Contents: Removal ↳ Installation ↳
Attention: This section covers the removal and installation of the engine together with the gearbox.
Removal
Place the car on a flat horizontal surface and loosen the front wheel nuts. Depressurize the fuel system. Remove the ground wire from the battery. Remove the protective covers on the fenders, then remove the hood. Drain the coolant from the cooling system and engine oil.
On MTX-75 gearboxes, install a suitable container under the gearbox, then unscrew the drain plug and drain the oil. Replace the plug and tighten to the required torque. Remove the air filter housing and engine air supply system components.
Equalize the pressure in the fuel tank by unscrewing the filler cap. Disconnect the supply and return fuel hoses and plug them with plugs.
Disconnect the accelerator cable from the throttle. Disconnect the power steering pressure sensor connector. Disconnect the ground bus from the engine.
Label and disconnect the following vacuum hoses:
- from the rear of the intake manifold.
- brake booster hose from the intake manifold.
- vacuum hose from the air filter.
Unscrew the bolt securing the ground bus to the gearbox. Remove the speedometer drive cable (see Fig. 4D.19).
Remove the additional ground bus located at the top of the engine-to-gearbox connection. Remove the clutch cable. Label and disconnect the electrical connectors from the following components (see Fig. 4D.20-4D.22):
- from the ignition coil
- noise suppression connector
- multi-pin connectors
- connector behind the ignition coil
- multi-pin connectors for speed and crankshaft position sensors and vehicle speed
- oxygen sensor connector
Loosen the exhaust manifold heat shield mounting bolt and remove it. Remove the auxiliary drive belt.
Label and disconnect the following system hoses:
- hoses from the thermostat housing
- hoses from a metal drain pipe
- upper radiator tank hoses
Loosen the nut securing the power steering pump hose clamp to the timing belt cover.
Raise the front of the car and secure it on stands or lift the car. Remove the front wheels. Disconnect the electrical wires from the starter and generator.
Disconnect the oil pressure sensor connector.
On models with automatic transmission, disconnect the starter interlock connector and disconnect the gear selector cable. On models with manual transmission, disconnect the gear shift rod, after making alignment marks on the rod and gear shift shaft (see Fig. 4D.23, 4D.24).
On models with automatic transmission, clean the areas around the pipe connections to the transmission and disconnect the pipes. Plug the ends of the pipes with plugs.
Unscrew the nuts and disconnect the exhaust pipe from the exhaust manifold. If the car is equipped with air conditioning, remove its components that will prevent the engine from being removed.
Caution: Do not disconnect any hoses in the air conditioning system.
Disconnect the anti-roll bar from the left and right front suspension. Unscrew the lock nut and remove the TORX bolt securing the lower control arm to the hub.
Insert a suitable lever between the gearbox housing and the drive shaft joint and, pressing the lever, remove the drive shaft from the gearbox. At the same time, pull the wheel to the side to completely remove the drive shaft from the gearbox. Tie the inner part of the drive shaft to the steering gear. In place of the drive shaft removed from the gearbox, insert a suitable plug to hold the differential half-axle gear in place.
Remove the left drive shaft from the gearbox in the same manner. Remove the oil filter.
Remove the two upper bolts and one lower bolt and remove the right engine mounting retainer. Attach the engine to the slings of the lifting mechanism and lift the engine so that the weight of the engine is supported by the lifting mechanism. Remove the two bolts securing the left rear transmission mount. Remove the two nuts securing the right mount to the body. Remove the two bolts securing the left front mount to the body.
Make sure the engine and transmission are completely disconnected from the vehicle.
Lower the engine and gearbox and remove them from under the car. Separate the gearbox from the engine.
Check the powertrain suspension and replace worn parts if necessary.
Installation
Installation is performed in the reverse order of removal. However, the following points should be noted:
- install new snap rings from the drive shaft groove to secure them in the gearbox
- replace the sealing gasket when installing the exhaust inlet pipe to the exhaust manifold
- check that the grounding bars are clean and securely fastened
- tighten the bolts and nuts to the required torque
- install a new oil filter, fill the engine and gearbox with motor oil
- fill the cooling system with liquid