65637bd9



3.2.2.3. The power unit from the manual transmission

Dismantle

Prevention

The engine can be dismantled from the car as a part of the power unit (i.e. assembled with transmission), then transmission separates from the engine for capital repairs.

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 with respect for all standards of safety.
2. Remove forward wheels.
3. Unscrew screws and remove all guards of protection of a case and mudguards of the engine.
4. Remove a cowl.
5. Merge cooling liquid in a vessel (if liquid is suitable for further use).
6. Merge oil from the check point. Wrap a drain stopper and a stopper of a control / filling opening, tighten both stoppers with the set moment.
7. If the engine understands, then merge oil and if necessary remove an oil filter. Clear and wrap a drain stopper, tighten with the set moment.
8. Remove a radiator assembled with hoses and with fans.
9. Remove the generator and disconnect conducting from a starter.
10. Remove the pump of the hydraulic booster.
Carburetor engines
11. On carburetor engines remove or disconnect the following details and units:

      – air filter;
      – a hose of supply of fuel and the return hose from the fuel pump (all openings muffle to exclude losses of fuel and hit of dirt);
      – cable of the drive of a butterfly valve;
      – conducting sockets from the carburetor;
      – the vacuum hose of the amplifier of brakes, a hose of cooling liquid, vacuum hoses of valves and hoses of ventilation of a case mounted on the soaking-up collector;
      – a basic arm of the soaking-up collector;
reception pipe of the muffler.
12. On the cars equipped with catalytic converter disconnect the socket from the sensor of exhaust gases.
Odnoforsunochny injector engines
13. On odnoforsunochny injector engines (with preliminary preparation of fuel mix) remove the air filter.
14. Execute actions for a decompression of fuel system, disconnect a hose of supply of fuel and the return fuel hose from the camera of a butterfly valve (all openings muffle to exclude losses of fuel and hit of dirt).
15. Disconnect a cable of the drive of a butterfly valve.
16. Disconnect conducting sockets from the camera of a butterfly valve, the soaking-up collector and other details.
17. Disconnect the vacuum hose of the amplifier of brakes, a hose of cooling liquid, vacuum hoses of valves and hoses of ventilation of a case mounted on the soaking-up collector.
18. Remove a basic arm of the soaking-up collector.
19. Remove a reception pipe of the muffler.
Injector engines with direct injection of fuel
20. On injector engines with direct injection of fuel execute the following events remove an air duct of the air filter.
21. Execute actions for a decompression of fuel system, disconnect a hose of supply of fuel and the return fuel hose from the camera of a butterfly valve (all openings muffle to exclude losses of fuel and hit of dirt).
22. Disconnect a cable of the drive of a butterfly valve.
23. Disconnect conducting sockets from the camera of a butterfly valve, the soaking-up collector and other details. Take conducting aside from a collector and a head of cylinders that it did not interfere with removal of the engine.
24. Disconnect a vacuum hose of the amplifier of brakes, a hose of cooling liquid, vacuum hoses of valves (1) and hoses of ventilation of a case from the soaking-up collector (2 – bolts of connection with weight).
25. Remove a basic arm of the soaking-up collector.
26. Weaken collars and disconnect hoses of a heater and other hoses of the cooling system from the engine, previously having marked an initial arrangement of each hose.
27. On the cars equipped with the conditioner turn off bolts of fastening of the compressor and take the compressor aside. Tie up the compressor to a body so that its weight was not perceived by tubes and hoses of the highway of the conditioner. Not to disconnect hoses from the conditioner.
28. Being guided by the description (see subsection 7.7.4), disconnect all sockets of conducting 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.
29. Turn off bolts and remove all wires of connection with weight on a head of cylinders
30. Remove half shafts assembled with cardan hinges (see subsection 10.2).
31. Disconnect from the check point a coupling drive cable (see subsection 8.3).
32. Disconnect from the check point a rod of inclusion of transfers (1), drafts of gear shifting (2), a cable of a speedometer and sockets of conducting.
33. Bring таль the elevator and fix on arms of a head of cylinders, pull таль that it apprehended the weight of the power unit.
34. Put with paint or a marker tags of an arrangement of a coupling bolt (it is specified by an arrow) on an arm of a forward support of the power unit that at assembly to establish this bolt in former situation.
35. Weaken an inhaling and turn off a nut of a coupling bolt (it is specified by an arrow), get a bolt from a support. Turn off a nut and get a coupling bolt of a back support of the power unit.
36. Turn off four bolts of fastening of the central longeron, remove a longeron, having got it from under the power unit.
37. Turn off a nut and get a coupling bolt of the right support of the power unit, then turn off bolts of fastening of a support and get a support from a motor compartment.
38. If landing of the rubber pillows established on both parties of an arm of a support from a body is weakened, then remove pillows.
39. Turn off and get a coupling bolt of the left support of the power unit. Then turn off three bolts of fastening of a support to the check point and displace a support aside. If landing of the rubber pillows established on both parties of an arm of a support is weakened, then remove pillows.
40. Be once again convinced that all details, wires and hoses which can interfere with dismantle of the power unit are disconnected or removed. Be convinced also that at dismantle of the unit there will be no sdeformirovana or other details of the car are damaged (for example draft and a rod of management of the check point).
41. If there is a low cart, then drive it under the engine that will facilitate extraction of the removed unit from under the car. Lower the power unit, watching to damaging or to hook on the details which are a row. It is expedient to carry out this operation with the assistant as it will be required to incline a little the unit not to touch the body panel. When lowering the engine be extremely careful.
42. Roll out the power unit from under the car.

Removal of the check point from the engine

PERFORMANCE ORDER
1. Fix the removed power unit wooden whetstones, having put it on a workbench or on the pure flat platform in a workshop.
2. Turn off bolts and remove a starter.
3. Make sure that the power unit is reliably fixed and turn off bolts of fastening of a case of the check point to the engine. Mark an arrangement of bolts (and on some cars and the corresponding arms) to establish at assembly on former places.
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. If adjusting pins of the check point freely rock, then get them and you store subsequently to establish on the former place.

Installation

PERFORMANCE ORDER
1. If the check point acted from the engine, then execute the operations described below in subitem 2-6. If the check point did not act, then carry out installation being guided by item 7 and further.
2. On vents of a main shaft of the check point apply a thin film of refractory lubricant. Excess of lubricant is not allowed, otherwise oiling of a frictional disk is possible.
3. Install pins on the engine or the check point (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 when the shaft comes into vents of the conducted clutch plate.
5. Wrap bolts of fastening of a case of the check point, having convinced of correctness of installation of all arms, tighten bolts with the set moment.
6. Establish a starter and tighten bolts.
7. Place the power unit under the car and attach to engine arms таль the elevator.
8. Working with the assistant, lift the power unit in a motor compartment, watching to touching the details located nearby.
9. Establish rubber pillows on an arm of the left support of the power unit, having tracked that hairpins of pillows entered arm openings. Establish into place a support, wrap bolts of fastening of a support to the check point and tighten them with the set moment. Insert a coupling bolt and tighten a nut by hand.
10. Establish rubber pillows on the right arm of a suspension bracket from a body, having convinced that hairpins of pillows entered openings in an arm. Establish a support and tighten bolts with the set moment. Insert a coupling bolt and tighten a nut by hand.
11. Make sure that all rubber pillows are established on the places. On a back support establish a restrictive ring. Establish the central longeron, wrap bolts, previously having dressed on them washers and tighten by hand. Tighten longeron bolts with the set moment.
12. Insert a coupling bolt of a back support and tighten a nut by hand.
13. Insert a coupling bolt of a forward support. Orient the power unit so that the coupling bolt of a forward support was precisely combined with the tag put before dismantling then tighten a bolt with the set moment.
14. Shake the power unit, having besieged into place, then tighten coupling bolts of forward, right and left support with the set moment.
15. Further installation of the power unit is carried out upside-down. At installation be convinced that conducting is laid on former routes and is fixed by clips and brackets and that all sockets are attached.
15. Replace epiploons of half shafts and establish half shafts at the check point.
16. Attach all hoses of the cooling system and fix by collars.
17. Adjust a cable of the drive of a butterfly valve.
18. Attach and adjust a coupling drive cable (see subsection 8.3).
19. Establish and adjust drive belts.
20. Replace oil in the engine and check points, the recommended brands of oil and filling volumes (see subsection 1.12.7).
21. Fill in cooling liquid.
22. Upon termination of start the engine and check existence of leaks.