Contents: Removal ⇊ Installation ⇊
Note: Read the entire section first. The engine and gearbox are removed as an assembly. The gearbox is removed outside the vehicle.
Removal
1. On fuel injected models, relieve the fuel pressure in the system (see Chapter 4).
2. Disconnect the negative cable from the battery.
3. Place the protective covers on the fenders and remove the engine hood (see Chapter 11).
4. Remove the air cleaning unit (see Chapter 4).
5. Raise the vehicle and place it on stands. Drain the coolant and oil, remove the drive belts (see Chapter 1).
6. Label and then disconnect all vacuum lines, hoses, wires, ground cables, and fuel lines. Mark them with tape or paint.
7. Remove the fan, diffuser and radiator of the cooling system.
8. Release residual fuel pressure in the tank (open the lid) and disconnect the fuel supply from the housing to the engine (see Chapter 4). Close the open tubes.
9. Disconnect the throttle linkage, throttle valve linkage and hand throttle linkage from the engine (see Chapter 4).
Note: Do not bend the inner traction cable. Replace the faulty cable with a new one.
10. If the car is equipped with power steering (GUR), disconnect the GUR pump. If there is free space nearby, secure the GUR pump there without disconnecting the hoses from it; otherwise remove the power steering pump (see Chapter 10).
11. On vehicles equipped with air conditioning, remove the compressor and, without removing the hoses, place it aside (see Chapter 3).
12. Disconnect the exhaust pipe from the exhaust manifold (see Section A).
13. Disconnect the wheel drives (see Chapter 8), wires, shaft traction and speedometer cable from the gearbox (see Chapter 7).
Note: On 4WD vehicles, remove the control cable from the transfer case housing. Disconnect the axle shaft from the transmission.
14. Install the hoist hooks into the engine bracket. Tighten the straps with very light force.
Fig. 5.14 Engine lift
15. Make sure again that nothing other than the engine mounts is connected to the engine and gearbox housing.
16. Place a jack under the gearbox. Place a piece of wood between the jack and the gearbox housing. Remove the through bolt from the engine mount and unscrew the stand (see Section A), unscrew the gearbox support bracket (if it is installed) from her.
Caution: Do not place any part of your body under the engine when the power unit is on the jack.
17. Slowly lift the power unit. If necessary, pull the supports off the frame with some kind of lever.
18. Remove the power unit from the vehicle and carefully lower it onto stands.
19. Remove the engine/gearbox reinforcement link.
20. On models with automatic transmission, remove the protective cover from the torque converter. Remove the clamps from the torque converter drive clutch (see Chapter 7) and pull the transformer out of the housing.
21. Unscrew the bolts securing the gearbox to the engine and remove the gearbox
22. Place the engine on the floor and remove the flywheel. Mount the engine on the stand.
Fig. 5.21 Removing the gearbox
Installation
23. Inspect the engine and gearbox mounts. They should not be worn or damaged.
24. On models with manual transmission, check the condition of the clutch (see Chapter 8). On an automatic transmission, check the condition of the seals and bushings.
25. On models with manual transmission, apply high-melting constant grease to the crankshaft support bearing.
26. On models with automatic transmission, lubricate the tip and sealing lip of the oil seal.
27. Carefully install the gearbox into place, following the procedure described in Chapter 7.
Note: Do not use bolt tightening to align the transmission to the engine. This may cause damage to major components.
28. Securely fasten the gearbox to the engine.
29. Lower the power unit into the engine compartment.
30. Install the mounting bolts and tighten them.
31. Install the removed parts in the reverse order of disassembly.
32. Fill with coolant and oil. If necessary, add transmission fluid to the power steering pump reservoir (see Chapter 1).
33. Start the engine and check its operation. Stop the engine and check the level of all fluids.
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