Removal and installation of the engine

Engine suspension elements

Withdrawal

Removal of the engine without gearbox is made upwards from the engine compartment using a lifting mechanism. It is also possible to remove the engine together with the gearbox, but this is much more difficult, since this requires installing the car on a lift and using an additional lift to lower the engine along with the gearbox down, having previously disconnected and removed the units that prevent the lowering of the power unit.

1. Remove the negative cable from the battery.

2. Remove the crankcase protection and mudguard.

3. Remove grille.

4. Disconnect the hood release cable from the hood closing mechanism and remove from the clips.

5. Remove the hood, having previously marked the position of the hinges, to facilitate reinstallation and disconnecting the windshield washer tube.

6. Drain the coolant from the cooling system by placing an appropriate container under the radiator drain plug and opening the drain plug located at the bottom of the radiator. To speed up the draining of the coolant, open the cap of the expansion tank. To drain the coolant from the cylinder block, unscrew the drain bolt located in the cylinder block.


7. Loosen the clamps and remove the pipes and hoses of the cooling system:

• upper and lower radiator pipes;
• expansion tank hoses;
• interior heating hoses;
• body of the automatic carburetor starter.

8. Unscrew the four bolts securing the upper front cross member, two bolts from both sides at the top and the two lower bolts securing the cross member support and remove it together with the radiator.

9. Remove air filter.

10. Remove the fuel supply hose from the fuel pump and plug it with a plug.

11. Remove the accelerator cable from the carburetor.

12. Disconnect the brake booster vacuum pipe from the intake manifold

13. Disconnect electrical wires and remove connectors from the following units and sensors:

• generator;
• starter;
• ground bus;
• temperature sensor;
• engine control temperature sensor;
• oil pressure sensor;
• solenoid valve on the high pressure fuel pump;
• electromagnetic fan clutch;
• fuel injection systems;
• electric intake manifold heater;
• high voltage wire from the ignition coil;
• radiator temperature sensor.

14. Remove the high voltage distributor with wires from the ignition distributor.

15. Disconnect the multi-pin connector from the ignition distributor.



16. Remove the oil level sensor.


17. Disconnect the accelerator pedal cable from the carburetor.

18. Disconnect the fuel and vacuum hoses, as well as electrical wires from the carburetor.

19. Remove V-belt and auxiliary steering pump (if present in this version). Suspend the auxiliary pump to the vehicle body with a soft wire.

20. Unscrew the front exhaust pipe from the exhaust manifold.

21. Unscrew the stabilizer clamps and remove the stabilizer.

22. Install engine hoist (tool 21.068) and lift the engine, and then unscrew the engine holders.

23. Unscrew the bolts connecting the engine to the gearbox.

24. Disconnect electrical wires and remove starter.

25. Disconnect ground wire from engine.

26. Remove the holder located between the engine and gearbox.

27. Support the gearbox with a suitable hoist and wide board and raise the gearbox slightly.

28. Using a hoist, carefully lift the engine and separate the gearbox from it.

Lifting the engine at the same time move it forward and turn it in a horizontal plane to remove it up.

Installation

1. The engine is installed in the reverse order of removal, while paying attention to some features.

2. Lubricate the splines of the gearbox clutch shaft with oil before connecting these assemblies.

3. When installing the clutch on the flywheel, it is necessary to center the clutch disc with a centering mandrel.

4. If, when connecting the gearbox to the engine, the input shaft of the gearbox does not enter the clutch disc, it is necessary to turn the crankshaft of the engine a little.

5. Install a new front exhaust pipe gasket.

6. Fill the cooling system with the appropriate fluid and bleed the air from the cooling system.

7. Check and, if necessary, adjust the ignition timing, as well as the engine idling speed and the concentration of CO in the exhaust gases.