Engine (view from above): 1 - pads with carburetor wires; 2 - fuel return hose; 3 - heater hoses; 4 - vacuum booster hose; 5 - fuel supply hose; 6 - clutch cable tip; 7 - ignition coil wire; 8 - radiator hoses; 9 - thrust throttle; 10 - draft air damper; 11 - wire of the sensor of a control lamp of emergency oil pressure
Engine (bottom view): 1 - generator; 2 - right front support; 3 - engine; 4 - gearbox; 5 - starter; 6 - light switch for reversing lights; 7 - stretching; 8 - left front support; 9 - left front wheel drive; 10 - plug of the oil drain hole of the gearbox; 11 - rear support; 12 - gearshift drive rod; 13 - oil sump; 14 - right front wheel drive; 15 - engine oil drain plug
Removing the engine
Before removing the engine, disconnect the wire from the terminal "—" battery.
Drain:
- coolant;
- crankcase oil (see subsection 11.12.);
- gearbox oil (see subsection 11.12.).
Recommendations
Remove the engine complete with gearbox.
When removing the engine, lower it from the engine compartment down.
It is more convenient to remove the engine by placing the car on a lift.
1.Turn away bolts of fastening and remove protection of a case.
2. Remove the exhaust pipe of the muffler (see subsection 11.6.1.).
3. Remove the air filter (see subsection 11.2.).
4. Loosen the clamp and disconnect the brake booster vacuum hose from the engine intake pipe.
5. Loosen the bolt and disconnect the wire "masses" from the clutch housing.
6. Loosen the clamps and disconnect the hoses from the thermostat.
7. Disconnect a high-voltage wire from the central plug of a cover of the distributor of ignition.
8. Press the spring clip with a screwdriver and disconnect the block with low-voltage wires from the ignition distributor terminal.
9. Loosen the clamp and disconnect the fuel supply hose from the fuel pump.
10. Loosen the nuts on the end of the clutch release cable.
11. Remove the cable end from the clutch release lever.
12. Disconnect the block with the wire from the terminal of the starter traction relay.
13. Turn away a fastening nut and disconnect a wire from a contact bolt of the traction relay of a starter.
14. Disconnect the block with the wire from the generator terminal.
15. Loosen the nut and disconnect the wires from the generator terminal.
16. Disconnect the block with the wire from the carburetor shut-off solenoid valve terminal.
17. Loosen the clamp and disconnect the fuel return hose from the carburetor. Remove the hose from the plastic clamp.
18. Loosen the bolt securing the choke linkage to the choke control lever.
19. Loosen the bolt securing the air damper linkage shell to the bracket and disconnect the cable.
20. Remove the accelerator cable spring retainer from the throttle actuator sector.
21. Remove the throttle actuator return spring.
22. Remove the accelerator drive cable from the throttle drive sector.
23. Loosen the fastening nut and remove the accelerator cable bracket from the valve cover.
24. Disconnect the block with the wire from the economizer limit switch of forced idling (EPHH).
25. Disconnect the wire from the coolant temperature sensor.
26. Disconnect the wire from the oil pressure sensor.
27. Loosen the clamp and disconnect the heater supply hose.
28. Loosen the clamp and disconnect the heater outlet hose.
29. Loosen the clamp and disconnect the gear shift rod from the hinge tip.
30. Loosen the fastening nut and disconnect the cable from the speedometer drive.
31. Disconnect the wiring harness from the reversing light switch on the transmission.
32. Loosen the nuts securing the left and right extensions to the suspension arms.
33. Unscrew the three bolts securing the brace bracket to the body and move the left and right brace to a position so that they do not interfere with the removal of the power unit.
34. Remove the cotter pin from the tie rod ball joint to the swing arm.
35. Loosen the tie rod ball joint nut.
36. Press the tie rod ball joint pin out of the strut pivot arm using a special puller.
37. Remove the two bolts and disconnect the suspension arm ball joint from the steering knuckle.
38. Press the shank of one of the internal CV joints of the drive shafts out of the gearbox using a mount and take it aside.
39. Insert a technological mandrel instead of a hinge (e.g. old inner CV joint), so that the side gear does not rotate. After that, disconnect the second CV joint in the same way as the first.
40. Remove the three mounting bolts and remove the clutch housing shield.
The operations specified in points 40 and 41 are carried out to facilitate work on a removed engine with a gearbox.
41. Loosen the three bolts and nuts securing the clutch housing to the cylinder block.
42. Hook the engine on the eyelets and tighten the hoist cables.
43. Unscrew the two nuts securing the rear support of the power unit to the body.
44. Loosen the nut, lift the engine slightly and remove the right front power unit mount bolt.
45. Turn away a nut and take out a bolt of the left forward support of the power unit.
46. Lower the engine on stands, raise the car and remove the engine from under it.
Before lowering the engine, check that all wires and hoses are disconnected from the engine.
Engine installation
Fill in:
- coolant;
- oil in the crankcase;
- oil in the gearbox.
1. Tightening torques for threaded connections see Appendix 3. Finally tighten the threaded fasteners of the power unit supports and front suspension parts after the vehicle is on the floor (rock the front of the car two or three times before tightening).
3. After installing the engine on the car, adjust the carburetor air and throttle actuators, the clutch actuator, as well as the angles of the front wheels.
2. When connecting the front wheel drives to the gearbox, replace the circlips on the splined shank of the inner joints.
Do not install used retaining rings on splined shanks of the joints - this may cause the front wheel drives to disconnect from the gearbox while driving.
4. Start the engine and check for fuel, oil and coolant leaks. Check oil pressure. Listen to the engine, it should run smoothly, without extraneous noise and knocks. Check the operation of the control lamps in the instrument cluster.