Engine 1.25/1.4 l
Since it is impossible to take into account all the variations during removal, it is recommended to mark each wire with adhesive tape before removal. Please note the instructions for the 1.3L engine, diesel and Ford KA model at the end of the section.
Necessary tools and equipment:
- Puller for steering rod joints.
- A lift with a towing device or a mounting stand.
Removal
Remove the battery and battery console.
Caution: When the battery is disconnected, the data in the electronic memory units is erased. See the instructions in the chapter "Electrical equipment".
Remove the air filter and air hose from the throttle valve fitting.
Raise and support the vehicle, remove the lower engine compartment cover.
Drain the oil from the gearbox.
Engage fourth gear on the gearbox.
[Article is based on website data: Mazbook.ru]
Loosen the clamp bolt (2) and pull the gearshift rod off the gearbox shift shaft. Loosen the bolt and remove the stabilizer (1), marking the installation position of the washer to avoid errors during reinstallation
Unscrew the bolts and remove the spacer between the engine and the mount from the bottom of the body.
Remove both drive shafts.
Press the wire clamp out of the mount on the gearbox. Disconnect the reverse light switch plug.
Remove the vacuum hose from the EGR valve (on the exhaust manifold).
Unscrew the speedometer drive shaft/speed sensor from the gearbox.
Disconnect the hydraulic line from the slave cylinder on the gearbox. To do this, pull the fastening bracket out of the connection (1) and pull the wire off. Press the wire out of the guide (2).
Caution: Use a rag to collect any leaking brake fluid. The rules for handling brake fluid are described in Chapter "Brake system".
Close the open pipe with a plug or cap to prevent dirt from getting inside.
Attach the engine to the lift with a cable or chain.
Raise the engine to relieve the load on the engine mounts.
Unscrew the bolts securing the left support of the power unit (from the gearbox side).
Loosen the bolts/nuts securing the right engine support.
Carefully lower the power unit (engine/gearbox) by about 10 cm.
Remove the mounting bolts from the throttle body.
Lightly support the gearbox with a jack and a wooden block.
Remove the three front gearbox flange bolts.
Unscrew the rear bolts of the gearbox flange - this will also remove the gearbox ground wire.
Slightly lift the gearbox and use a crowbar to push it away from the engine.
Carefully remove the gearbox.
Installation
Check the clutch before installation.
Check the ease of movement of the clutch release bearing. If, before removing the gearbox, noise from the release bearing appeared when pressing the clutch pedal, it must be replaced.
Clean the gearbox input shaft splines and lightly lubricate them with molybdenum-based grease. Do not apply too much grease, otherwise it will be squeezed out onto the clutch working surfaces, which will cause poor clutch operation.
Check whether both dowel pins for centering the engine/gearbox are present in the cylinder block, insert if necessary. Align the intermediate plate with both dowel pins.
Lift the gearbox and insert it horizontally into the clutch. If the gearbox input shaft does not fit into the clutch driven disc during installation, turn the input shaft slightly by turning the drive shaft flange by hand.
Insert the bolts connecting the engine and gearbox and tighten them one by one to a torque of 45 Nm. Secure the ground wire to the upper bolt of the gearbox flange.
Screw the speedometer drive cable/speed sensor into the gearbox.
Carefully lift the power unit into the engine compartment, aligning the engine correctly.
Install the right and left engine mounts, securing them with new nuts.
Caution: Nuts on left engine mount (from the gearbox side) tighten by hand 5-6 turns, but do not tighten.
Tighten the right engine mount nuts to 70 Nm.
Unhook the engine from the hoist or winch.
Install the spacer and tighten its bolt on the mount to a torque of 70 Nm, on the gearbox - to a torque of 50 Nm.
Align the engine mounts by vigorously rocking the engine so that they sit without tension.
Now tighten the left engine mount nuts (from the gearbox side) torque of 70 Nm.
Install the holder (mount) on the throttle body. Attach the hose to the EGR valve and the plug to the transmission reverse light switch.
Install the hydraulic line on the clutch slave cylinder. To do this, pull out the fastening bracket in the connection (1), push the line in and reinstall the bracket. Press the line into the guide (2).
Remove air from the clutch hydraulic system.
Install the stabilizer with a washer on the gearbox housing and tighten the bolt to a torque of 55 Nm.
Clean the connection points of the gear shift rod and gear shift shaft and connect the parts.
Adjust the shift mechanism.
Install both drive shafts with new retaining rings.
Install the battery tray, tightening the three mounting bolts to a torque of 25 Nm.
Install the battery.
Set the clock readings, enter the required codes.
Install the air filter.
Check the oil level in the gearbox and engine and top up if necessary.
Start the engine and warm it up while driving to operating temperature. Check the tightness of the hose connections.
Install the lower engine compartment cover.
Specially for 1.3L engine
Remove the starter.
Remove the front exhaust pipe.
Hook the engine and loosen the engine mounts.
Note: Engine mounts on Ford KA models are shown at the beginning of the chapter "Engine".
Specially for diesel engine
Remove the starter.
Lower the engine/gearbox assembly slightly using a hoist and remove the engine mount bracket.
Unscrew the upper resonator mounting bolts.
Unscrew the lower resonator mounting bolt.