Contents: Removal ↓ Installation ↓
Removal
Disconnect the wire from the negative terminal of the battery.
Open the expansion tank cap.
Disconnect the hoses from the radiator and drain the coolant.
Disconnect the electrical wires from the radiator and remove the radiator.
Remove the clutch drive cable from the adjusting sleeve.
Disconnect the engine cooling system and interior heating hoses.
Disconnect the electrical wires from the sensor and from the electric fan of the cooling system.
Disconnect the fuel supply and return hoses from the fuel pump.
Disconnect the wires from the electrical components installed on the engine.
Disconnect the vacuum hoses and control cables from the carburetor.
Remove the air filter.
Remove the hood.
Disconnect and remove the clutch cable.
Loosen the nut of the silent block bolt of the left engine mount bracket.
Loosen the nut of the silent block bolt of the right engine mount bracket.
Loosen the bolts securing the upper engine mount bracket flange.
Disconnect the exhaust pipe from the exhaust manifold flange.
Disconnect the wires from the starter.
Remove the starter.
On vehicles with automatic transmission, loosen the torque converter mounting bolts.
Disconnect the exhaust pipe from the gearbox bracket.
Remove the lower bolts securing the gearbox to the engine.
Remove the lower clutch housing cover.
Place a support under the gearbox.
Secure the engine. Remove the engine mount bracket.
Loosen the bolts securing the gearbox to the engine.
Turn and remove the engine from the engine compartment.
On vehicles with automatic transmission, lock the torque converter in the crankcase.
Installation
On vehicles with a manual transmission, apply a thin layer of consistent grease to the splines of the transmission input shaft.
Install the engine assembly with the intake manifold, exhaust manifold and generator into the engine compartment.
Attach the gearbox to the engine.
Install the engine mount brackets.
Remove the support from under the gearbox.
On vehicles with automatic transmission, tighten the torque converter bolts to the flywheel.
Install the starter and connect the wires to it.
Install the lower clutch housing cover.
Secure the exhaust pipe to the intake manifold flange using a new gasket.
Secure the exhaust pipe to the gearbox bracket.
Install the upper engine mount bracket flange in place.
Tighten the nuts of the bolts securing the silent blocks of the left and right engine mount brackets.
Connect the wires to the electrical components installed on the engine.
Connect the control cables and vacuum hoses to the carburetor.
Connect the hoses to the fuel pump.
Connect the cooling system and interior heating hoses to the engine.
Install the radiator.
Connect the wires to the electric cooling fan and the electric fan on/off sensor.
Connect the hoses to the radiator pipes.
Fill the cooling system with liquid.
Install and adjust the clutch cable.
Install the air filter.
Install the hood.
Check coolant and oil levels and top them up if necessary.
Connect the wire to the negative terminal of the battery.
Start the engine and check its operation.
Engine mount:
1 — subframe;
2, 9 — silent blocks;
3 — right suspension bracket (except DS engine);
4 — DS engine right mount bracket;
5 — flange;
6 — buffer;
7 — upper suspension bracket;
8 — left suspension bracket;
10, 11 — rubber-metal supports.
Cylinder block details:
1 — cylinder block;
2 - oil pan;
3 — crankshaft rear oil seal holder;
4 — spacer;
5 — front crankshaft oil seal holder;
6 - gaskets;
7 — crankshaft oil seals;
8 — ignition distributor sensor mounting sleeve;
9 — oil drain plug;
10 — plug gasket.
Details of the engine crank mechanism:
A - cars with manual transmission;
B - cars with automatic transmission.
1 - flywheel;
2 - toothed crown;
3 - leading disk;
4, 5 - spacer washers;
6 - needle bearing;
7 — crankshaft;
8 - toothed pulley of the crankshaft;
9 — crankshaft pulley;
10 — connecting rod;
11 — piston;
12 - piston rings.
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