Dismantling
Attention! The engine can be dismantled from the car as part of the power unit (those. complete with transmission), then the transmission is separated from the engine for overhaul.
The power unit is lowered and gets out from under the car. In order to freely get the engine in this way, the car must be raised to a height of at least 75 cm (floor to front bumper) and place on stands.
1. Perform the operations described in pp. 1–10 of subsection 3.2.2.3.
Injection engines with pre-mixture of the fuel mixture
2. On injection engines with pre-mixture, remove the air filter.
3. Carry out measures to decompress the fuel system, disconnect the fuel supply hose and the fuel return hose from the throttle valve chamber (plug all openings to prevent fuel loss and dirt ingress).
4. Disconnect the throttle cable.
5. Disconnect the wiring connectors from the throttle chamber, intake manifold and other parts.
6. Disconnect the brake booster vacuum hose, coolant hose, valve vacuum hoses and crankcase ventilation hoses mounted on the intake manifold.
7. Remove the suction manifold support bracket.
8. Remove the muffler intake pipe.
Injection engines with direct fuel injection
9. On injection engines with direct fuel injection, remove the air filter duct.
10. Decompress the fuel system, disconnect the fuel supply hose and the fuel return hose from the throttle body (plug all openings to prevent fuel loss and dirt ingress).
11. Disconnect the throttle cable.
12. Disconnect the wiring connectors from the throttle chamber, intake manifold and other parts. Move the wiring away from the manifold and cylinder head so that it does not interfere with the removal of the engine.
13. Disconnect the brake booster vacuum hose, coolant hose, valve vacuum hoses and crankcase ventilation hoses mounted on the intake manifold.
14. Remove the suction manifold support bracket.
15. Remove the muffler intake pipe.
16. Loosen the clamps and disconnect the heater hoses and other hoses of the cooling system from the engine, having previously marked the original location of each hose.
17. On vehicles equipped with air conditioning, remove the compressor mounting bolts and move the compressor to the side. Tie the compressor to the body so that its weight is not perceived by the tubes and hoses of the air conditioning system. Do not disconnect air conditioning hoses.
18. Remove the axle shafts with cardan joints (see subsection 10.2).
19. Disconnect the gear selector lever cable from the transmission.
20. Disconnect the downshift cable from the throttle chamber.
21. Disconnect the wiring connectors from the transmission.
22. Disconnect the transmission fluid cooler hoses from the transmission.
23. Disconnect the speedometer cable.
24. Bring the lift hoist and fix it on the cylinder head brackets, tighten the hoist so that it takes the weight of the power unit.
25. Loosen the tightening and unscrew the nut of the coupling bolt of the rear support of the power unit, remove the bolt from the support.
26. Unscrew the four bolts securing the central side member, remove the side member, removing it from under the power unit. Remove the restrictor ring installed between the rear support of the power unit and the bracket.
27. Turn away a nut and get a coupling bolt of the right support of the power unit, then turn away bolts of fastening of a support and get a support from a motor compartment. If the fit of the rubber pads mounted on both sides of the support bracket on the body side is loose, remove the pads.
28. Turn away and get a coupling bolt of the left support of the power unit. Then unscrew the three bolts securing the support to the transmission case and move the support to the side. Remove the pads installed on both sides of the support bracket.
29. Once again, make sure that all parts, wires and hoses that may interfere with the dismantling of the power unit are disconnected or removed. Also make sure that other parts of the car will not be damaged when dismantling the unit (e.g. axle shafts).
30. If there is a low cart, then roll it under the engine, which will make it easier to remove the removed unit from under the car. Lower the power unit, being careful not to damage or snag nearby parts. It is advisable to carry out this operation with an assistant, since it will be necessary to tilt the unit slightly in order to not touch the body panels. Be extremely careful when lowering the engine.
31. Roll the power unit out from under the car.
Removing the transmission from the engine
1. Secure the removed power unit with wooden blocks by placing it on a workbench or on a clean, level area in the workshop.
2. Turn away bolts and remove a starter from a case of transmission.
3. Remove the bolts and remove the mounting plate from the oil pan flange, after which access to the torque converter mounting bolts will open. Unscrew the first available bolt, then turning the crankshaft with a socket wrench by the pulley, unscrew the remaining bolts of the torque converter to the drive disk in turn, as you access these bolts. There are four bolts in total.
4. Take measures to prevent the torque converter from falling when removing the transmission, for which fix the torque converter with a piece of metal strip, screwing the strip with a bolt to one of the starter mounting holes.
5. Make sure that the power unit is securely fixed and unscrew the bolts securing the transmission case to the engine. Mark bolt locations (and on some vehicles and the corresponding brackets), to install when reassembling in their original places.
6. Carefully separate the gearbox from the engine. If the guide pins in the transmission case or in the cylinder block wiggle freely, remove them and store them so that they can be reinstalled later.
Installation
1. If the gearbox was removed from the engine, then perform the operations described below in paragraphs. 2–7. If the checkpoint was not removed, then be guided item 8 and so on.
2. Before installing, make sure the torque converter is properly installed on the transmission. This can be checked by measuring the distance from the torque converter mounting bolt holes to the split plane of the transmission housing, which must be at least 15.9 mm.
3. Install pins on engine or transmission (if they were removed).
4. Carefully install the transmission onto the engine along the guide pins. Wrap bolts of fastening of a case of transmission, having convinced of correctness of installation of all arms, tighten bolts with the set moment.
5. Remove the strip holding the torque converter from falling, which was installed before removal. Align the holes in the torque converter with the holes in the drive plate and tighten the mounting bolts.
6. Torque tighten the torque converter bolts, install the mounting plate on the oil pan and secure with the bolts until tight. 7. Install starter and tighten bolts.
8. Position the power unit under the vehicle and attach the hoist to the engine brackets.
9. Working with an assistant, lift the power package into the engine compartment, being careful not to hit any nearby parts.
10. Install the rubber cushions on the bracket of the left support of the power unit, making sure that the studs of the cushions fit into the holes of the bracket. Reinstall the support, wrap the bolts securing the support to the transmission and tighten them to the specified torque. Insert the pinch bolt and hand tighten the nut.
11. Install the rubber pads to the right suspension bracket from the body side, making sure that the pad studs fit into the holes in the bracket. Install the support on the bracket and tighten the bolts to the specified torque. Insert the pinch bolt and hand tighten the nut.
12. Make sure all rubber pads are in place and install the stop ring on the rear powertrain mount. Install the center spar, align it with the engine mount and tighten the bolts, after putting washers on them. Tighten the side member bolts to the specified torque.
13. Insert the rear support pinch bolt and hand-tighten the nut.
14. Rock the power unit, settling it in place, then tighten the front, right and left mount pinch bolts to the specified torque.
15. Further, the installation of the power unit is carried out in the reverse order.
16. When installing, make sure that the wiring is routed and secured with clamps and brackets, and that all connectors are attached.
17. Replace the axle shaft seals and install the axle shaft assembly with hinges on the gearbox (see subsection 9.1.3).
18. Attach all hoses of system of cooling and fix collars.
19. Adjust throttle cable (see subsection 6.1.7).
20. Connect and Adjust the Gear Selector Lever Cable and Downshift Cable (see subsection 9.2.4).
21. Install and adjust the belt (belts) drive (see subsection 2.3.1.3).
22. Change the oil in the engine and gearbox, recommended brands of oil, fluids and filling volumes (see subsection 1.12.7).
23. Fill with coolant.
24. When finished, start the engine and check for leaks.