2.1.1. Car with manual transmission
- Disconnect the ground wire from the battery. To avoid metal parts, such as tools, falling on the battery, it is better to remove the battery.
- Loosen the engine compartment hood mounting bolts. Mark the outer contours of the hood hinges with a pencil to install the hood in its previous position.
- Remove the air filter. Cover the opening with a clean cloth to prevent foreign objects from getting into it. On an injection engine, remove the air hoses to access other parts.
- To avoid damage to the drive shaft seals, wrap them with rags.
- Place the front of the car on stands.
Do not support the vehicle under the oil pan or under the gearbox. Raise the vehicle in accordance with the instructions in Chapter 1.5.
- Drain the coolant from the cooling system.
- Disconnect the following electrical connectors:
- carburetor solenoid valve connector (1.6L engine with carburetor),
- cooling system temperature switch connector,
- fan motor connector, all fuel injection device connectors between the body and the engine,
- all other wires and cables between the body and the engine. Mark individual cable connections accordingly to ensure their correct connection.
- Unscrew the muffler pipe from the exhaust manifold.
In the engine compartment, carry out the following work:
- Remove the radiator (chapter 4.2).
- Disconnect the throttle cable from the carburetor or throttle body assembly.
- Loosen the clamp on the fuel pump nipple and disconnect the hose. Secure the hose with the opening facing up (carburetor engine). On an injection engine, disconnect the fuel hoses from the corresponding fittings.
- Disconnect the air damper cable from the carburetor and release it from the cylinder head cover (if installed).
- Disconnect the ground connections between the engine and the body.
- Follow the routing of the powerful hose secured to the bulkhead and disconnect it from the intake manifold fitting. This is the brake booster vacuum hose.
- Disconnect the high-voltage ignition wires from the ignition distributor and ignition coil.
- Disconnect the wiring harness from the rear of the generator.
- Disconnect the thin ground wire. It is attached to the thick wire harness coming from the battery.
- Disconnect the thick and thin wires from the starter.
- Disconnect the temperature gauge temperature sensor connector at the front of the engine (top).
Perform the following work under the vehicle:
- Remove the engine mount.
- Unscrew the clutch slave cylinder from the gearbox without disconnecting the hydraulic connections.
- Disconnect the gear shift cables from the transmission.
- Perform all work described in the chapter "Gearbox" and related to separating the gearbox from the chassis.
- Place a jack under the differential and lift it slightly.
- Insert the cable into the engine lifting brackets and secure it to the lift.
- Carefully lift the engine with the gearbox. First check that all wires and hoses are disconnected. If there is any interference when pulling out the engine, immediately determine the cause.
The engine is installed in the reverse order, but the following points must be taken into account:
- Fill the engine with oil.
- Fill the cooling system with coolant through the expansion tank.
- Start the engine and check that there are no oil, fuel or coolant leaks.
- Adjust valve clearances, ignition timing, idle speed, if any work has been carried out that could change these adjustments.
2.1.2. Car with automatic transmission
- Removal an engine on a car with an automatic transmission is very different from removing an engine on a car with a manual transmission.
- Disconnect the battery ground. To avoid metal parts, such as tools, falling on the battery, it is better to remove the battery.
- Loosen the engine compartment hood mounting bolts. Mark the outer contours of the hood hinges with a pencil so that you can later install the hood in its original position.
- Remove the air filter and disconnect the air supply hoses and other hoses connected to it.
- Unscrew and remove the radiator grille.
- Place the front of the car on stands.
Do not support the vehicle on the oil pan or gearbox. Raise the vehicle in accordance with the instructions chapters 1.5.
- Drain the coolant from the cooling system.
Depending on the car model, perform the following work in the engine compartment:
- Disconnect the upper water hose from the engine (releasing the clamp).
- On the left side between the carburetor and the front wing, disconnect the connector of the wire of the electromagnetic valve of the idle speed of the carburetor.
- On the left side, disconnect the thin hose from the carburetor (between the carburetor and the wall).
- On the left rear in the engine compartment, disconnect the hoses from the fuel pump, having first released the clamps holding them in place. Secure the hoses with the holes facing up.
- Disconnect the throttle cable from the carburetor and release it from the cylinder head cover.
- On an injection engine, disconnect all connections belonging to the injection device between the engine and the body. Mark the cable connections accordingly so that they can be reconnected correctly.
- Trace the route of the powerful hose secured to the bulkhead and disconnect it from the intake manifold. This is the brake booster vacuum hose.
- Disconnect both heater hoses, first loosening their clamps.
- Disconnect the ignition wires from the distributor and ignition coil.
- Disconnect the wiring harness from the rear of the alternator.
- Disconnect the thin ground wire.
- Disconnect the thick and thin wires from the starter, as well as the starter interlock connector near the starter.
- Unscrew and remove the starter.
- Disconnect the temperature sensor connector of the temperature gauge, disconnect the ground wire and disconnect the oil cooler hoses. Drain the oil from the box. Secure the hoses with the holes facing up.
- Remove the lower water hose between the engine and the radiator.
- Unscrew the fan shroud and push it away from the radiator.
- Unscrew the radiator mount and carefully pull it upward.
- Disconnect the throttle rods from the carburetor lever or from the throttle valve assembly lever. To remove the roller from the cable, move the segment.
- Unscrew the muffler pipe from the exhaust manifold flange.
- Unscrew the union nut from the oil cooler pipe.
- Loosen the muffler pipe clamp.
Perform the following work under the vehicle:
- Disconnect the oil cooler pipe from the gearbox.
- Remove the engine mount.
- Support the gearbox with a jack, placing a wooden block between the jack and the gearbox.
- Loosen the gearbox mounting bolts to the chassis in accordance with the instructions chapters 10.1.
- Hook the engine with a rope or a target and pull it out. If something is blocking the engine, immediately determine the cause.
The engine is installed in reverse order.