To remove the power unit, roll the car onto a lift (better two-post) and brake it with the parking brake. Place chocks under the rear wheels and hang up the front wheels. Open the hood and remove it if the power unit will be removed with a hoist. Remove the spare wheel and disconnect the wire from the negative terminal of the battery.
Raise the car on a lift and remove the engine mudguards by unscrewing the bolts that secure them to the body. Drain the coolant from the radiator, cylinder block and heater by unscrewing the drain plugs on the cylinder block and radiator (just two plugs); remove the expansion tank cap and open the heater tap by moving the lower heater control lever to the right. Lower the car.
Disconnect the wires from the starter and generator, from the coolant temperature gauge and oil pressure warning lamp sensors, from the reverse light switch and the carburetor electromagnetic valve. Disconnect the wires from the spark timing sensor and remove the high-voltage wires, disconnecting them from the spark plugs and ignition coil. Disconnect the ground wire from the power unit by unscrewing the nut securing the wire tip to the clutch housing.
Remove the air filter by disconnecting the crankcase ventilation hose from the cylinder head cover and the warm air supply hose from the warm air intake. Close the carburetor from above with a technological plug.
Disconnect the fuel supply hose from the fuel pump, and the brake booster hose from the inlet pipe. Disconnect the coolant drain hose to the radiator from the pipe on the cylinder head, and the coolant supply hose and the hose going to the expansion tank from the thermostat. Disconnect the fluid supply and drain hoses from the heater pipes on the front shield.
Disconnect the air and throttle valve drive cables from the engine by unscrewing the nuts and bolt securing the cable casings to the brackets on the intake pipe and carburetor and disconnecting the cable ends from the carburetor.
The flexible speedometer drive shaft is disconnected from the gearbox by unscrewing the union nut, and the clutch drive cable is disconnected by unscrewing the nuts securing the cable sheath to the gearbox cover and disconnecting the cable tip from the clutch release fork lever. Measures are taken to ensure that there are no sharp bends in the speedometer drive shaft when removing the power unit.
If the power unit is removed using a hoist, then it is hooked onto the brackets installed on the cylinder head and gearbox. The car is raised on a lift, while simultaneously tightening the hoist chain so that the power unit remains suspended.
Disconnect the rod 13 (see figure 80) the gear shift lever drive from the gear selection rod hinge by unscrewing the clamp bolt 12. Disconnect the reaction rod 14 from the gearbox by unscrewing the mounting bolt.
Loosen the bolts that hold the flanges of the intake pipe and the muffler pipe together and remove the sealing ring located between the flanges.
Disconnect the ball joints of the suspension arms from the steering cams. Unscrew the nuts of the clamps securing the steering gear and disconnect it from the subframe. Unscrew the nuts securing the tips of the outer joints of the front drive shafts to the hubs and disengage the tips from the wheel hubs.
If the power unit is removed using a special trolley with a hydraulic lift, then it is moved under the car and the hydraulic lift support brackets are raised until they stop against the subframe.
Loosen the bolts securing the subframe to the body and lower the power unit with the subframe down. If a hoist is used, then gradually release the hoist chain and carefully lower the power unit with the subframe onto the trolley. Loosen the bolts securing the power unit suspension supports to the subframe and remove the power unit from the subframe.
Install the power unit in the reverse order of removal. After connecting the air and throttle valve drives to the carburetor, adjust them as described in Section. "Engine adjustments". The clutch release drive and the gearbox drive are also adjusted (see section. "Clutch" and "Transmission"). Check and adjust the front wheel alignment angles (see section. "Front suspension, wheels").
After installing the power unit on the car, carefully check the quality of the installation. Let the engine run for some time, and then check for coolant and fuel leaks in the pipe connections, and tighten the connections if necessary. Check whether the electrical equipment wire contacts are reliable and whether the signal lights on the instrument panel are working correctly.