A. Direction of movement; 1. Intake manifold; 2. Thermostat housing; 3. Exhaust manifold; 4. Power steering pump; 5. Generator; 6. Intermediate roller; 7. Belt tensioner; 8. Air conditioning compressor; 9. Crankshaft pulley; 10. Oil pan; 11. Camshaft position sensor; 12. Oil pump; 13. Water pump.
The engine is removed together with the gearbox down. To remove the engine, you need a hoist or winch.
Since some connections at the bottom of the car must be loosened during removal, the car must be jacked up and supported by four stands. Before starting work in the engine compartment, cover the wings with a piece of protective fabric.
Depending on the year of manufacture and vehicle equipment, electrical wires, hoses for vacuum and coolant may be located in the engine compartment in different ways. To avoid confusion during subsequent installation, it is necessary to mark all necessary wires and hoses before removal. Specific instructions for the Ford KA model are given at the end of the section.
Necessary additional tools and accessories:
- Tie rod joint puller.
- Winch with tow hitch or mounting stand.
- Belts for mounting the engine on the assembly stand.
- Molybdenum disulphide grease (MoS2).
- Tapes for wire harnesses.
Removing
Disconnect the negative cable from the battery with the ignition off.
Attention: This will erase the data from the electronic memory blocks. See instructions in chapter «electrical equipment».
Remove the battery.
Loosen the bolts and remove the battery tray.
Drain coolant.
Remove the fan/thermal switch plug at the bottom left of the heatsink.
Loosen the intake pipe clamps on the air filter and on the intake manifold, remove the intake pipe.
Remove the following coolant hoses from the engine by first squeezing the clamps with a special tool or combination pliers and sliding them back:
- hose (2) from the radiator to the thermostat housing. Open the wire clamp (1), as it shown on the picture;
- hose at the top of the radiator;
- two hoses on the radiator at the bottom right;
- hose on the water pump.
Pull off the heater hose at the coolant connector by compressing the quick coupling by hand.
Unhook the rope (cravings) gas on the throttle body and from the support, set it aside.
Remove the electrical wires from the engine by cutting the connecting tapes and first marking the positions of the wires.
- Two plugs (1).
- Plug connection for lambda probe (located in the exhaust manifold).
- Coolant temperature sensor plug on the cylinder block.
- Speed sensor plug on the bulkhead of the engine compartment.
- Disconnect wire «masses» on the front of the gearbox.
- Disconnect the generator wires.
- Disconnect wires from starter.
Disconnect the vacuum hose (2) for the brake booster.
Disconnect the vacuum hose (3) for activated carbon filter system. If necessary, cut the plastic clamp and replace it with a screw clamp during installation.
Remove the oil filler plug. Remove the crankcase ventilation hoses from the oil filler neck. Put the cork back on.
Unscrew the speedometer drive shaft from the gearbox.
Raise and support the vehicle.
Remove the lower engine compartment cover.
Remove V-belt.
Remove the three bolts securing the power steering pump to the holder through the pulley holes. The picture shows the top two bolts.
Remove the power steering pump mounting bolt from the rear and attach the pump to the body with a wire.
Attention: The hoses remain connected.
Remove the bottom cover for the V-belt.
Loosen the bolts and remove the bottom radiator cap.
Vehicles with air conditioning
Warning: The refrigerant line of the air conditioner must not be opened. The refrigerant can cause frostbite if it comes into contact with the skin.
In order to be able to remove the engine without opening the refrigerant line, the following must be done.
- Loosen the screws and remove the air conditioner condenser from the radiator.
- Unscrew the two bolts of the radiator cross member on both sides.
- Carefully pull the radiator and radiator fan downwards.
- Fasten the capacitor with wire to the body - it remains in the car.
- Remove the plug (1) from the air conditioning compressor. Unscrew the air conditioning compressor bolts together with the holder (2) and secure it to the body with wire so that the lines and hoses for the refrigerant are not stretched.
Attention: The pipes and hoses of the air conditioner must not be twisted, kinked or bent.
Remove the front exhaust pipe.
Engage fourth gear on the gearbox.
Remove shift rods from gearbox.
In the lower part (on the bottom) unscrew the bolts and remove the spacer between the engine and the power unit mount.
Disconnect the hydraulic line from the clutch slave cylinder on the gearbox. To do this, pull out the fastening bracket in the connection (1) and pull out the pipeline. Pull the pipeline out of the guide (2).
Attention: Collect leaking brake fluid with a cloth. Features of handling brake fluid are described in chapter «Brake system».
Seal the open pipeline with a plug or cap to prevent dirt from getting inside.
Remove the fuel supply and return hoses from the fuel distributor by compressing the quick coupling by hand. To avoid confusion, mark the hoses with adhesive tape.
Warning! The fuel system is under pressure! Before loosening the hose connections, place thick rags under them. This will allow the hoses to be safely removed. In this case, protective goggles should be used.
Remove both drive shafts.
Substitute mounting table (stand) under the engine by placing wooden blocks between the table and the power unit.
Fasten the engine with a belt on the mounting table (booth).
If there is no mounting table, then hang the engine on the chain on the lifting device.
Raise the engine so that the engine mounts are unloaded.
Loosen the bolts on the left side (fastening) power unit (from the gearbox side).
Loosen the right engine mount bolts.
Carefully lower the power unit.
Check if all hoses and wires that go from the engine to the body are disconnected.
Attention! Lowering the engine must be done very carefully so as not to damage the detna of the body!
Lower the power unit down from the engine compartment.
Installation
Check coolant, oil and fuel hoses and engine mounts for pores and cracks and replace if necessary.
With a high mileage of the car, separate the engine and gearbox, check the clutch disc for the thickness of the lining and their general condition. In case of premature wear or high mileage, the entire clutch must be replaced.
Check the release bearing in the slave cylinder for wear and replace if necessary.
Clean input shaft splines and lubricate them lightly with MoS grease.
Check whether there are guide bushings for centering the engine and gearbox in the cylinder block and, if necessary, insert these bushings.
Connect the engine and gearbox. In doing so, turn the input shaft of the gearbox so that it enters the clutch and the flywheel. You can also rotate the crankshaft by its central bolt.
Tighten engine/gearbox connecting bolts to 45 Nm.
Carefully lift the power unit into the engine compartment while pointing the engine in the desired direction.
Install new nuts on the left and right engine mounts.
Attention: Nuts on the left engine mount (from the gearbox side) hand tighten 5-6 turns until tight.
Tighten nuts on right engine mount to 70 Nm.
Unhook the lifting device from the engine.
Tighten the spacer bolts on the mounting to 70 Nm, on the gearbox to 50 Nm.
Align the engine mounts by rocking strongly so that they are seated without tension.
First tighten the nuts on the left engine mount (from the gearbox side) torque 70 Nm.
Install the hydraulic line to the clutch slave cylinder. To do this, pull out the fastening bracket in the connection (1), push in the pipeline and reinsert the bracket. Press the pipeline into the guide (2).
Install both drive shafts.
Install the shift rods on the gearbox and adjust the shift mechanism.
Install the front exhaust pipe.
Install the radiator.
Vehicles with air conditioning: Fasten the condenser to the radiator with two bolts, tightening them to 15 Nm. Fasten the compressor with four bolts on the engine, tightening them to a torque of 25 Nm.
Put the coolant hoses on the engine and on the heater, secure them with clamps.
Remove the wire and fasten the power steering pump to the holder with four bolts, tightening them to a torque of 25 Nm.
Install V-belts.
Install the lower V-belt cover.
Install the speedometer cable to the transmission.
Lower the car.
Connect all electrical wires to the engine and gearbox. Fix the wires in the holders at the previously marked places.
Fit and secure the fuel supply and return hoses to the fuel distributor.
Attention! To avoid confusion during installation, use the marks made earlier.
Put on all vacuum hoses, securing them, if necessary, with clamps.
Attach the crankcase ventilation hoses to the oil filler neck.
Attach the air inlet hose to the air filter and inlet pipe, secure with clamps.
Attach cable (cravings) management «gas» on the throttle body and support and adjust it. О Install the battery tray and secure it with three bolts (tightening torque - 25 Nm).
Install the battery.
Check the oil level in the engine and gearbox and top up if necessary.
Check the concentration of the coolant and fill it into the system.
Bleed the air from the hydraulic clutch.
Install the lower engine cover.
Start the engine and warm it up to operating temperature, monitor which on the coolant temperature gauge.
Finally, drive at least 5 km more to be sure that the required temperature has been reached.
Check the tightness of all hose connections.
Set the clock, enter the codes into the radio.
Especially for Ford KA
Loosen the locknut five turns (2) on the suspension strut (3) left and right, while holding the shock absorber rod with a hex wrench (1). The tightening torque during installation is 50 Nm.
Remove the air filter housing.
Loosen the spacer bolts on the gearbox and on the holder.
Unscrew the two fastening nuts and remove the left gearbox support.
Note: When installing, the protrusion (arrow) on the support must fit into the corresponding recess.
Unhook the wire holder and unscrew one bolt and two nuts of the right engine mount.
Lower the engine until the coolant hose on the water pump can be removed. Remove the hose and then completely lower the engine.