Removal and installation of CVH and PTE engines

Attention. This chapter describes the removal of the engine together with the gearbox

Withdrawal

On engines with a fuel injection system, depressurize the fuel system.

Remove the ground wire from the battery. Drain coolant and engine oil Install a drain plug on the oil pan. Remove the hood.

Remove the air filter housing and elements of the air supply system to the engine. Loosen the clamps and remove the top hose, heater hose and radiator hose from the thermostat housing. Remove the coolant hose from the intake manifold and water pump base.

On 1.4 dm³ engines with CFI injection, disconnect the coolant hose from the pump On engines with EFI and SEFI injection, disconnect the heater hose from the Y-connector (see fig. 4D.9, 4D.10).





Disconnect the accelerator cable from the throttle. On engines with a carburetor, remove the fuel supply hose from the fuel pump and the return hose from the carburetor.


On engines with a CFI injection system, remove the fuel supply hose from the injector and the fuel return hose by depressing the coupling and releasing the hose from the connection. On engines with EFI and SEFI injection systems, unscrew the nut and separate the fuel supply hose from the fuel line and disconnect the return pipe from the pressure regulator. Plug the removed pipelines with plugs.



Remove the brake booster hose from the intake manifold, to do this, press the clamping ring and at the same time remove the hose.

On engines with CFI and EFI injection systems, disconnect the vacuum hose from the absolute pressure sensor and the hose connecting the carbon filter and the fuel injection system Disconnect the following electrical connectors (see fig. 4D.12-4D.14):

• coolant temperature sensor;
• oil pressure sensor;
• ignition coils;
• engine temperature sensor;
• radiator fan thermal switch;
• carburetor;
• radio grounding;
• reversing light switch from the gearbox;
• crankshaft angle sensor;
• ground bus connecting the gearbox and engine;

On engines with a fuel injection system, additionally remove the connectors:

• incoming air temperature sensor;
• vehicle speed sensor;
• throttle control motor (CFI models);
• throttle position sensor;
• injector harness;
• idle speed control valve;

Unscrew the bolts and separate the suspension of electrical wiring and coolant hoses above the gearbox.

Disconnect the speedometer cable from the transmission. On manual transmission models, remove the clutch cable from the release lever on the transmission. Unscrew the two bolts and separate the engine and gearbox mounting mount (see fig. 4D.15).



Raise the front of the vehicle and support it on jack stands or raise the vehicle on a hoist so that there is enough space under the vehicle to remove the engine along with the transmission. Remove the connector from the oxygen sensor.

Unscrew three bolts of fastening and disconnect a reception exhaust pipe from a final collector. Remove the gasket. Disconnect the front exhaust pipe from the rest of the exhaust system and remove it from under the vehicle.

Remove the 4 nuts and two bolts securing the front of the heat shield to the bottom and remove the heat shield.


Remove wires from starter and alternator. Unscrew and remove the starter.

Models with manual transmission

On 4-speed gearboxes, shift to 2nd gear, on 5-speed gearboxes, shift to 4th gear. Apply alignment marks to the shift rod and shift shaft. Unscrew the clamping bolt and remove the shift rod from the shaft (see fig. 4D.16).



Unscrew a bolt and disconnect the stabilizer from a transmission.

Models with automatic transmission

Disconnect the connector from the starter lock sensor (on the gearbox housing).

Disconnect the accelerator cable from the carburetor or injector. Remove the two nuts from the gear selector cable hanger that connect it to the lever on the shaft.

Unscrew the union nuts and disconnect the oil supply from the oil cooler and the return pipes from the gearbox.

All models

Unscrew the lock nut and remove the TORX bolt securing the lower control arm.

Remove the right tie rod joint. Insert an appropriate lever between the gearbox housing and the drive shaft pivot and press the lever to remove the drive shaft from the gearbox. Pull the wheel away from the vehicle at the same time. After removing the drive shaft from the gearbox, use a wire to hang the drive shaft from the steering gear.


Replace the removed drive shaft with a suitable plug in the differential to hold the side gear in place. Remove the left drive shaft from the gearbox in the same way Unscrew the bolts and remove the retainer located between the gearbox and the front suspension mount (see fig. 40.17).



Hook the engine with the hoist cables. Unscrew the two bolts securing the front of the gearbox. Unscrew the three bolts and remove the additional drive belt cover from under the crankshaft pulley. Unscrew the two nuts and remove the right engine mount. On engines with an EFI injection system, remove the absolute pressure sensor (see fig. 40.18). Check that the engine and gearbox are completely disconnected.



Lower the engine together with a transmission down a motor compartment. Install a trolley under the engine, on which you can then remove the engine from under the car. When lowering and moving the engine, be careful not to damage engine components. Disconnect the gearbox from the engine.

Check engine mounting mount and replace if necessary.

Installation

Installation is carried out in the reverse order of removal, taking into account the following points:

• install new circlips in the grooves of the right and left ends of the drive shafts. Lubricate the shaft splines with engine oil;
• when connecting the exhaust pipe to the exhaust manifold, install a new gasket;
• make sure that the heat shields are correctly installed and securely fastened;
• check that all ground rails are clean and secure.
• tighten all nuts and bolts to the required torque;
• install a new oil filter and fill the engine and gearbox with engine oil;
• pour coolant into the cooling system;