Note. Reliable lifting equipment with approved rigging will be required to perform engine removal and installation procedures.
Removing
1. Raise the hood and take care of the reliable protection of the front body panels of the car.
2. Circle the hood hinges with a marker to facilitate subsequent installation. Disconnect the windshield washer fluid supply hose from the hood.
3. Give fixing bolts and by means of the assistant remove a cowl from the car.
4. Disconnect the negative cable from the battery.
5. Empty the cooling system and remove the radiator with hoses from the car.
6. Give nuts of fastening of assembly of the fan to a pulley of the water pump and remove the fan.
7. Remove the air cleaner from the engine.
8. Loosen the clamps of the fuel supply and return hoses to the fuel pump. Disconnect the hoses. Seal the open ends of the hoses to prevent dirt from entering the power system.
9. Disconnect the heating hoses from the heater pipes on the bulkhead of the engine compartment - try not to accidentally damage the latter. If necessary, cut the hoses to facilitate their removal.
10. Loosen the throttle cable mounting nuts on your bracket, rotate the lever to move the throttle to the fully open position and remove the end of the cable from the holder. Move the cable to the side, laying it in such a way that it does not interfere with further work.
11. Disconnect from the inlet pipeline a vacuum hose of the amplifier of brakes.
12. Disconnect the main power wire of the starter and disconnect the electrical connector of the traction relay.
13. Disconnect the engine wiring connectors near the battery, release the wires from the retainer under the carburetor.
14. Disconnect the electrical connectors of the temperature sensor, ignition coil, distributor and carburetor (the layout of the components in the engine compartment is shown in the accompanying illustration, which shows the engine with the air cleaner removed). Loosen the bolt and disconnect the ground wire from the carburetor drive cable bracket.
15. On models equipped with air conditioning, disconnect the idle speed stabilizer vacuum hoses from the throttle damper and intake manifold.
16. In the left side of the engine compartment, disconnect the ground wires from the lifting eye of the power unit.
17. Disconnect the carbon canister hoses from the steel tubes on the engine.
18. Install a drain container under the steering pump, loosen the return hose clamp, disconnect the hose and drain the power steering hydraulic fluid. Give the hollow bolt on the pump - try not to lose the copper sealing washers.
19. Tie up the power steering hoses away from the work area, wrapping them in a clean, lint-free rag to prevent dirt from entering the system.
20. Jack up the front of the car and place it on jack stands.
21. Give bolts and release plastic screw clips of fastening of protection of a case. Remove protection.
22. On models equipped with air conditioning:
- Loosen the tension roller locknut and, turning the adjusting bolt with a screwdriver, remove the drive belt from the compressor pulley.
- Give the bottom bolts and nuts of fastening of the compressor.
- Turn out the top fixing bolts, lift the compressor and fix it on the mudguard of the left wing.
Note. Do not loosen the high pressure lines of the compressor to avoid injury and frostbite damage from direct contact with the refrigerant. In addition, the loss of refrigerant will result in the need to recharge the system.
23. Give nuts of fastening of a flange of a reception pipe of system of release of the fulfilled gases to a final collector. Unclip the exhaust pipe without changing its position on the vehicle.
24. Give bolts of fastening of a sleeve of a crankcase of coupling and an arm of a hose to the left wall of the engine under a starter.
25. Give the mounting bolts and remove the starter from the engine - you may have to overcome some resistance associated with the need to destroy the sealant layer.
26. Hang the engine with suitable lifting equipment, taking the weight of the power package off its supports.
27. Give nuts of fastening of support of the engine to the block of cylinders and bolts of fastening of support to the chassis.
28. Raise the engine slightly and remove the supports. Lower the engine onto the chassis for easy access to the upper flywheel housing mounting bolts.
29. Give the top bolts of fastening of a casing of a flywheel to transmission.
30. Using a suitable tool, cut through the sealant along the perimeter of the flywheel housing joint with the transmission. Be careful not to damage mating surfaces.
31. Carefully lift the engine assembly and slide it forward on the vehicle. Make sure the transmission input shaft comes out freely from the clutch assembly.
32. With extreme care, being careful not to damage fragile components, remove the engine assembly from the vehicle. In the event of the slightest uncertainty, it makes sense to spend time on the preliminary removal of interfering nodes.
Installation
Installation is basically done in reverse order.
1. Take care of a thorough cleaning of the mating surfaces of the flywheel housing and the engine. Apply a pad of sealant to the mating surface of the transmission.
Note. The tight fit of the rear plate to the engine is also extremely important, as it prevents water from leaking into the flywheel housing.
2. Do not forget to center the clutch disc on the flywheel using a false shaft or a special tool, only then tighten the basket fasteners.
3. Before installing the front supports of the power unit, screw in the upper bolts of the flywheel housing to the engine.
4. With the weight of the engine on the supports, tighten the bolts and nuts securing the latter to the chassis and engine.
5. Fill the engine with the required amount of oil of the required grade. Refill the cooling system.
6. Connect a reception pipe of system of release of the fulfilled gases to a final collector, having established a new lining.
7. Lubricate the starter mounting flange with sealant and install the starter in its place.
8. Adjust throttle cable.
9. Before starting the engine for the first time, check the correctness of all settings and adjust the tension of the drive belts.
10. After starting, monitor engine temperature and oil pressure. Check the engine for leaks, if any, eliminate their causes.