Engine assembly — removal and installation (Largus 1)

Removal

Place the vehicle on a two-post lift, apply the parking brake and turn off the ignition.

For vehicles with air conditioning

Perform a complete evacuation of the refrigerant from the air conditioning system.

For vehicles with a "station wagon" body

Tilt the rear row of seats forward (for 5-seater configuration) or the middle row (for 7-seater configuration).

Disconnect and lift the floor trim.

Remove the electric fuel pump hatch cover.

Disconnect connector 1, Figure 2-1, of the rear wiring harness from module 2 of the electric fuel pump.



Start the engine and let it run at idle speed until it stops completely to relieve pressure in the fuel system, ensuring the exhaust gases are removed (exhaust coil with a fan of the SERF/SP type from SovPlym). Turn off the ignition.

Disconnect the ground wire terminal from the battery.

Connect the connector, wiring harness to the electric fuel pump module.



Install the electric fuel pump hatch cover.

Install and secure the floor covering.

Lower the rear (for 5-seater configuration) or average (for 7-seater configuration) row of seats.

Remove air intake pipe 1, Figure 2-2.

For cars with K7M engine:

• remove air filter housing 3.

For cars with K4M engine:

• - remove muffler 1, figure 2-3, intake noise;
• - remove protection 2 of the fuel rail;
• - remove throttle valve block 3.

Operations are common for all vehicle configurations

Remove the battery. Remove the battery tray.

Remove controller 1, Figure 2-4, ECM.

Remove the engine wiring harness fuses and relays from their holders in the fuse box 2.



Remove the 3 engine wire harness from its mounting on the battery shelf.

Place the wiring harness with fuses and relays on the engine.

Remove the front wheels.

Loosen the hub nuts using the tool (rou. 604-01 device, replaceable head 32, ratchet).

Remove the engine crankcase guard.

For cars with K4M engine additionally:

• - remove the front bumper;
• - disconnect the gasoline vapor recovery system hose.

Operations are common for all vehicle configurations

Remove the inner linings and side mudguards.

Unscrew plug 1, figure 2-5, of the drain hole in the gearbox housing 2 and drain the oil (8mm internal square key, technological container).

Drain the coolant.





Disconnect the shoe (two pads - for cars with air conditioning) harness 3 wires from the electric fan 4 of the engine cooling system.

Disconnect the wiring harness from the electric fan of the engine cooling system.

For vehicles with power steering additionally:

Disconnect connector 1, Figure 2-6, of the wiring harness from sensor 2 of the pressure in the power steering system.



Loosen the bolts and nuts securing the power steering pipes:

• - on the upper part of subframe 2, figure 2-7, front suspension (replacement head 10, ratchet wrench);
• - on bracket 3, figure 2-8, fastening of mounted units (for a car with a K7M engine) (replacement head 10, ratchet wrench);
• on cylinder block 3, figure 2-9 (replaceable head 13, ratchet wrench).

Unscrew the cap of reservoir 1, Figure 2-10, of the power steering pump and pump out the working fluid from the system (brush pump, process tank).

Loosen clamp 6, disconnect hose 4 from power steering pump 5 and install plugs in the openings of the pipeline and pump (pliers for elastic clamps Mot. 1202-02, technological plugs).





Loosen clamp 2, disconnect hose 2 from the power steering pump reservoir and install plugs in the holes of the hose and reservoir (pliers for elastic clamps Mot. 1202-02, technological plugs).

Remove the power steering pump reservoir with hose 4 as an assembly.

Remove hose 3 from the holder on the engine cooling system electric fan housing.

Unscrew bolt 1, Figure 2-11, securing bracket 2, unscrew nut 3 of the fitting, disconnect high-pressure line 4 from power steering pump 5 and install plugs in the holes of the line and power steering pump (for a car with a K7M engine) (spanners 10, 17).



For cars with K4M engine additionally:

• unscrew the bolts securing the high pressure line to the gearbox and gearbox support (replaceable head 13, ratchet wrench).

For vehicles with air conditioning system additionally: - disconnect connector 1, figure 2-12, of the wiring harness from refrigerant pressure sensor 2;



- unscrew the bolt securing the pipeline to the air conditioner compressor, disconnect the pipeline from the compressor and install plugs in the holes of the pipeline and compressor (spanner 10, technological plugs).

Operations are common for all vehicle configurations

Disconnect the ball joint 1, Figure 2-13, of the accelerator drive cable from the throttle pipe.

Press the lock 2 and remove the accelerator cable 4 from the bracket 3. Disconnect:

• harness connector from the purge solenoid valve of the adsorber;

• brake booster vacuum hose from intake manifold;
• - crankcase ventilation hose from the intake manifold;
• - fuel pipe 1, figure 2-14, from fuel rail 2.

Caution: For vans, first cover the place where the fuel pipe connects to the fuel rail with a rag and prevent fuel from escaping when disconnecting the fuel line, since the pressure in the fuel line remains.

Loosen clamps 1, Figure 2-15, and disconnect cooling system hoses 2 from the engine (pliers for elastic clamps Mot. 1202-02).



Remove the cooling system hoses 1, Figure 2-16, from the holders 2.



Loosen bolts 1, Figure 2-17, fastenings and disconnect wires 2 "ground" from gearbox 3 (replaceable head 13, extension, ratchet wrench).



Remove the front brakes 1, Figure 2-18.



Loosen nuts 2 securing the ball joint pins of the outer ends 3 of the steering rods and press the pins out of the steering knuckle arms 6 (replacement head 16, ratchet, Tav. 476 device).

Loosen nuts 4 of bolts securing shock absorber struts 5 to steering knuckles, remove bolts 7 and disconnect shock absorber struts from steering knuckles (spanner 18, replaceable head 18, ratchet).

Remove the front wheel drives.

Loosen and remove bolts 1, Figure 2-19, of the upper fastening of the struts 2 of the front suspension subframe to the body (replaceable head 13, ratchet wrench).

For cars with K4M engine additionally:

• loosen the steering gear heat shield mounting bolts and remove the heat shield (replaceable head 13, ratchet wrench).

Operations are common for all vehicle configurations

Loosen the two bolts securing the steering gear to the front suspension subframe (replacement head 18, ratchet handle).

Secure the steering gear to the body (technological hooks).

For vehicles with JH3 gearbox

Disconnect:

• - cable 1, figure 2-20, clutch drive from clutch release fork 2;
• - the clutch drive cable from the clutch drive cable housing stopper.

Remove the protective cover 1, Figure 2-21, of the gear shift lever on the gearbox.

Loosen bolt 2 of the gearbox control drive rod (replacement head 10, ratchet wrench).





Secure the 3rd gearbox control drive rod to the body (technological hook).

For vehicles with JR5 gearbox

Disconnect the joints 1, Fig. 2-22, of the gear selection and shift cables from the gearbox levers 2 (flat head screwdriver);





Disconnect the 3 locks of the gear selection and shift cable housings from the bracket on the gearbox by pressing on the locks from both sides.

Disconnect the pipeline 1, Figure 2-23, of the clutch hydraulic drive from the working cylinder 2 by pressing the lock 4.

Caution: Do not pull the latch. In case of any erroneous action, it is necessary to replace the pipeline.

Drain the brake fluid from the pipeline and plug the holes in the pipeline and the working cylinder of the clutch hydraulic drive (technological capacity, technological plugs).

Operations are common for all vehicle configurations

Remove the rear engine mount.

Disconnect the exhaust system.

Move the exhaust pipe towards the rear of the car and hang it on the body (technological hooks).

Remove the front suspension subframe.

Install a crossbar on the gutters of the engine compartment and hook it with two hooks to the lifting eyes on the engine on the timing belt side and on the flywheel side (crossbar for hanging the engine type RST-500 ES f. "RANGER").

Remove the right engine mount.

Unscrew nut 1, Figure 2-24, studs securing the gearbox to cushion 2 of the left engine mount (replacement head 16, extension, ratchet).

Lower the engine and gearbox assembly to separate it from the left engine mount.



Using a bronze punch, knock out pin 5 of the gearbox mount from the left suspension support cushion and separate the engine with the gearbox assembly from the support cushion (bronze technological punch, hammer).

Unscrew two nuts 4 and remove the left engine mount cushion (replacement head 18, ratchet, extension).

Install a transport trolley under the engine and gearbox assembly (trolley for installation and transportation of the engine - self-made).

Lower the vehicle to the level of the transport trolley, install shock-absorbing pads and lower the engine with gearbox assembly onto the trolley, while excluding damage to the attachments (technological gaskets).

Disconnect the crossbar hooks from the lifting eyes.

Raise the vehicle and remove the engine and gearbox assembly from the engine compartment.

Installation

Operations are common for all vehicle configurations

Install the transport trolley with the engine and gearbox assembly under the vehicle (trolley for installation and transportation of the engine - self-made).

Lower the vehicle to the level of the transport trolley and install the engine mounts.

Install according to the marks on the body made during removal:

• right engine mount;
• left engine mount.

Install:

• front suspension subframe;
• two bolts securing the steering gear to the front suspension subframe (replacement head 18, ratchet handle);
• steering gear heat shield (for cars with K4M engine) (replaceable head 13, ratchet wrench);
• bolts 1, figure 2-19, upper fastening of the front suspension subframe struts (replaceable head 13, extension, ratchet wrench);
• front wheel drives;
• bolts 7, figure 2-18, fastening shock absorber struts 5 to steering knuckles 6 (replacement head 18, ratchet wrench);
• ball joints of the outer ends of 3 steering rods (replaceable head 16, ratchet wrench);
• front brakes 1 (replacement head 18, extension, ratchet wrench).

Tightening torques (torque wrench):

• steering gear mounting bolts to front suspension subframe 105 Nm (10.5 kgf·m) (replacement head 18);
• upper bolts for fastening the front suspension subframe struts 21 N·m (2.1 kgf·m) (replacement head 13);
• shock absorber strut mounting bolts to steering knuckle 105 Nm (10.5 kgf·m) (replacement head 18);
• nuts for fastening the pins of the ball joints of the steering rod ends 37 N·m (3.7 kgf·m) (replacement head 16);
• front brake mounting bolts 105 Nm (10.5 kgf·m) (replacement head 18).

Install ground wires on gearbox (replaceable head 13, extension, ratchet handle).

Tightening torque of bolts 1, figure 2-17, fastening wires 2 "ground" on the gearbox 21 N·m (2.1 kgf·m) (replaceable head 13, extension, torque wrench).

Install the exhaust system.

Install the rear engine mount.

For vehicles with JH3 gearbox

Apply MOLYKOTE 33 grease to bolt 2, Figure 2-21, securing the gearbox control rod.

Article copied from the resource: LADAMAN.RU

Connect the 3rd gearbox control drive rod to the gearbox.

Tightening torque of the bolt securing the gearbox control rod to the gearbox 27.5 N·m (2.75 kgf·m) (replaceable head 10, extension, torque wrench).

Install protective cover 1 on the gear shift lever.

Install the clutch cable.

For vehicles with JR5 gearbox

Install stoppers 3, Figure 2-22, of the gear selection and shift cable housings onto the gearbox bracket.

Attach the joints 1 of the gear selection and shift cables to the levers on the gearbox.

Remove the plugs from the holes in the pipeline and the clutch hydraulic drive working cylinder.

Connect pipeline 1, Figure 2-23, of the clutch hydraulic drive to the working cylinder 2 by pressing the lock 4.

Remove air from the clutch hydraulic circuit.

For vehicles with power steering additionally

Install the power steering fluid reservoir into the body bracket.

Install and connect the high and low pressure power steering lines.

Connect connector 2, Figure 2-6, of the wiring harness to the power steering pressure sensor.

Operations are common for all vehicle configurations

Install the cooling system hoses into the holder.

Connect hoses 2, Figure 2-15, of the engine cooling system with new clamps (pliers for elastic clamps Mot. 1202-02):

• to thermostat housing 3;
• to the coolant supply pipe;
• to the radiator of the engine cooling system.

Join:

• brake booster vacuum hose to intake manifold;
• crankcase ventilation hose to intake manifold;
• fuel supply line 1, Figure 2-14, to fuel rail 2;
• harness connector to the purge solenoid valve of the adsorber;
• retainer 2, figure 2-13, throttle cable sheath;
• ball end 1 drive cable to throttle body;
• wiring harness pads 3, Figure 2-5, to electric fan 4 of the engine cooling system;
• wiring harness to the cooling system fan.

Replace the sealing gasket of drain plug 1 and install the plug with a new gasket. Tightening torque of drain plug 22 Nm (2.2 kgf·m) (8mm internal square wrench, 8mm internal square replaceable socket, torque wrench).

Unscrew the filler plug.

Fill the gearbox with oil. The oil level should reach the lower edge of the filler hole (filling unit C-223-1, transmission oil according to the current "Codifier of the main and auxiliary materials used in the maintenance and repair of LADA vehicles" K 3100.25100.00018-2008, filling rate: for JH3 - 2.8 l; for JR5 - 2.5 l).

Install the filler plug.

Fill the cooling system with liquid.

For vehicles with air conditioning system additionally

Remove the process plugs and connect the pipeline to the air conditioning compressor.

Connect connector 1, Figure 2-12, of the wire harness to refrigerant pressure sensor 2.

For cars with K4M engine additionally:

• connect the fuel vapor recovery system hose;
• install the front bumper.

Operations are common for all vehicle configurations

Install the hub mounting nuts using the tool. Tightening torque of the hub mounting nut 280 N·m (28.0 kgf·m) (rou. 604-01 device, replaceable head 32, ratchet, torque wrench).

Install:

• side mudguards and pads;
• engine crankcase protection;
• front wheels;
• Injection system ECU.

Install:

• fuse holders and relay sockets in block 1, figure 2-4, relay and fuse;
• fuse and relay box cover.

Install the 3-wire engine harness into the mount on the battery shelf.

For cars with K4M engine

Install block 3, Figure 2-3, of the throttle valve.

Install fuel rail protection 2.

Install intake noise muffler 1.

For cars with K7M engine

Install housing 3, Figure 2-2, of the air filter.

Operations are common for all vehicle configurations

Install air intake pipe 1.

Install the battery tray.

Install battery 2.

For vehicles with power steering additionally

Fill the power steering system with working fluid (power Steering Oil Mobil ATF 52475).

Bleed the power steering system by turning the steering wheel from the leftmost position to the rightmost position.

Start the engine and bleed the power steering system by turning the steering wheel from the leftmost position to the rightmost position.

Bring the working fluid level in the power steering pump reservoir to normal.

Make sure there are no leaks of working fluid.

Operations are common for all vehicle configurations

Bleed air from the engine cooling system.

For vehicles with air conditioning system additionally

Charge the refrigerant into the air conditioning system circuit.