Place the engine on a lift and remove the hood.
Disconnect the wire from the negative battery terminal.
Set the heater control knob to position «warm» («heating»).
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 outlet hose from the radiator.
Loosen the clutch cable and disconnect it from the clutch switch fork.
Disconnect the coolant supply hose from the engine. coming from the radiator.
Disconnect the hose going to the expansion tank from the radiator pipe and drain the liquid.
Disconnect the outlet hose from the water pump.
Disconnect the heater fluid return hose from the rear of the cylinder head and the radiator return hose.
Loosen the race of the silent block mounting bolt to the right engine mount bracket.
Remove the front engine mount bracket.
Disconnect the sensor connector on the radiator to turn on the electric fan.
Disconnect the hose from the upper radiator inlet.
Disconnect the upper silent block of the engine mount to the body.
Disconnect the cooling fan motor connector.
Remove radiator.
Unbolt the muffler exhaust pipe mounting bracket from the exhaust manifold flange.
Detach the front muffler pipe from the rubber holders.
Remove protective shield.
Loosen the nut of the bolt securing the left silent block to the subframe.
Disconnect wires from starter.
Place a hydraulic jack or other support under the gearbox (e.g. VW 785/1).
Unscrew the upper bolts securing the gearbox to the engine and release the lower coolant outlet hose.
Detach left engine mount from subframe.
Place the gearbox on a stand or hydraulic jack.
Note. Fasten ropes and hoist hooks, taking into account the center of gravity.
Hang the engine with a hoist so that the engine mount brackets are free.
Separate the engine from the gearbox.
Raise the engine at some angle and remove it from the powertrain compartment.
Installation
Engine installation is made in an order, the return to 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 engines with fuel injection 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 switch, the additional air supply valve and the starting nozzle;
- remove the bundle of electrical wires;
- remove the regulator of the manager and barely them, and disconnect the fuel lines from it;
- unscrew the injection nozzles from their sockets without disconnecting the fuel lines;
- remove the starting injector for starting a cold engine without disconnecting the fuel line;
- close the nozzles of the injection and starting nozzles with plugs.
Install the engine in the reverse order of collapse.
Details of the crank mechanism: 1 - cranked sluggish; 2 - segment key; 3 - crankshaft pulley; 4 - toothed pulley of the crankshaft; 5 - stopper; 6 - a bolt of fastening of a gear pulley of a cranked shaft; 7 - washer; 8 - a bolt of fastening of a pulley of a cranked shaft; 9 - flywheel; 10 - locating pin; 11, 12 - washers; 13 - needle bearing of the input shaft of the gearbox; 14 - gear Nenets flywheel; 15 - flywheel mounting bolt; 16 - a bolt of fastening of a ring gear; 17 - retaining ring; 18 - connecting rod; 19 - connecting rod bolt; 20 - piston; 20a - piston pin circlip; 21 - bushing of the upper head of the connecting rod; 22, 23 - a set of liners with thrust collars of the middle main bearing; 24, 25 - crankshaft main bearing shells; 26 - connecting rod bearing shells.
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