Table of contents: Installation ↓ Removal and installation of engines… ↓
Removal
Place the engine on a lift and remove the hood.
Disconnect the wire from the negative terminal of the battery.
Set the heater control handle to the "warm" position.
Remove the air filter and close the carburetor with a technological plug.
Remove the cap from the radiator.
Drain the coolant from the cooling system by disconnecting the drain hose from the radiator.
Loosen the tension on the clutch cable and disconnect it from the clutch release fork.
Disconnect the cooling system supply hose from the engine, coming from the radiator.
Disconnect the hose leading to the expansion tank from the radiator pipe and drain the liquid.
Disconnect the drain hose from the water pump.
Disconnect the heater coolant drain hose from the rear of the cylinder head and the radiator drain hose.
Loosen the bolt race securing the silent block to the right engine mount bracket.
Remove the front engine mount bracket.
Disconnect the electric fan switch connector on the radiator.
Disconnect the hose from the upper radiator inlet pipe.
Disconnect the upper silent block of the engine mount from the body.
Disconnect the cooling system electric fan connector.
Remove the radiator.
Unscrew the bracket for mounting the muffler inlet pipe from the exhaust manifold flange.
Disconnect the exhaust pipe from the rubber holders.
Remove the protective shield.
Loosen the nut of the bolt securing the left silent block to the subframe.
Disconnect the wires from the starter.
Place a hydraulic jack or other support under the gearbox (for example, VW 785/1).
Remove the upper transmission-to-engine mounting bolts and release the lower coolant drain hose.
Disconnect the left engine mount bracket from the subframe.
Place the gearbox on a support or hydraulic jack.
Note: Secure the hoist ropes and hooks taking into account the center of gravity.
Raise the engine using a hoist to free the engine mounting brackets.
Separate the engine from the gearbox.
Raise the engine at a slight angle and remove it from the powertrain compartment.
Installation
The engine is installed in the reverse order of removal. Finally tighten the engine mounting bolts to the suspension brackets with the engine idling. Pay attention to the correct connection of the wires to the starter.
Removal and installation of engines with fuel injection system
Removal and installation of fuel injection engines are carried out in the same way as carburetor engines, taking into account the following:
- disconnect the connectors of the control pressure regulator from the thermal time relay, the additional air supply valve and the starting nozzle;
- remove a bundle of electrical wires;
- remove the control regulator from them and disconnect the fuel lines from it;
- unscrew the injection nozzles from their sockets without disconnecting the fuel lines;
- remove the cold start injector without disconnecting the fuel line;
- close the injection and starting nozzles with plugs.
Install the engine in the reverse order of removal.
Crank mechanism parts: 1 - crankshaft; 2 - segment key; 3 - crankshaft pulley; 4 - toothed pulley of the crankshaft; 5 - stopper; 6 - crankshaft toothed pulley mounting bolt; 7 - washer; 8 - crankshaft pulley mounting bolt; 9 - flywheel; 10 - mounting pin; 11, 12 - washers; 13 - gearbox primary shaft needle bearing; 14 - toothed flywheel gear; 15 - flywheel mounting bolt; 16 - ring gear mounting bolt; 17 - retaining ring; 18 - connecting rod; 19 - connecting rod bolt; 20 - piston; 20a - piston pin retaining ring; 21 - connecting rod upper head bushing; 22, 23 - set of liners with thrust flanges of the middle main bearing; 24, 25 - crankshaft main bearing shells; 26 - connecting rod bearing shells.