Removing
- Disconnect the wire from the negative battery terminal.
- To remove the engine, perform the following steps in sequence.
- Relieve the fuel pressure in the fuel system. See chapter «Reducing the pressure in the fuel system» given in section «Multipoint fuel injection system (MPI)».
- Remove the air filter.
- Remove the hood.
- Remove the radiator.
- Remove the gearbox.
- Disconnect the electrical connectors from the crankshaft position sensor, knock sensor, boost pressure sensor, EGR solenoid valve, ignition coil, injectors, canister purge solenoid valve, throttle position sensor, throttle control servo, misfire detection sensor, camshaft position sensor shaft, coolant temperature sensor, coolant temperature indicator sensor and front oxygen concentration sensor, throttle control servo, air conditioning compressor, generator, pressure sensor and starter (pic. 3.53).
Pic. 3.53. Places for connecting connectors and hoses to the 4G13 engine: 1 - connector of the crankshaft position sensor; 2 - knock sensor connector; 3 - boost pressure sensor connector; 4 - connector for the exhaust gas recirculation solenoid valve; 5 - ignition coil connector; 6 - injector connectors; 7 - canister cleaning solenoid valve connector; 8 - throttle position sensor connector; 9 - throttle control servo connector; 10 - connector for the misfire detection sensor; 11 - camshaft position sensor connector; 12 - coolant temperature sensor connector; 13 - connector for the sensor of the coolant temperature indicator; 14 - connector of the front oxygen concentration sensor; 15 - throttle control servo connector; 16 - air conditioner compressor connector; 17 - generator connector; 18 - pressure sensor connector; 19 - starter connector; 20 - vacuum hose of the vacuum brake booster; 21 - vacuum hose; 22 - power steering pump and air conditioning compressor drive belt
- Disconnect vacuum hoses.
- Disconnect the vacuum hose from the brake booster.
- Turn out a bolt and disconnect a wire of connection of the block of cylinders of the engine with «weight».
- Loosen the tension and remove the power steering pump and A/C compressor drive belt.
- Loosen the bolts and remove the power steering pump along with the attached hose and bracket (pic. 3.54).
Pic. 3.54. Removable elements and fastening elements of the 4G13 engine:1- power steering pump and bracket; 2 - air conditioner compressor; 3 - heater hoses; 4 - fuel return hose; 5 - high division fuel hose; 6 - sealing ring; 7 - engine bracket; 8 - engine
Note. Use cord or soft wire to secure the removed power steering pump to the engine compartment so that it does not interfere with engine removal.
- Disconnect a socket, turn out bolts and remove the conditioner compressor together with the connected hoses from an arm.
Note. Secure the removed compressor in the engine compartment with a cord or soft wire so that it does not interfere with the removal of the engine.
- Loosen the clamps and disconnect the heater hoses.
- Loosen the clamps and remove the fuel return hoses.
- Turn out bolts, disconnect a fuel hose of a high pressure and remove a sealing ring.
- Remove the special tool used to remove the transmission from the engine.
- Fasten the engine to the traverse and hang it on a hoist or similar device (pic. 3.46).
- Insert a piece of wood between the jack foot and the engine oil pan and lift the engine slightly to relieve the weight of the engine support, then remove the engine support bracket.
- Check that all wires are disconnected from the engine (electrical connectors), hoses, etc., and then slowly lift the engine up from the engine compartment.
Installation
- Installation is carried out in the reverse order of removal, taking into account the following.
- When installing the engine, make sure that the wires, hoses and wire connectors are not pinched.
- Place a hydraulic jack under the engine (by inserting a block of wood between the jack foot and the engine oil pan) and install the engine support bracket while adjusting the engine position with a jack.
- While supporting the engine with a jack, disconnect the hoist.
- When installing the high pressure fuel hose, lubricate the O-ring with a small amount of clean engine oil (pic. 3.36).
Warning. Do not allow oil to enter the fuel line.
- Slightly turning the fuel hose flange to the right or left, carefully insert it into the fuel line so as not to damage the O-ring. After installation, check that the hose turns smoothly in the fuel line.
- If the hose flange sticks when turning, the cause may be a damaged O-ring. Detach the flange (complete with hose) from the fuel line and check the gasket for damage, then reinsert it and check for smooth turning.
- Screw in the high pressure fuel hose mounting bolts and tighten them to 5 Nm.
- Further installation is carried out in the reverse order of removal.
- Connect and adjust the accelerator cable.
- Install the gearbox.
- Install the radiator.
- Install the hood.
- Install the air filter.
- Install the lower engine mudguard.
- Connect the wire to the negative battery terminal.