Preparatory work
The engine, together with the gearbox, is removed upwards. This will require a chain hoist that can be stably installed at a sufficient height. It is also advisable to have an assistant nearby. Before doing this work, look at the illustrations showing the engine compartments to know where the corresponding parts are located. For vehicles manufactured after August 1979, the necessary special tool must be purchased to remove the exhaust manifold, otherwise the removal of the engine will not be successful when removing the exhaust system. see chapter "Turbocharger".
Dismantling
Remove engine hood (see chapter "Body").
Remove battery wires.
Drain coolant (see chapter "Cooling system").
Remove the water hose from the front of the cylinder head fitting, also remove the hoses between the engine, radiator, heater and expansion tank.
Disconnect the plug connections at the radiator fan and at the thermal switch.
Unscrew the fixing screws of the radiator (see chapter "Cooling system").
Remove the radiator together with the fan, support ring and pneumatic guides.
Disconnect the fuel filter from the body and lay it next to the washer reservoir.
Disconnect the clamps for the fuel supply and return lines at the fuel pump.
Disconnect the accelerator link near the high pressure fuel pump lever; completely detach the retaining clip.
On vehicles with automatic transmission, remove the accelerator link holder at the fuel pump or at the cylinder head. Make sure you don't change its setting.
Remove the cold start accelerator (see section "Replacing the cold start accelerator rod").
Remove the electrical cable or disconnect the plug connections from the following devices: generator, fuel pump switch, glow plugs, oil pressure sensor, temperature sensor and thermal switch.
Remove alternator (see section "Dismantling the generator").
Remove the electrical wires from the starter.
Remove starter (see section "Starter removal" in chapter "Starter").
Completely remove the restraints (torsional loads) next to the oil filter.
Sleep clutch rod (see section "Clutch rod replacement").
Disconnect the speedometer shaft from the gearbox. Close the hole in the gearbox with a rubber plug so that oil does not leak out.
Remove the vacuum hose leading to the brake booster, as well as the hose from the vacuum pump.
Remove connecting rod, control rod and shift lever (see chapter "Gearbox and final drive").
Set the automatic transmission control lever to position "R".
Raise the machine on stands from the front.
Disconnect the exhaust pipe from the holder near the gearbox.
Remove front exhaust pipe from exhaust pipe elbow (see section "Dismantling the exhaust pipe").
Disconnect the wire from the reverse switch on the gearbox.
On the right and left of the gearbox, disconnect the axle shafts and hang them near the body with a wire (see section "Drive shaft disassembly").
For an automatic transmission, disconnect the control lever linkage cable clamps, remove the accelerator pedal linkage, and the linkage bracket.
At the rear, unscrew the shift mechanism supports from the body and from the gearbox housing. remove supports.
Lower the car.
Pull two chains or sufficiently strong cables through the eyelets on the right and left of the engine and fasten it to the chain hoist.
Slightly lift the engine/gearbox unit so that it is under slight tension.
Unscrew the engine mount fixing bolt.
Remove the gearbox support on the left.
Carefully remove the shift mechanism assembly (with slight rotation).
When lifting the engine, guide it by hand so as not to damage anything.
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