Removing and installing engine

1. The engine is removed together with the gearbox down, t. E. The vehicle must be raised, respectively, to have enough space. To facilitate the work required or valve, or a strong assistant to lower unit by a cable and a steel rod.
2. Because of differences in the removal of injection and carburetor engines procedures are described separately for the first injection engines.
3. Remove the battery earth cable. The battery can be removed to provide more space. Furthermore, this prevents a short circuit during operation (for example, if the terminals drops tool).
4. Unscrew the hood. Circle the panel joints of the bonnet and unscrew bolts. Ask the assistant to hold the hood, so it can not tip over. Place the hood in a safe place so as not to damage it.
5. Remove all plates under the front of the car.
6. Remove the air filter as described in the relevant section.
7. Drain the coolant as described in Chapter Cooling and heating systems. Contains antifreeze coolant concentrate, and for re-use should be collected in a clean container. For release to remove the lower radiator hose (after opening the cover).
8. Remove the heat sink with a fan, as described in Chapter Cooling and heating systems. In the case of automatic transmission oil cooler hoses and disconnect from a radiator. Collect gear oil into the outstretched the capacity.
9. Remove the power steering pump without disconnecting the hoses. Remove the generator and, if available, the air conditioning compressor. Do not disconnect the hose from the compressor pipes.
10. Remove the front exhaust pipe from the exhaust manifold and loosen the fastening of a reception pipe from the suspension. Chapter suspension and steering are further instructions for this work.
11. Guided illustration, disconnect switch bar (1) and thrust plate (2) with manual gearbox installed.
    Chapter Manual transmission, differential and the main transfer given further details of this work.

Removing the rods switch when installed manual gearbox

1 - switching rod 2 - sliding fence

12. When you set an automatic transmission disconnect switch on the side of the cable box and the throttle cable on the engine side.
13. Loosen lying inside the fork head nut (see. Illustration below) and disconnect the cable from the clutch lever off when it will be long enough for that.

Clutch cable retained to the inner side of the head plug.

14. Following the curve of the speedometer cable, remove the bolt mounting plate. Remove the entire clutch cable from the transmission. The drive gear is on the cable. Plug the hole in the gearbox with a cloth (see. Illustration below).

Fixing the speedometer cable (1) in the left figure, and taking out the cable with the pinion (2) on the right figure.

15. Disconnect the throttle cable from the throttle body.
16. Disconnect all vacuum and air hoses between the engine and the body. Depending on the country of destination and of the laws of adjusting the composition of the exhaust gas varies lining of vacuum hoses. Head of the Power supply system and the exhaust contains details on adjusting the composition of the gases.
17. Disconnect all electrical wires between consumers current on the engine and the body. These include the alternator, oil pressure sensor, thermal sensor remote thermometer, distributor starter and so on. D.
18. Before turning off the supply piping system should reduce the pressure in the system. To do this, open the fuse box cover and remove the fuse shown in the illustration. Start the engine. After a while it will stall, as it will not be supplied fuel. Once again two or three times crank the starter to all the pressure eased. Immediately insert the fuse in place. You can now disconnect all fuel hoses between the engine and the body.

The position of the fuel pump fuse (1) in the fuse box.

19. Replace the front part of the car on support and unscrew the front wheels.
20. Remove brake calipers on both sides. This brake calipers and hoses of the pipeline does not unscrew. After loosening two screws hang the caliper on a wire to the front suspension to support not hung on the hose.
21. On each side of the car, loosen the nut of the ball joint from the steering knuckle and remove the ball joint from the knuckle by means of a stripper. Press the control arm down until the pivot pin is not released. In the illustration, the lower arrow indicates the place of the ball joint. Section Front suspension is described in detail the removal of the ball joint front suspension.

Arrows indicate the connections that need to be disassembled to remove the drive shafts.

22. In the same way, disconnect the tie rod, but this time from lever steering. This compound is indicated in the illustration above left arrow. Sections steering without power steering and steering with the hydraulic booster (servo) described in detail the use of a stripper.
23. Drain the transmission oil.
24. Disconnect drive shafts from the gearbox, as described in Chapter Coupling and power shafts and removing the knuckle, press shafts out of gear box. This hinge is set for a screwdriver. Short jerk screwdriver, remove the differential pinion shaft retaining ring and pops out. Depending on the tree removal may be different, as described in more detail in Chapter Coupling and power shafts. It does not damage the oil seal in the gearbox. If the packing is damaged, before installing the drive shaft must be replaced.
25. Attach the appropriate cable or chain to the two eyes of the engine and tie rope or chain to the crane. If the lifting lugs no need to prepare two strong steel bracket and screw one behind the other in front of the cylinder head. Slightly lift the unit from the engine compartment to the cable tight. Keep the engine and the gearbox in such a position.
26. Substitute under transmission mobile lift (tucked in between wooden lining) and lift the gear box. You may need to pull the lift motor.
27. On the lower side of the gear box, unscrew and remove the high beam. It is on both sides fixed with two screws and also supports the suspension is connected to the front and rear of the unit.
28. Unscrew shown in front suspension and engine shown in rear engine mount. Also unscrew the suspension of transmission. Always make sure that the weight of the unit has been removed from the supports. If necessary, lower or lift crane. When unscrewing the engine mount should be carried out some guidelines:

• With the weakening of the suspension on the front side, remove only inserted in the middle of the bolt and nut.

Front suspension injection engine.

• With the weakening of the rear engine mount bracket only unscrew the engine from the engine block.

The rear suspension of the engine. Injector and carburetor engine.

• Supports engine suspension stay on the engine and can be loosened if necessary, after removal of the unit.

29. Make sure that all connections between the unit and the body have been weakened and slowly lower the engine down. At the same time, respectively, operate the hoist and crane. In order to guide the machine, need help assistant. When lowering, make sure not to damage parts of the engine, ie. E. Hoses, cables, pipelines and so on. D. Be careful not to have been damaged brake lines and brake master cylinder.

1. Disconnect the cable of weight from the battery. The battery must be removed to provide more space. In addition, short-circuiting is prevented (for example, if the terminals drops tool).
2. Unscrew the hood. Circle pencil and joints loosen the bolts. The assistant must hold the hood, so it does not overturned. Place the hood in a safe place so as not to damage it.
3. Remove all screwed under the front of the body panel.
4. Remove the air filter as described in the relevant chapter.
5. Drain the coolant as described in Chapter Cooling and heating systems. Antifreeze coolant concentrate comprises, so reuse should be collected in a clean container. To drain, disconnect the lower radiator hose (after opening the radiator cap).
6. Remove the heat sink with a fan.
7. Remove the intake manifold support to be able to get to the cable connected to the starter battery.
8. Loosen the power steering pump belt and remove the pump without disconnecting the hoses.
9. Remove the front exhaust pipe from the exhaust manifold and loosen the fastening of a reception pipe from the suspension.
   Chapter Suspension and steering are given detailed instructions on this work.
10. Guided disconnect switch bar (1) and thrust plate (2). Chapter Manual transmission, differential and the main transfer this work is described in more detail.
11. Loosen the nut inside the fork head (see. and disconnect the cable from the clutch lever off when it will be long enough for the attenuation of the nut.
12. Following the curve of the speedometer cable, remove the bolt mounting plate. Remove the entire clutch cable from the transmission. The drive gear is on the cable. Plug the hole in the gearbox with a cloth (see.
13. Disconnect the throttle cable from the lever on the carburetor.
14. Disconnect all hoses and pipes between the engine and the body.
15. Disconnect all electrical wires between energy consumers on the engine and the body. To them includes a generator, oil pressure sensor, thermal sensor remote thermometer, distributor starter and so on. d.
16. Disconnect the fuel line between the fuel pump and the pipe from the tank.
17. Replace the front part of the car on support and unscrew the front wheels.
18. Remove brake calipers on both sides. This brake calipers and hoses of the pipeline does not unscrew. After loosening two screws hang the caliper on a wire to the front suspension to support not hung on the hose.
19. On each side of the car, loosen the nut of the ball joint from the steering knuckle and remove the ball joint from the knuckle by means of a stripper. Click wishbone down until the pivot pin is not released. In the the lower arrow indicates the place of the ball joint. Section Front suspension is described in detail the removal of the ball joint front suspension.
20. In the same way, disconnect the tie rod, but this time from lever steering. This compound is indicated in steering without power steering and steering with the hydraulic booster (servo) described in detail the use of a stripper.
21. Drain the transmission oil.
22. Disconnect drive shafts from the gearbox, as described in Chapter Coupling and power shafts and removing the knuckle, press shafts out of gear box. This hinge is set for a screwdriver. Short jerk screwdriver, remove the differential pinion shaft retaining ring and pops out. Depending on the tree removal may vary as described in detail in Chapter Coupling and power shafts. It does not damage the oil seal in the gearbox. If the packing is damaged, before installing the drive shaft must be replaced.
23. Attach the appropriate cable or chain to the two eyes of the engine and tie rope or chain to the crane. If the lifting lugs no need to prepare two strong steel bracket and screw one behind the other in front of the cylinder head. Slightly lift the unit from the engine compartment, so it was a bit tight. Keep the engine and the gearbox in such a position.
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1. Place the engine and gearbox under the car and fix the cable on the eyes. Lift the unit on the cable in the engine compartment while it is not just about takes the desired position. Check that the path has not been disconnected elements. When lifting, make sure that does not flatten any elements. Be careful not to have been damaged brake lines and brake master cylinder.
2. Align the engine suspension and set the cable tension is to be able to fix the engine mount. Engine mounts when connecting the following points:

• Tighten the nuts and bolts of the front engine mount, t. E. Shown in the illustrations and the rear suspension of the engine. Injector and carburetor engine or engine mount on the front side of the carburettor engine, with a force of 45 - 55 N ??? m. If the engine mount has been unscrewed from the console (injection engine) or the engine (petrol engine), it should be screwed to the force of 50 - 60 N ??? m.

The height of the engine mount on the crossbar must comply with the specified size. Only then inserted horizontally tighten bolts and nuts.

3. Horizontal inserted bolts torque to 45 - 55 N ??? m.

• Tighten the bolts and the rear suspension unit with a force of 45 - 55 N ??? m. Tighten the large through bolt with the same effort.
• When you set manual gearbox shown in the illustration above the engine mounting must be adjusted in height. Console suspension has longitudinal holes and inserted a bolt nut should be tightened with a force of 62 - 78 N ??? m, when it is stored as shown in size.
• Tighten the crossbeam on the bottom side at both ends with a force of 77 - 98 N ??? m. If you have to remove the back support and tighten it with a force of 50 - 60 N ??? m. If you have unscrewed the bracket on the other side of the engine should be tightened to 45 - 55 N ??? m.
• All other engine mount tightening torques shown in the illustrations mounTed injection engine elements and the suspension elements of the engine mounted on the crossbar. The arrow points to the front of the car Since torques are very different from each other, should be very careful not to break the bolt.

4. Detach the cable from the power unit and remove the lift.
5. Insert the drive shaft in the gearbox, as described in Chapter Coupling and power shafts.
6. Connect all electrical wires between consumers of electricity to the engine and bodywork. These include the alternator, oil pressure sensor, thermal sensor remote thermometer, distributor starter, parts supply system, and so on. D. Reconnect the fuel lines.
7. Connect all the vacuum and air hoses between the engine and the body. Depending on the country of destination and of the laws of adjusting the composition of the exhaust gas seal vacuum hoses different. Chapter power supply system and exhaust system are details adjusting the composition of the exhaust gases.
8. Reconnect the throttle cable and check that the throttle at squeezing the accelerator pedal is fully open.
9. Insert the speedometer cable and install the mounting plate, as shown in the Tighten the bolts to the mounting plate.
10. Connect the clutch cable to the lever on and tighten the adjusting nut. Adjust the clutch pedal, as described in Chapter Coupling and power shafts and tighten the lock nut.
11. When you set an automatic transmission, connect the cable to the switch box and the throttle cable.
12. Guided attach the bar switch (1) and thrust plate (2), if you have installed a manual gearbox. Chapter Manual transmission, differential and the main transfer a detailed description of the work.
13. Screw the front exhaust pipe to the exhaust manifold and secure the pipe in suspension. This work is described in detail in Chapter Suspension and steering.
14. Install the power steering pump, if any.
15. Install the heat sink, as described in Chapter Cooling and heating systems. If an automatic transmission, connect the radiator cooler. Check the transmission oil level, top up if necessary.
16. Fill with coolant as described in Chapter Cooling and heating systems.
17. Set the air filter and connect suction hoses.
18. Screw the hood. Tags joints must be the same. Put the hood using the assistant, so he could not fall over.
19. Start and warm up the engine. Check ignition timing and idling engine, adjust if necessary.

1. Remove the starter from the clutch housing.
2. Loosen the bolts between the engine and transmission.
3. Disconnect the box from the engine. Keep the weight of the gearbox is not working on the clutch shaft. Joining the gearbox in reverse order.