Contents: Removal ↡ Installation ↡
Removal
1. To lift the hood, pull the locking lever (3) on the left in the direction of the arrow and lift the hood slightly so that the locking lever is not locked. Disconnect the right locking lever and position the engine hood vertically.
Caution: The left locking lever must enter the upper lock.
2. Disconnect the ground (–) cable from the battery.
Warning! This will erase the radio's anti-theft code. Before disconnecting the battery, read the instructions in the section on removing and installing the battery.
3. Disconnect the air hose (arrow) from the air filter and diffuser by slightly twisting the hose and squeezing it lengthwise.
4. Remove the air filter.
5. Unscrew the crossbar (1) with the spacer (2) (arrow).
6. Disconnect the engine hood link.
7. Remove the throttle control cable and set it aside.
8. Disconnect all electrical wires running from the body to the engine, having previously marked them with adhesive tape. For example:
- remove the plug with the thermal switch;
- unscrew the glow plug wire fastenings (key size 10mm) and remove from the holders;
Attention! In some models, the fasteners are inserted into the cable lugs to avoid losing them.
- air Conditioner: Disconnect the electrical wire from the air conditioner compressor.
9. Disconnect and remove the electrical wires from the holders.
10. Disconnect all vacuum hoses that run from the body to the engine compartment. For example:
- unscrew the brake booster vacuum hose from the vacuum pump.
11. Remove the fuel lines, marking them with adhesive tape to facilitate subsequent installation. Blot any spilled fuel with a rag.
12. Raise the car.
13. Remove the lower engine compartment cover.
14. Disconnect the positive cable (X4) from the contact element on the bottom left side of the car and place it on top of the engine.
15. Unscrew the exhaust pipe outlet flange from the exhaust manifold.
16. Drain the coolant.
17. Remove the radiator.
Attention! In cars with air conditioning, immediately after removing the radiator, install a protective shield on the condenser.
18. Disconnect all coolant hoses between the engine and the body, first loosening and completely removing the fastening clamps.
19. Remove the plug of the oil pressure switch (43) and the oil level sensor (44).
20. Disconnect the electrical wires (45) from the starter.
21. Release the harness (46) from the holder.
22. Remove the plug connection from the three-phase current generator.
Installation
1. Check engine mounts, coolant hoses, fuel lines and oil lines for porosity and cracks, replace if necessary.
2. Check the crankshaft radial ball bearing and clutch thrust bearing for ease of rotation, and the clutch bearing for ease of movement.
3. Check whether the thickness and condition of the clutch friction disc linings are sufficient.
4. If it has separated, attach the gearbox to the engine and insert them together into the engine compartment.
5. When installing, the engine should be lowered carefully to avoid damaging the drive shaft, clutch and body.
6. Tighten the bolts connecting the engine and gearbox.
7. Tighten the front bearing mounting bolts by hand.
8. Tighten the rear engine bracket mounting bolts to 45 Nm and the nuts to 70 Nm.*
9. Tighten the front engine bearing bolts to 30 Nm.
10. Remove the jack and disconnect the cable from the engine.
11. Install the driveshaft into the gearbox.*
12. Screw the convector into the middle tunnel.*
13. Screw the side support of the exhaust device to the gearbox.*
14. If the engine was removed without the gearbox, install the starter.
15. Screw the ground wire between the starter and the body.
16. Connect the electrical wires to the starter.
17. Screw on the speed sensor (L3).*
18. Screw in the tachometric inductive sensor if present.
19. Automatic transmission: Connect the gearshift lever to the gearbox and insert the wiring connector for the starter lock and reversing light switches (S 16/1). Install the wiring connector for the kickdown solenoid valve on the right side of the gearbox. Check the adjustment of the gearshift mechanism.*
20. Screw on the clutch sensor hydraulic hose, bleed the air from the clutch sensor.*
21. Manual transmission: Install the fork rods onto the gearshift handles and secure with clamps. Check the adjustment.
22. Automatic transmission: Bolt on the air-to-oil cooler oil lines.
23. Remove the hose clamps.
24. Level adjustment: Screw the oil lines/hoses to the oil injection pump.
25. Tighten the hydraulic hoses of the servo pump to a torque of 30 Nm.
26. Connect all electrical wires, i.e. glow plugs, thermoswitch plug, three-phase generator wire, oil level sensor and oil pressure switch.
27. Secure the phase wire in the holder above the starter.
28. Air conditioning: tighten the refrigeration compressor to 25 N·m. Install the ribbed V-belt.
29. Install the radiator.
30. Install all coolant hoses and secure connections.
31. Check the coolant for antifreeze and add more.
32. Bolt the exhaust manifold to the exhaust pipe outlet flange.
33. Connect the positive cable (X4) to the connecting element located on the lower left side of the vehicle.
34. Install the lower engine compartment cover.
35. Lower the car.
36. Install the throttle control cable and adjust it.
37. Insert the rod into the engine hood.
38. Screw in the front cross support beam with the spacer.
39. Insert the fuel lines according to the markings on them.
40. Screw the brake booster vacuum hose to the vacuum pump.
41. Install all vacuum hoses leading to the engine.
42. Check the oil level in the gearbox and top it up if necessary.
43. Fill the hydraulic oil for the power steering, bleed the air from the booster.
44. Clean the air filter and replace it if necessary.
45. Install the air filter.
46. Install the air hose.
47. Connect the ground wire to the battery.
48. Bring the engine to operating temperature, check the brake fluid level and check the tightness of all hose connections.
49. To close the engine hood, pull the locking lever at the left hinge and slowly lower the hood until the lever locks into place.