Dismantling
Attention! The engine can be dismantled from the car only as part of the power unit (those. complete with transmission). The power unit is lowered and gets out from under the car. In order to freely get the engine in this way, the car must be raised to a height of at least 75 cm (floor to front bumper) and place on stands.
1. Park the vehicle on a firm, level surface. Block the rear wheels, apply the handbrake. Raise the front of the car and place on stands.
2. Remove the front wheels.
3. Loosen the screws and remove all motor shields.
4. Remove the hood (see subsection 13.7).
5. Drain the coolant.
6. Drain the oil from the gearbox, wrap and tighten both plugs.
7. Drain the oil and remove the oil filter, clean and tighten the drain plug.
8. Remove the battery.
9. Remove expansion tank with bracket.
10. Remove the straps.
11. Remove the generator.
12. On vehicles equipped with air conditioning, remove the compressor bolts, move the compressor aside and secure. Do not disconnect air conditioning hoses.
13. Remove the power steering pump (see subsection 12.15).
14. Remove the brake calipers, set aside and secure without disconnecting the hoses.
15. Disconnect the CV joints from the hubs.
16. Disconnect half shafts (see subsection 10.2).
17. Disconnect the gear shift rods and clutch cable from the gearbox.
18. Remove the spar.
19. Disconnect the muffler intake pipe.
20. Remove the radiator with hoses and fans.
21. Disconnect the anti-roll bar (see subsection 12.6).
22. On carbureted engines, remove or disconnect the following parts and assemblies:
- air filter;
- fuel hoses;
- throttle cable;
- carburetor wires;
- vacuum booster hose, cooling systems and other sensor and valve hoses;
- suction manifold rack;
- exhaust sensor connector.
23. On injection engines, do the following:
- remove the air filter duct;
- perform measures to decompress the fuel system, disconnect the fuel hoses from the throttle body;
- disconnect the throttle cable;
- disconnect wiring connectors;
- move the wiring away from the engine.
24. Disconnect all hoses from the suction manifold.
25. Remove the intake manifold stand.
26. Apply identification marks and disconnect the heater hoses and cooling system hoses from the engine.
27. Disconnect the wiring connectors from the ignition distributor, ignition coil and transistor power supply. Release the wiring sleeve from the clips on the cylinder head and take it to the side. Turn away bolts and remove all wires of connection with weight on a head of cylinders and on a soaking-up manifold.
28. Disconnect the speedometer cable and wires from the gearbox.
29. Fasten the hoist hoist to the cylinder head lugs, tension the hoist so that it takes the weight of the power unit.
30. Mark the position of the pinch bolt (indicated by an arrow) on the front support bracket of the power unit, unscrew the nut of the coupling bolt and remove the bolt.
31. Unscrew the nut and remove the rear support pinch bolt (indicated by an arrow). Remove the front support and bracket.
32. Remove the right support and rubber pads.
33. Remove the left support and rubber pads.
34. Make sure that all parts, wires and hoses that may interfere with dismantling are disconnected, removed and laid aside.
35. Roll a cart under the engine and carefully lower the power package. It is advisable to carry out this operation with an assistant, since it will be necessary to tilt the engine slightly so as not to touch the body.
36. Roll the power unit out from under the car.
Removing the checkpoint
1. Fix the removed power unit with wooden blocks, placing it on a clean, level area.
2. Turn away bolts and remove a starter.
3. Remove the gearbox mounting bolts, noting the location of each bolt.
4. Carefully separate the gearbox from the engine, making sure that the weight of the gearbox is not taken up by the input shaft as it exits the clutch disc.
5. Remove the gearbox dowel pins if they are loose.
Installation
1. If the gearbox was removed from the engine, then perform the operations described below in paragraphs. 3–7. If the gearbox has not been removed, then perform the installation, guided by paragraph 8 and below.
2. Apply a thin layer of refractory grease to the splines of the gearbox input shaft.
3. Install pins (if filmed), make sure the release bearing is securely attached to the clutch release fork.
4. Carefully install the gearbox on the engine along the guide pins. When installing, the weight of the gearbox should not be taken by the input shaft.
5. Reinstall the gearbox housing mounting bolts to their original positions and tighten to the specified torque.
6. Install starter.
7. Position the power unit under the vehicle and attach the hoist hoist.
8. Working with an assistant, carefully lift the power package into the engine compartment.
9. Install the rubber cushions on the left support bracket, making sure that the cushion studs fit into the holes in the bracket. Install the support and tighten the bolts to the specified torque. Tighten the pinch bolt nut by hand.
10. Install the pillows on the right body side bracket. Install the support and tighten the bolts to the specified torque. Tighten the pinch bolt nut by hand.
11. Insert the rear support pinch bolt and hand-tighten the nut.
12. Install the side member and tighten the bolts.
13. Install the front support bracket and tighten the bolts. Insert the pinch bolt. Orient the engine so that the support pinch bolt is exactly aligned with the mark made before disassembly, tighten the bolt nut to the specified torque. The distance between the centers of the bolts of the support and the bracket must be 55 (±1,0) mm.
14. Rock the power unit and tighten the remaining pinch bolts to the specified torque.
15. Further, the installation of the power unit is carried out in the reverse order.
16. Make sure the wiring is routed and secured with clips and braces, and that all connectors are connected.
17. Replace the axle shaft seals and install the axle shafts on the gearbox.
18. Connect all hoses of the cooling system.
19. Adjust throttle cable (see subsection 6.1.7).
20. Connect and adjust the clutch cable (see subsection 8.3).
21. Install and adjust drive belts.
22. Change the oil in the engine and gearbox.
23. Fill with coolant.
24. Start the engine and check for leaks.