Removing
The engine, together with the gearbox, is removed from the engine compartment forward. Finally, the gearbox can be separated from the engine. Before you begin, please read the following instructions.
The condition for extracting the engine is the use of a powerful lifting mechanism.
Must be dismantled: the front of the car, fan casing, shock absorber (push rod) and refrigeration unit.
If a radio is installed, it has an anti-theft code that must be known before the battery can be disconnected from the mains.
To prevent damage to the engine electronics control unit, the batteries should only be disconnected when the ignition is switched off. In this case, it is necessary to additionally pay attention to the fact that after switching off the ignition, you must wait at least 20 seconds. before disconnecting the negative battery cable. So-called «hot wire» in the air flow meter must burn steadily before. how the circuit is interrupted.
Most cables are secured with cable ties and staples. When removed, their position is noted, and when installing the power unit, the cable is reattached in the same places. Some cable ties have to be cut. to release the cable. In such cases, new clamps should be used.
If an air conditioner is installed, under no circumstances should the refrigeration circuit be opened. This is a job for trained personnel who, thanks to the use of special devices and only in the workshop, are able to reduce the pressure in the air conditioner and re-set the unit under pressure.
In order to still dismantle the power unit with the air conditioner installed, loosen the air compressor and firmly tie it to the wall so that the hoses are not energized. Be sure to take into account that the pipes are very sensitive to bending, so when dismantling this compressor, be especially careful. The cable connecting the battery to the housing must be disconnected in accordance with the above instructions (observe the anti-theft device code for the radio installation), and then remove the battery. The storage battery is held on the wall by means of a pressure plate -1- and a bolt -3- as shown in fig. and supported on the other side by a safety sheet. When installing the battery, the bolt is tightened with a force of 20 Nm.
You can unscrew the engine hood, although this is not essential. If this is done, then the outer dimension of the hinge of the engine hood sheet is outlined with a pencil in order to re-install the hood during installation in its original position.
The heating system regulator is set to position «Warm» («Warm»).
The locking cap of the temperature compensation tank of the cooling system is unscrewed, the engine must remain cold
Remove the air filter completely, together with connecting elements. Close the openings properly to prevent foreign objects from entering the engine.
Move the vehicle to either a pit or vehicle platform lift, or raise the front side far enough on jack stands to allow access to the underside of the body. Be sure to use reliable goats.
Drain the cooling system of liquid. There is a drain plug in the coolant pipe on the top side, which can be removed.
Otherwise, release the lower water hose from the fitting and pull it off. The heater control valve must remain open so that all coolant that has been poured in can drain out of the heater. The coolant contains an anti-freeze agent, which should be fished out, if only because it has been present in the system for a long time. To do this, either turn the coolant tube slightly to direct coolant into the reservoir, or place a large, flat reservoir under the disconnected radiator hose to catch most of the leaking fluid.
The outlet of the coolant is preferably carried out in the external free space, so as not to pollute the place.
Remove the front body. Be sure to pay attention to the fact that during this work the lacquer coating is not damaged.
Loosen the upper water hose clamp and disconnect it from the cylinder head. Release also a hose from the union of a radiator. Secure the hoses either with a spring clip or with screw clamps. During assembly, the spring clips can be exchanged for staples with screws, since special pliers are required to tighten the spring clips.
Dismantle the fan shroud together with the buffer rod and with the radiator. When removing the radiator, the work described below is carried out, respectively.
Disconnect the electrical cable from the thermostat switch and from the radiator fan.
Disconnect the cable connector from the back of the three-phase alternator.
Disconnect the low pressure hoses from the top of the intake manifold.
Unscrew the radiator retaining bracket on the top side.
Remove any remaining coolant hoses (cylinder head radiator, water pump radiator and conservator vessel radiator).
Completely release the radiator mountings and remove it from the engine compartment along with the air intake duct and fan.
Disconnect the 1.8 bar oil pressure cut-off line, this is the switch with the yellow cable. In the same way, disconnect the 0.3 bar oil pressure cut-off line - this is the switch with the blue/black cable.
Disconnect the oil temperature sensor.
Pull the high voltage cable out of the middle of the ignition distributor.
Pull the connector out of the ignition distributor wall.
Disconnect the electrical leads from the gearbox.
Disconnect the temperature sensor of the remote thermometer.
Trace all lines between body and engine, mark lines appropriately and disconnect from engine. Press these lines against the wall so that they do not interfere later.
Unscrew the body wire from the cylinder head casing.
Disconnect the lines from the starter.
Disconnect the wiring harness from the transmission after releasing the fastener.
Release and pull the coolant hoses from the cylinder head.
Unscrew the take-up cylinder from the gearbox and properly screw it firmly in a hanging position on the chassis.
Unscrew the flexible jumper from the gearbox.
Disconnect the shift cable drive from the gearbox. In addition to this, unscrew the cable drive holder from the gearbox.
Unscrew from the gearbox and disconnect the tachometer coil. Close the opening in the gearbox to prevent dirt from getting into it.
Disconnect the throttle cable from the segment drive and release it from the counterhold. Do not pull the retaining clip from the throttle cable.
Locate the cable harness in the engine compartment and the large connector separator. (42 connecting contacts).
Disconnect the low pressure hose from the brake booster.
Unscrew the power steering pump from the console and screw it in a hanging position on the lines of the engine support bracket.
Remove the spark plug cable guide, spark plug cable and distributor head. This work is described when disassembling the engine. The cover over the cylinder head must also be removed.
Raise the engine from the hangers using the appropriate cable loops. It is also possible to fasten rope loops to the drive mechanism in a suitable manner. The other end of this cable is attached to the other side of the cylinder head. This cable is hung on a chain hoist or on a crane and is easily lifted to the state of cable tension.
The rubber-metal holder is unscrewed and completely removed.
Both remaining suspensions of the drive mechanism are unscrewed and removed. At the same time, they check whether the engine hangs firmly on the cables.
Release the drive shafts from the flange connections and, after release, fasten with a wire in a suitable place in a horizontal position on the chassis, an insert tool is used to unscrew the bolts, similar to an 8 mm Allen key, without which the bolts can only be removed with great effort, especially in when they are tight enough.
Separate the exhaust pipe connection on the manifold flange and release it from the fastening on the transmission mechanism.
Slightly raise the drive mechanism and turn until. until it can be removed from the engine compartment.
Pay attention not to forget about any of the conclusions and that the engine and gearbox are not left to hang anywhere. This can only be achieved through slow withdrawal.
Separate the engine from the gearbox.
Installation
Installing the motors is carried out in the reverse order, however, it is necessary to pay attention to the following points.
Check the condition and replace, if necessary, the clutch release bearing.
Lightly grease the release clutch bearing surfaces and wedge engagements with graphite grease. In this case, however, the guide sleeve of the clutch release clutch bearing must not be lubricated.
The engine and gearbox are guided by matching pins. Before the two parts are assembled, the matching parts must already be in the cylinder block. If they remained in the gearbox during flaring, they must be transferred to the cylinder block, namely: removed from the gearbox and driven into this block.
Position the engine and gearbox in the correct position. When lowering the drive mechanism, pay attention to "pass the" past the drive shafts.
When installing engine mounts, it is necessary to adhere to Fig. The grooves in the rear right and front bearing yokes of the engine must engage with the matching pins in the rubber-metal holders. engine, therefore. first lowered into the hangers before installing the bolts.
First of all, hand-tighten all the bolts of the engine and gearbox mounts as tightly as possible five or six turns by hand.
Pump the engine well back and forth until the drive mechanism is well seated before tightening the individual engine and transmission mounts.
Attach the drive shafts and multi-toothed bolts with a special socket wrench and tighten them to a tightening torque of 45 Nm.
Connect the release device. Align the main muffler and the exhaust tube and then secure with the rubber ring. If the rubber is stretched, you can slightly bend the fastening hooks on the exhaust device. If too much tension is applied, the rubber rings will break.
Fill the cooling system if the heater tap is open. Fill the dilator vessel up to the marking, and then tighten the plug. Let the engine run a little to push all the air out. Finally, check the coolant level and correct if necessary.
Check the installation of the switch cable. If required, make the necessary adjustment or new installation.
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