Disconnect the wires from the battery. Disconnect the windshield washer hoses from the hood and remove the hood from its hinges. Remove the crankcase exhaust hose from the cylinder head cover cavity into the intake manifold. Remove the air filter and disconnect the vacuum hose from the intake manifold. On engines with injection, remove the air pipe connecting the metering distributor to the throttle body (Fig. 2.1).
Drain the coolant into a prepared container and disconnect the hose from the lower radiator hose. Remove the upper radiator hose. On engines with injection, also remove the hose connecting the thermostat, water pump and oil cooler tee. Release the clamp and disconnect the throttle actuator cable together with the bracket. On engines with injection, disconnect the wires from the starting injector, control pressure regulator, thermal time relay, additional air supply valve and the ground jumper from the throttle body. Disconnect the fuel supply hose from the fuel pump, and the vacuum supply hose to the brake booster from the inlet pipe. On engines with injection, also remove the fuel supply hoses to the control pressure regulator, starting injector and metering valve-distributor, plug all openings in the fuel lines, disconnect the vacuum supply hose to the electromagnetic shut-off valve and the crankcase ventilation valve hose. Disconnect the wires from the generator, oil pressure sensor, ignition coil, electromagnetic shut-off valve, reverse light switch and oil level sensor (depending on the configuration), and on engines with injection, also disconnect the wires from the starting injector, control pressure regulator, thermal time relay, additional air supply valve, throttle position sensor, and also the throttle ground jumper. Unscrew the nut securing the flexible shaft of the speedometer drive and remove the cable from the clutch release fork lever.
Remove the heat shield (on the GLA engine - the air heater casing) and disconnect the intake pipe from the exhaust manifold. Place the car on stands. The stands must be high enough to allow the engine to be removed by lowering it down. Loosen the exhaust tract fastening parts and remove it. Disconnect the wires from the starter and the engine ground jumper. Loosen the gearshift drive rod and return spring. Disconnect the gearbox reaction rod (Fig. 2.2). Unscrew the cap nut of the gearshift rod retainer. Remove the spring and retainer and drain the oil from the gearbox housing. Remove the suspension arm from the right side of the car.
Install the tool as shown in Fig. 2.3, press the wheel from the inside out and knock the drive shaft out of the gearbox with light hammer blows. Hang the drive shaft to the body. To prevent the differential gears from moving, install a plastic plug or an old internal drive joint. Remove the suspension arm on the left side, remove the left wheel drive shaft and hang it to the body.
Loosen the front and rear gearbox mounting bolts. Tie down the power unit. Loosen the suspension longitudinal tie rod mounting nuts (only on a vehicle with a GLA engine). Loosen the mounting bolts and remove the anti-roll bar (Fig. 2.4). Loosen the engine mount support stud mounting nuts to the side members and the front fender mudguard mounting bolts. Carefully lower the power unit down.
Before installing the power unit, apply sealant such as Omni Fit 3 OM to the cap nut threads, install the gearshift rod retainer and spring and tighten the cap nut (Fig. 2.5).
Insert the power unit into the engine compartment from below, lifting it so that the engine mount studs can be inserted into the side member holes. Install and secure the front fender mudguards. Install and secure the anti-roll bar (and longitudinal strut on a car with a GLA engine). Insert the two gearbox mounting bolts and brackets and lower the power unit. Remove the slings and tighten the engine and gearbox mounts. Install the coolant hose mounting bracket.
Install the left-hand drive with a new locking ring. Insert the ball joint pin of the suspension arm into the hole in the steering knuckle, install the special bolt and tighten the joint nut to a torque of 7.5-9.0 kgf·m. Remove the plastic plug or the old constant velocity joint and install the right-hand drive with a new locking ring. Install the suspension arm on the right side. Install the gearbox reaction rod, place a washer between the rod and the gearbox housing. Make sure that the highest (IV or V) gear is engaged and connect the gear shift drive rod to the gear selector rod. Using device 16-032 for a five-speed gearbox or a 3.5 mm drill shank, pull the gear shift rod down and secure it to the linkage of the support cup. Using a drift, turn the gear selector rod clockwise until it stops and press it into the housing.
Using a rubber ring placed behind the cap nut of the retainer, secure the rod in this position and tighten the rod mounting clamp bolt. Remove the rubber band, take out the drill and attach the return spring to the drive rod. Connect the engine ground jumper and the wires to the starter. Mount the exhaust tract on supports with rubber cushions. Install the air heater casing (only on a vehicle with a GLA engine). Install a new gasket and attach the inlet pipe to the exhaust manifold. and for GMA and GPA engines. in addition, install the heat-insulating shield. Connect the speedometer drive cable to the gearbox and the clutch drive cable to the fork lever. Connect the wires to the generator, coolant temperature sensor, oil pressure sensor, ignition coil, reversing light switch and oil level sensor (if installed). Connect the brake booster hose to the intake manifold and the fuel supply hose from the fuel pump.
On fuel-injected engines, connect the crankcase ventilation hose to the valve, the vacuum supply hose to the additional air supply valve, connect the fuel lines to the metering distributor, to the starting injector, to the control pressure regulator. Connect the wires to the starting injector, the control pressure regulator, to the thermal time relay, to the additional air supply valve and to the throttle body. Install the throttle cable bracket on the carburetor and connect the cable. Connect the hoses and fill the cooling system.
Fill the engine and gearbox with oil. Install the hood and windshield washer hoses. Connect the wires to the battery. On engines with fuel injection, install the pipe connecting the metering distributor to the throttle body. Adjust the ignition and CO content in the exhaust gases. Install the air filter, the gas suction hose from the cylinder head cover cavity, and the vacuum ignition timing regulator hose.