Table of contents: Removal ↓ Installation ↓
Removal
Place the car on a lift and remove the hood.
Disconnect the wire from the negative terminal of the battery.
Remove the air filter and close the carburetor on top with a technological cover.
Set the heater control handle to the "warm" position.
Remove the plug from the expansion tank. Disconnect the supply hose from the radiator, unscrew the plug from the cylinder block located under the exhaust manifold, and drain the coolant into a container placed under the engine.
Disconnect the throttle cable from the bracket and from the throttle control lever.
Disconnect the fuel drain hose (blue color) from the carburetor and the fuel supply hose from the fuel pump and close their openings with plugs
Disconnect the wires from the electromagnetic shut-off valve, coolant temperature sensor, carburetor automatic starting device temperature sensor, oil pressure sensor.
Disconnect the low-voltage wires from the ignition distributor and the high-voltage wire going to the ignition coil.
Remove the distributor cap, distributor rotor and dust shield.
Unscrew the ignition distributor capacitor and the interior heater control rod.
Disconnect the wires from the ignition coil.
Disconnect the wires from the generator and release the wiring harness.
On an engine with a Solex 1B1 carburetor, disconnect the air damper drive cable from the carburetor.
Disconnect the vacuum hose from the ignition timing delay fitting of the vacuum regulator of the ignition distributor.
Disconnect the brake booster vacuum hose from the inlet pipe.
Disconnect all electrical wires from the starter and remove the clamp.
Disconnect the reverse light switch wiring harness connector located near the battery bracket.
Remove the mounting clamp and disconnect the connector on the generator.
Disconnect the clutch cable.
Note: Secure the clutch cable so that it cannot come loose from the clutch pedal.
Loosen the nuts securing the muffler inlet pipe to the exhaust manifold flange.
Crush the radiator cap.
Disconnect the connector of the electric fan switch and the electric fan motor of the cooling system.
Remove the radiator.
Disconnect the hoses leading to the heater from the engine.
Remove the upper bolts securing the gearbox to the engine.
Disconnect the right support from the engine mount bracket, then disconnect the front support.
Disconnect the exhaust pipe from the exhaust manifold and from the mounting bracket to the gearbox.
Remove the clutch housing protective cover.
Remove the lower bolts securing the gearbox to the engine.
Secure the engine taking into account the center of gravity when lifting the engine.
Suspend the engine using a hoist until the weight is supported by the hooks and cables so that the metal and rubber parts of the power unit suspension can be removed.
Place a support under the gearbox.
Separate the engine from the gearbox.
Turn the engine over and remove it from the engine compartment.
Installation
The engine is installed in the reverse order of removal, taking into account the following:
- finally tighten the engine mounting bolts to the suspension brackets with the engine idling;
- fill the cooling system with liquid;
- adjust the throttle cable;
- secure the exhaust pipe to eliminate excessive vibration;
- adjust the clutch cable;
- after installation, check the running engine for fuel, coolant and oil leaks.
Cylinder block and oil pan parts: 1 - cylinder block; 3 - oil pan gasket; 4 - oil pan; 6 - gasket; 7 - Crankshaft rear oil seal holder; 9 - rear crankshaft oil seal; 9 - breather; 10 - crankcase ventilation hose; 11 - oil drain plug.
Crank mechanism parts: 1 - crankshaft; 2 - segment key; 3 - crankshaft pulley; 4 - toothed pulley of the crankshaft; 5 - stopper; 6 - pulley mounting bolt; 7 - washer; 8 - crankshaft toothed pulley mounting bolt; 9 - flywheel; 10 - flywheel ring gear; 11 - mounting pin; 12 - needle bearing of the primary shaft of the gearbox; 14 - connecting rod; 15 - connecting rod bolt; 16 - connecting rod upper head bushing; 17, 18 - set of liners of the middle main bearing of the crankshaft; 19, 20 - set of crankshaft main bearing shells; 21 - set of lower connecting rod head liners; 22 - piston; 23-25 - piston ring set; 26 - piston pin retaining ring; 27 - piston pin.
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