S40/V40
1. General information
2. Operation and maintenance of the car
3. Design and technical characteristics of engines
4. Repair of the engine
4.1. Removal of a head of the block of cylinders
4.2. Installation of a head of the block of cylinders
4.3. Removal and installation of support of the engine
4.4. Removal of the engine
4.5. Dismantling and assessment of a condition of details of the engine
4.6. Assembly and installation of the engine
5. Transmission
6. Brake system
7. Forward suspension bracket and steering
8. Back suspension bracket
9. Control system of the Fenix 5.1 engine
10. Electric equipment. Conducting and components
11. Body
12. Schemes of electric equipment
 



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4.4. Removal of the engine

For removal of the engine make the following:
1) remove the rechargeable battery
2) merge liquid from the engine cooling system;
3) remove a radiator for what:
— disconnect the socket, turn out two bolts of fastening of a casing of the fan from a radiator and remove an elektrovenilyator of cooling of the engine;

Fig. 4.22. Places of fastening of branch pipes of a radiator


— disconnect the top and lower branch pipes from a radiator (fig. 4.22);
— disconnect two hoses from a broad tank;
— disconnect a hose of the automatic transmission;
— turn out four bolts of fastening of a radiator;
— remove a radiator;

Fig. 4.23. A forward rack with the removed wheel


4) Remove both forward wheels (fig. 4.23);
5) on the cars equipped with the automatic transmission:
— remove spherical hinges of steering drafts from fastenings of rotary fists, brackets of brake tubes, ABS system wire brackets;
— turn out bolts of fastening of shock-absorbers on rotary fists on both sides;

Fig. 4.24. Removal of a half shaft


— remove the left half shaft, use the taking fork of 999 5462 (fig. 4.24);
— remove the heat-insulating screen and a reception pipe of the muffler;
— turn out bolts of fastening of support of the engine in front and behind;
— remove engine support from the distributor;
— remove the lower beam of the engine;
— disconnect the speedometer socket;
6) on the cars equipped with the mechanical transmission:
— remove the oil pallet of the transmission;
— merge oil and put a drain stopper with a new sealing ring;
— remove a guard under a longeron from the transmission;
— turn out three bolts, take out the left half shaft and hang up it on a stabilizer bar;
— remove a spring bracket from a flexible shaft of a speedometer and disconnect a cable;
— turn out bolts of fastening of the transmission and engine in front and behind;
— remove the right half shaft (take out the fixing forelocks) and hang up it on a stabilizer bar;
— remove the gear shifting lever from the transmission;
7) lower the car;
8) remove the shelf of the rechargeable battery;

Fig. 4.25. Places of fastening of a hose of an intake of air to the air filter and temperature sensor (are shown by shooters)


9) disconnect an air intake hose from the air filter / the air pump (fig. 4.25);
10) disconnect the socket of the sensor of temperature of the entering air;

       NOTE
If the car is equipped with system of maintenance of the set speed, it is necessary to disconnect a vacuum hose and wires from the vacuum pump.


Fig. 4.26. Places of fastening of hoses (are shown by shooters)


11) disconnect an inlet hose of the air valve (fig. 4.26);
12) disconnect a hose of the air valve of idling;
13) disconnect a hose from the air supply pump to an inlet air hose;
14) disconnect a flame arrester hose from an inlet air hose;
15) disconnect a hose of the valve of production of air;
16) remove a hose of preliminary heating;
17) turn out bolts from a casing of the air filter;
18) lift knot of the air filter and remove it;
19) remove a cable of a butterfly valve from a cam;
20) disconnect two hoses of a heater and a hose of a radiator sideways of the engine;

Fig. 4.27. Hose of the amplifier of a brake


21) disconnect a hose of the amplifier of a brake from the engine (fig. 4.27);
22) disconnect a vacuum tube from the EVAP system pump;
23) remove a gear shifting cable arm;
24) on the cars equipped with the automatic transmission:
— disconnect the socket;

Fig. 4.28. Gear shifting cables


— disconnect a gear shifting cable from the transmission (fig. 4.28);
— by means of pincers of Seeger, or the similar tool disconnect two hoses of the oil heater from the transmission;
25) remove the fixing bracket from a tube on the working cylinder of coupling;
26) remove the working cylinder of coupling;
27) remove a mass wire from the rechargeable battery on the transmission;
28) take off a belt of the drive of auxiliary units;
29) turn out five bolts of the pump of the amplifier of steering and take the pump aside;
30) remove the conditioner compressor, for this purpose:

Fig. 4.29. Fastening of the compressor of the conditioner


— remove fastening of conducting from the engine (fig. 4.29);
— turn out four bolts of fastening of the compressor of the conditioner;
— remove the compressor and incline it forward as far as possible;
— remove fastening of a tube of the conditioner of air over an engine support;
31) remove plaits of conducting of the engine;

Fig. 4.30. Places of points of fastening of a plait of conducting: 1 — the sensor of pressure and temperature of oil;
2 — the conditioner compressor; 3 — the generator; 4 — temperature sensor; 5 — the detonation sensor; 6 — the air valve of idling; 7 — nozzles; 8 — coils; 9 — the sensor of position of the camshaft; 10 — the sensor of frequency of rotation of a bent shaft; 11 — the automatic transmission;
12 — the weights plugs; 13 — a potentiometer of a butterfly valve


32) disconnect all sockets from the engine;

       NOTE
Mark the provision of all points of fastening of a plait of conducting shown in fig. 4.30.

33) disconnect a vacuum hose of the sensor of pressure of air;
34) disconnect a vacuum hose from the electromagnetic valve of the air pump;

Fig. 4.31. The socket from a positive wire of the rechargeable battery


35) disconnect the plug of a wire and the socket from a positive wire of the rechargeable battery (fig. 4.31);
36) turn off a nut from the plastic holder of conducting;
37) remove the distributor block;
38) put on nozzles of the holder 999 5533.
39) lift and put sideways the block of distribution of fuel and a nozzle;
40) disconnect a vacuum hose from pressure regulator;
41) disconnect brackets of wires of the block of distribution of fuel;
42) close openings of nozzles;

       PREVENTION
Do not damage nozzles of nozzles and raspylitelny needles.


Fig. 4.32. Installation of lifting eyes 999 5185, 999 5186 and lifting beam 999 2810


43) establish lifting eyes of 999 5185 and 999 5186 (fig. 4.32);
44) lift the engine to unload support;
45) take out axial bolts of support of the engine;
46) put the compressor of the conditioner on a stretcher;
47) remove fastening of the engine from the transmission;
48) take out a bolt of fastening of the engine on the party of the distributor;
49) lift the engine by means of lifting beams 999 2810;

       NOTE
You watch closely that the power unit did not touch a body or other equipment.

50) remove the automatic transmission:
— turn out bolts of fastening of the hydrotransformer;
— turn out bolts of fastening of the engine/transmission, remove a box;
51) remove the mechanical transmission:
— turn out bolts of fastening of the engine/transmission;
— accurately remove the check point, watching that it did not hang on shlitsevy connection, remove a main shaft of the check point and the conducted disk;
52) remove a drive plate and a flywheel, for this purpose:
— use a gear clamp 999 5112 for fixing of a flywheel from a provorachivaniye;
— turn out bolts of fastening of a drive plate;
— remove a drive plate;
— turn out bolts of fastening of a flywheel;
— remove a flywheel;
53) install the engine on the stand. Use the floor stand 999 2520 and a clamp 999 5297;
54) remove the lifting equipment;
55) remove from the engine from a box of change of transfers:

Fig. 4.33. Arrangement of some equipment: 1 — a hose of cooling liquid;
2 — the sensor of frequency of rotation of a bent shaft;
3 — ignition coils (2 pieces) and wires of spark plugs; 4 — the sensor of position of the camshaft; 5 — the lower hose of a radiator


— ignition coils (2 pieces) (fig. 4.33) and wire of spark plugs;
— sensor of position of the camshaft;
— lower hose of a radiator;
— hose of cooling liquid;
— sensor of frequency of rotation of a bent shaft;
56) remove from the engine from an exhaust collector (fig. 4.33):
— lifting eyes;
— heat-insulating screen and plate of a preliminary heater;
— final collector;
— tube of cooling liquid;
— fastenings of a fuel-supply line;
— right support of the engine.
57) remove from the engine from an inlet collector:
— arm of fastening of auxiliary units and generator;
— temperature sensor;
— inlet collector, detonation sensor, (moment of an inhaling of 20 N · l);
— masloulovitel and hose;
— the maslomerny probe with a tube;
— starter;
— forward support of the engine.


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4.5. Dismantling and assessment of a condition of details of the engine