Pic. 14. Dismantling the power unit
A lifting hoist or hand winch is required to dismantle the power unit. The power unit is removed forward after removing all shown in Fig. 14 parts for the front of the car, which is a lot of work. It should be remembered that its mass is approximately 200 kg, so the recommended chain hoists or lifting hand winches must withstand such a load. Since it is very difficult to remove the power unit by lifting it up, a manual crane with a retractable boom is best suited for this job. The instructions below apply to all types of engines.
Each of the most important steps for dismantling the power unit is described below, however, some vehicles may be equipped with additional connections that will need to be disassembled and which are not indicated in the description. In the driver's cab, it is only necessary to disconnect the gear lever from the gearbox. The power unit is removed forward after dismantling the parts of the front of the car.
The dismantling of the power unit must be carried out as follows:
- open the hood and fold it completely over the windshield. To do this, you need to detach the support at the top of the hood. Before that, you need to put some old blanket on the windshield;
Pic. 15. Location of the battery in the engine compartment (left front)
- disconnect both battery terminals (disconnect first to avoid short circuit «negative» terminal!). The battery is located in the front of the engine compartment (pic. 15). To avoid accidental dropping of the tool on the battery terminals and the formation of sparks, it is recommended to remove the battery from the engine compartment;
Pic. 16. Removing the grille (Arrows point to grille fixing bolts)
- remove the grille. To do this, unscrew the two bolts indicated by the arrows in Fig. 16. After that, the grille is easily pulled out, leaning forward;
- remove the radiator cap. The temperature of the coolant must not exceed 50°C. Drain the coolant from the engine cooling system according to the instructions in subsection 4.1;
- remove the radiator, following the instructions in the relevant chapter;
Pic. 17. Dismantling the air duct connecting the air filter and the intake manifold (on a 2.3 liter engine)
- remove the air duct connecting the air filter and the intake manifold (shown in fig. 17 on 2.3L engine);
- remove the front bumper and radiator mounting bracket;
- disconnect the muffler intake pipe from the exhaust manifold and gearbox;
Pic. 18. The location of the tachometer drive on the gearbox: 1 - tachometer drive; 2 - cardan shaft
- disconnect the cardan shaft from the gearbox output shaft flange and unscrew the tachometer drive (pic. 18);
Pic. 19. Location of the clutch release cylinder (1) on the gearbox
- dismantle the clutch slave cylinder from the gearbox and, without disconnecting the hoses, take it to the side. Fasten it with a piece of wire under the car so that it does not hang on the hoses. On fig. 19 shows the location of the working cylinder on the gearbox;
- disconnect «mass» the wire;
- Disconnect wiring from starter and alternator. Disconnect all wiring harnesses from the engine and take them to the side so that you do not confuse them later during assembly;
- disconnect the wiring from the glow plug relay;
- disconnect all vacuum tubes from the engine;
- remove the drive belt following the instructions in the relevant section;
- unscrew the three bolts securing the power steering pump drive pulley and remove the pulley from the pump hub;
- remove the power steering pump and, without disconnecting the hoses, take it to the side;
- disconnect the fuel lines from the coarse filter and close them to prevent dirt from getting inside;
Pic. 20. Disconnecting the brake booster vacuum hose from the vacuum pump fitting
- remove the vacuum hose from the vacuum pump fitting, as shown in fig. 20. This hose connects the pump to the brake booster;
- remove the handle from the gear lever, remove the rubber seal and pull the lever out of the gearbox after loosening the lock screw (see also sect. «Transmission»);
- loosen the clamp and remove the heater hose from the thermostat housing;
- remove starter;
- disconnect the oil lines from the oil filter housing;
- disconnect the gearbox mounting to the traverse (one nut);
- unfasten both engine mounts (both sides under the car);
- roll a manual crane with an arrow in front into the engine compartment and fasten its cable or chain slings to the lifting eyes on the engine. At the same time, place a dolly under the rear of the power unit at the engine/gearbox interface to support the unit from below. Now, before proceeding with the dismantling of the engine and gearbox mounts, you should make sure that the power unit is securely held by the lifting devices and will not fall off them;
- disconnect the control rods for the supply of a combustible mixture;
Pic. 21. Gearbox suspension mount
Pic. 22. Fastening the rear transaxle of the gearbox to the side members of the car
- Disconnect the fasteners of the gearbox and engine traverses. On fig. 21 and 22 show how these parts are fixed. Before disassembling the traverse fasteners, it is imperative to make sure once again that the power unit is securely suspended and held in lifting devices;
- turn the power unit slightly to the side so that the protrusion of the gear lever does not cling to the lower part of the body, and pull or roll out the unit on a rolling cart from the engine compartment of the vehicle. Try not to touch the steering parts.