Removing the engine
It is recommended to remove the engine and gearbox together as a single power unit and then disconnect the engine from the gearbox. The following work is carried out in the same way for all types of engines, additional instructions are given for vehicles with automatic transmission. When lifting the power unit, it must be tilted at a 45°angle to allow exit from the engine compartment of the gearbox. The power unit weighs more than 200 kg, so when removing it, special care must be taken not to damage the body surfaces or paintwork.
- Put protective covers on the fenders of the car to avoid damage. Release the locking lever on the left bracket of the hood and lift the hood up until the lever disengages. Then release the locking lever on the right hood bracket. Move the hood to the vertical position. On fig. 9. Shows the position of the latch.
Pic. 9. Open the hood to the 90°position.
- Disconnect the negative cable from the battery and remove the battery together with the mounting frame.
- Open the cap of the cooling system. Coolant temperature must not exceed 90°C
- Remove the coolant drain plug on the right and left sides of the cylinder block. At the same time, do not confuse the plugs with the crankshaft main bearing cap bolts. On fig. 10 and 11 show the coolant drain plugs and the arrows show the cap bolts.
- Remove heatsink and fan. To do this, remove the rubber supports and radiator mounting brackets. Remove the radiator, then remove the oil cooler. In vehicles with automatic transmission, before removing the radiator, remove the hoses from the gearbox oil cooler and plug the holes in the hoses.
- Remove expansion tank.
- Remove the exhaust system assembly.
- Suck the oil out of the power steering reservoir and disconnect the hoses from the power steering pump.
- Disconnect all hoses and pipes of the cooling system, lubrication system, power supply system and wires between the vehicle body and the engine. It is advisable to mark the pipelines.
Pic. 10. Location of the coolant drain plug (1) on the left side of the cylinder block. Do not loosen the bolts indicated by the arrows.
Pic. 11. Location of the coolant drain plug on the right side of the cylinder block. Do not loosen the bolts indicated by the arrows.
- Disconnect the fuel control rod.
- In vehicles with air conditioning, the refrigerant must be drained. The work must be done very carefully. In the absence of experience, technical assistance and guidance should be sought. Then disconnect the hoses from the double piping.
- Unscrew the bolts of the front engine mounts in the lower part of the body on the left and right; to unscrew, use an extension with a hinge that starts from below.
- Attach a lifting cable to the engine and put it on the hook of a crane or other lifting device. Tighten the cable slightly.
- In vehicles with adjustable wheel suspension, unscrew the four bolts securing the suspension hydraulic pump together with the connecting pipes, remove the pump and put it aside (see fig. 12). Remove pump drive parts.
- Remove the cross member of the rear engine support together with the support; before removing, mark the location of the cross member relative to the body.
- Detach propshaft from gearbox and move back. Do not loosen the clamping nut on the cardan shaft. Section 11 provides further guidance on these works.
Fig. 12. The arrows show the mounting bolts of the adjustable wheel suspension hydraulic pump.
- Disconnect wires from gearbox (reverse light switch wire). In automatic transmissions, disconnect the wires from the Kickdown device. Loosen one side of the steering damper mounting and turn it.
- Remove the engine mount dampers.
- Loosen the gearbox-to-engine bolts.
- Described in section 3.1 work is associated with the subsequent removal of the gearbox.
- Place a jack under the gearbox (install a wooden spacer between the jack base and the gearbox).
- Remove the protective mudguard of the body tunnel.
- Carefully lift the engine by tilting it at an angle of approximately 45°. Raise the gearbox with a jack, following the movement of the engine. Work on lifting the engine should be carried out slowly with constant monitoring, make sure that there are no connected wires or pipelines, especially if additional equipment is installed on the vehicle. Pay special attention to the fastening of the cable.
Engine installation
The engine is installed in the reverse order, observing the following points:
- Do not install units on the engine before installing it on the mounting supports and free sagging of the cable. Check the position of the engine mounts and tighten the mounting bolts to a tightening torque of 30 Nm.
- Tighten the coolant drain plugs.
- Attach cardan shaft.
- Check ignition timing.
- Check engine tightness.
- Remove oils and grease from rubber parts.
- Tighten all bolts and nuts to the required torque (see section 19).
- Check the freezing point of the drained coolant and, if correct, it can be reused.
- Check the cooling system together with the coolant pump for leaks (section 5.2.1).
- Check the air filter element for dirt and install it.
- Check idle speed and CO content in exhaust gases and adjust if necessary.
Instruction. If necessary, replace the rubber parts of the engine mount, (removal of the engine and gearbox is not required see _ section 2.13).