Dismantling
Attention! The engine can be removed from the vehicle as part of the power unit (i.e. assembled with the transmission), then the transmission is separated from the engine for major overhaul.
The power unit is lowered and removed from under the car. In order to freely remove the engine in this way, the car must be raised to a height of at least 75 cm (from the floor to the front bumper) and place on stands.
1. Perform the operations described in pp. 1–10 of subsection 3.2.2.3.
Injection engines with preliminary preparation of fuel mixture
2. On injection engines with pre-mixed fuel, remove the air filter.
3. Perform decompression of the fuel system, disconnect the fuel supply hose and the return fuel hose from the throttle chamber (plug all openings to prevent fuel loss and dirt ingress).
4. Disconnect the throttle cable.
5. Disconnect the wiring connectors from the throttle body, intake manifold and other components.
6. Disconnect the brake booster vacuum hose, coolant hose, valve vacuum hoses, and crankcase ventilation hoses mounted to the intake manifold.
7. Remove the intake manifold support bracket.
8. Remove the exhaust pipe.
Injection engines with direct fuel injection
9. On direct fuel injection engines, remove the air cleaner duct.
10. Perform fuel system decompression procedures, disconnect the fuel supply hose and the return fuel hose from the throttle chamber (plug all openings to prevent fuel loss and dirt ingress).
11. Disconnect the throttle cable.
12. Disconnect the wiring connectors from the throttle body, intake manifold, and other components. Move the wiring away from the manifold and cylinder head so that it does not interfere with engine removal.
13. Disconnect the brake booster vacuum hose, coolant hose, valve vacuum hoses, and crankcase ventilation hoses mounted to the intake manifold.
14. Remove the intake manifold support bracket.
15. Remove the exhaust pipe.
16. Loosen the clamps and disconnect the heater hoses and other cooling system hoses from the engine, after marking the original location of each hose.
17. On vehicles equipped with air conditioning, unscrew the compressor mounting bolts and move the compressor to the side. Tie the compressor to the body so that its weight is not supported by the air conditioning system pipes and hoses. Do not disconnect the hoses from the air conditioner.
18. Remove the axle shafts with cardan joints (see subsection 10.2).
19. Disconnect the gear selector lever cable from the transmission.
20. Disconnect the downshift cable from the throttle body.
21. Disconnect the wiring connectors from the transmission.
22. Disconnect the transmission fluid cooler hoses from the transmission.
23. Disconnect the speedometer cable.
24. Bring the hoist hoist and secure it to the cylinder head brackets, tighten the hoist so that it supports the weight of the power unit.
25. Loosen the tightening and unscrew the nut of the rear support tie bolt of the power unit, remove the bolt from the support.
26. Unscrew the four bolts securing the central side member, remove the side member by pulling it out from under the power unit. Remove the limiting ring installed between the rear support of the power unit and the bracket.
27. Unscrew the nut and remove the right powertrain support tie bolt, then unscrew the support mounting bolts and remove the support from the engine compartment. If the rubber cushions installed on both sides of the support bracket on the body side are loose, remove the cushions.
28. Unscrew and remove the left powertrain support tie bolt. Then unscrew the three bolts securing the support to the transmission housing and move the support to the side. Remove the cushions installed on both sides of the support bracket.
29. Once again, make sure that all parts, wires and hoses that may interfere with the removal of the power unit are disconnected or removed. Also make sure that no other parts of the car will be damaged when removing the unit (for example axle shafts).
30. If you have a low trolley, roll it under the engine, which will make it easier to remove the removed unit from under the car. Lower the power unit, making sure not to damage or catch nearby parts. It is advisable to perform this operation with an assistant, since you will need to tilt the unit slightly to avoid touching the body panels. Be extremely careful when lowering the engine.
31. Roll the power unit out from under the vehicle.
Removal the transmission from the engine
1. Secure the removed power unit with wooden blocks, placing it on a workbench or on a clean, level area in the workshop.
2. Loosen the bolts and remove the starter from the transmission housing.
3. Unscrew the bolts and remove the mounting plate from the oil pan flange, after which access to the torque converter mounting bolts will open. Unscrew the first accessible bolt, then, turning the crankshaft with a socket wrench by the pulley, unscrew the remaining bolts of the torque converter to the drive disk one by one, as you access these bolts. There are four bolts in total.
4. Take measures to prevent the torque converter from falling when removing the transmission by securing the torque converter with a piece of metal strip, bolting the strip to one of the starter mounting holes.
5. Make sure the power unit is securely fastened and unscrew the transmission housing mounting bolts to the engine. Mark the location of the bolts (and on some cars and the corresponding brackets), so that they can be installed in their original places during assembly.
6. Carefully separate the transmission from the engine. If the guide pins in the transmission case or in the cylinder block swing freely, remove them and store them for later installation in their original place.
Installation
1. If the gearbox was removed from the engine, then perform the operations described below in paragraphs 2–7. If the gearbox was not removed, then follow p. 8 and so on.
2. Before installation, make sure that the torque converter is correctly installed on the transmission. This can be checked by measuring the distance from the holes for the torque converter mounting bolts to the split plane of the transmission housing, which should be at least 15.9 mm.
3. Install the pins onto the engine or transmission (if they were removed).
4. Carefully install the transmission onto the engine using the guide pins. Tighten the transmission case mounting bolts, making sure all brackets are installed correctly, and tighten the bolts to the specified torque.
5. Remove the strip that holds the torque converter from falling, installed before removal. Align the holes in the torque converter with the holes in the drive disk and tighten the mounting bolts.
6. Tighten the torque converter bolts to the specified torque, install the mounting plate onto the oil pan and secure with bolts until tight. 7. Install the starter and tighten the bolts.
8. Place the power unit under the vehicle and attach the engine hoist to the engine brackets.
9. Working with an assistant, lift the power unit into the engine compartment, being careful not to hit any nearby components.
10. Install rubber cushions on the left powertrain support bracket, making sure that the cushion pins enter the bracket holes. Install the support in place, tighten the support-to-transmission mounting bolts and tighten them to the specified torque. Insert the tie bolt and tighten the nut by hand.
11. Install the rubber cushions on the right suspension bracket on the body side, making sure that the cushion pins enter the holes in the bracket. Install the support on the bracket and tighten the bolts to the specified torque. Insert the tie bolt and tighten the nut by hand.
12. Make sure all rubber pads are in place and install the limiting ring on the rear support of the power unit. Install the center side member, align it with the engine support and tighten the bolts, having previously put washers on them. Tighten the side member bolts to the specified torque.
13. Insert the rear support pinch bolt and tighten the nut by hand.
14. Rock the power unit back into place, then tighten the front, right and left support tie bolts to the specified torque.
15. Next, the installation of the power unit is carried out in the reverse order.
16. When installing, make sure that the wiring is laid along the previous routes and secured with clamps and staples, and that all connectors are connected.
17. Replace the axle shaft seals and install the axle shafts together with the joints on the gearbox (see subsection 9.1.3).
18. Connect all cooling system hoses and secure with clamps.
19. Adjust the throttle cable (see subsection 6.1.7).
20. Connect and adjust the gear selector lever cable and downshift cable (see subsection 9.2.4).
21. Install and adjust the drive belt(s) (see subsection 2.3.1.3).
22. Change the oil in the engine and gearbox, recommended grades of oil, fluids and filling volumes (see subsection 1.12.7).
23. Fill with coolant.
24. When finished, start the engine and check for leaks.