of the fan and the thermostat. Fix an electrical wiring plait.
  17. Connect the socket a lambda probe.

The electrical wiring should be laid as it is possible further from the fan.

  1. Attach the top and lower hoses to a radiator and fix them by collars.
  2. Establish a hose of air supply and the air filter. At the same time clear the air filter and its case, if necessary replace the filter (see the Head of the Power supply system, release and decrease in toxicity of the fulfilled gases).
  3. At the corresponding complete set fix the pump GUR on the holder. Put on a V-shaped belt (see the Head Nastroyki and routine maintenance of the car).
  4. Connect a negative wire of the rechargeable battery.

Attach the battery only at the switched-off ignition. Otherwise the control unit of system of injection can be damaged.

  1. Check quality of cooling liquid and fill in it in the cooling system (see the Head Nastroyki and routine maintenance of the car).
  2. Let's the engine cool down and check the level of cooling liquid. Check all connections of hoses for leaks.
  3. Check and if necessary modify oil level in transmissions.