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3.1.2.4. The power unit from the manual transmission

Dismantle

Prevention

The engine can be dismantled from the car only as a part of the power unit (i.e. assembled with transmission). The power unit falls and gets from under the car. Freely to get the engine in such a way, the car needs to be lifted on height not less than 75 cm (from a floor to a front bumper) and to establish on supports.

PERFORMANCE ORDER
1. Install the car on the firm flat platform. Block back wheels, turn on the emergency brake. Lift a forward part of the car and establish on supports.
2. Remove forward wheels.
3. Unscrew screws and remove all guards of the engine.
4. Remove a cowl (see subsection 13.7).
5. Merge cooling liquid.
6. Merge oil from the check point, turn and tighten both stoppers.
7. Merge oil and remove an oil filter, clear and tighten a drain stopper.
8. Remove the battery.
9. Remove a broad tank with an arm.
10. Take off belts.
11. Remove the generator.
12. On the cars equipped with the conditioner turn off compressor bolts, take the compressor aside and fix. Not to disconnect hoses from the conditioner.
13. Remove the pump of the hydraulic booster (see subsection 12.15).
14. Remove supports of brakes, take aside and fix, without disconnecting hoses.
15. Disconnect CV JOINTS from naves.
16. Disconnect half shafts (see subsection 10.2).
17. Disconnect from the check point of draft of gear shifting and a coupling cable.
18. Remove a longeron.
19. Disconnect a reception pipe of the muffler.
20. Remove a radiator with hoses and fans.
21. Disconnect the stabilizer of cross stability (see subsection 12.6).
22. On carburetor engines remove or disconnect the following details and units:

  – air filter;
  – fuel hoses;
  – cable of a butterfly valve;
  – carburetor wires;
  – hose of the vacuum amplifier, cooling system and other hoses of sensors and valves;
  – a rack of the soaking-up collector;
  – socket of the sensor of exhaust gases.
23. On injector engines perform the following operations:

  – remove an air duct of the air filter;
  – execute actions for a decompression of fuel system, disconnect fuel hoses from the case of a butterfly valve;
  – disconnect a cable of the drive of a butterfly valve;
  – disconnect conducting sockets;
  – take conducting aside from the engine.
24. Disconnect all hoses from the soaking-up collector.
25. Remove a rack of the soaking-up collector.
26. Put identification tags and disconnect hoses of a heater and hoses of the cooling system from the engine.
27. Disconnect conducting sockets from the distributor of ignition, the coil of ignition and the transistor power supply unit. Exempt a conducting sleeve from clips on a head of cylinders and take aside. Turn off bolts and remove all wires of connection with weight on a head of cylinders and on the soaking-up collector.
28. Disconnect a cable of a speedometer and a wire from the check point.
29. Fix таль the elevator on eyes of a head of cylinders, pull таль that it apprehended the weight of the power unit.
30. Designate the provision of a coupling bolt (it is specified by an arrow) on an arm of a forward support of the power unit, turn off a nut of a coupling bolt and get a bolt.
31. Turn off a nut and get a coupling bolt of a back support (it is specified by an arrow). Remove a forward support and an arm.
32. Remove the right support and rubber pillows.
33. Remove the left support and rubber pillows.
34. Make sure that all details, wires and hoses which can interfere with dismantle are disconnected, removed and taken aside.
35. Drive the cart under the engine and carefully lower the power unit. It is expedient to carry out this operation with the assistant as it will be required to incline a little the engine not to touch a body.
36. Roll out the power unit from under the car.

Removal of the check point

PERFORMANCE ORDER
1. Fix the removed power unit wooden whetstones, having put it on the pure flat platform.
2. Turn off bolts and remove a starter.
3. Turn off bolts of fastening of the check point, having marked an arrangement of each bolt.
4. Carefully separate the check point from the engine, watching that the weight of the check point was not perceived by a main shaft during its exit from the conducted clutch plate.
5. Get adjusting pins of the check point if their landing weakened.

Installation

PERFORMANCE ORDER
1. If the check point acted from the engine, then execute the operations described below in subitem 3-7. If the check point did not act, then carry out installation, being guided by item 8 and further.
2. On vents of a main shaft of the check point apply a thin film of refractory lubricant.
3. Establish pins (if acted), be convinced that the release bearing is reliably strengthened on a coupling switching off fork.
4. Carefully install the check point on the engine on the directing pins. At installation the weight of the check point should not be perceived by a main shaft.
5. Wrap bolts of fastening of a case of the check point on former places and tighten with the set moment.
6. Establish a starter.
7. Place the power unit under the car and attach таль the elevator.
8. Working with the assistant, carefully lift the power unit in a motor compartment.
9. Establish rubber pillows on an arm of the left support, having tracked that hairpins of pillows entered arm openings. Establish a support and tighten bolts with the set moment. Tighten a nut of a coupling bolt by hand.
10. Establish pillows on the right arm of the party of a body. Establish a support and tighten bolts with the set moment. Tighten a nut of a coupling bolt by hand.
11. Insert a coupling bolt of a back support and tighten a nut by hand.
12. Establish a longeron and tighten bolts.
13. Establish an arm of a forward support and tighten bolts. Insert a coupling bolt. Orient the engine so that the coupling bolt of a support was precisely combined with the tag put before dismantling tighten a bolt nut with the set moment. The distance between centers of bolts of a support and an arm has to be 55(±1,0) mm.
14. Shake the power unit and tighten other coupling bolts with the set moment.
15. Further installation of the power unit is carried out upside-down.
16. Make sure that conducting is laid on former routes and is fixed by clips and brackets and that all sockets are attached.
17. Replace epiploons of half shafts and establish half shafts at the check point.
18. Attach all hoses of the cooling system.
19. Adjust a cable of the drive of a butterfly valve (see subsection 6.1.7).
20. Attach and adjust a coupling cable (see subsection 8.3).
21. Establish and adjust drive belts.
22. Replace oil in the engine and the check point.
23. Fill in cooling liquid.
24. Start the engine and be convinced of lack of leaks.