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The power unit with manual transmission

Dismantling

The engine may be removed from the car as part of the power unit (ie, complete with transmission) and then separated from the transmission to the engine overhaul.

PERFORMANCE ORDER

1. Place the vehicle on a firm and level surface. Lock the rear wheels, handbrake turn. Lift the front of the car and establish on supports in compliance with all safety standards. 2. Remove the front wheels. 3. Remove the screws and remove all the guards and mud flaps protect the crankcase of the engine. 4. Remove the bonnet. 5. Drain the coolant into the container (if the fluid is suitable for further use). 6. Drain the oil from the checkpoint. Tighten the drain plug and oil level / filling holes, tighten both plugs with the specified torque. 7. If the engine will understand, then drain the oil and, if necessary, remove the oil filter. Clean and tighten the drain plug and tighten with the set moment. 8. Remove the radiator assembly with hoses and fans. 9. Remove the generator and disconnect the wiring from the starter. 10. Remove the power steering pump. Carbureted engines 11. On carburettor engines remove or disconnect the following parts and assemblies: - air filter; - The fuel hose and the return hose from the fuel pump (all apertures muffle to exclude losses of fuel and dirt); - The accelerator cable; - Wiring connectors from the carburettor; - Brake booster vacuum hose, coolant hose, vacuum hoses, valves and crankcase ventilation hoses mounted on the intake manifold; - Support bracket suction manifold; the front exhaust pipe. 12. On vehicles equipped with a catalytic converter, disconnect the connector from the exhaust gas sensor. Odnoforsunochnye injection engines 13. odnoforsunochnyh injection engines (with pre-fuel mixture preparation) remove the air filter. 14. Perform actions on the decompression of the fuel system, disconnect from the chamber throttle valve fuel hose and fuel return hose (all apertures muffle to exclude losses of fuel and dirt). 15. Disconnect the accelerator cable. 16. Disconnect from the chamber throttle body, intake manifold and other parts of the wiring connectors. 17. Disconnect the brake booster vacuum hose, coolant hose, vacuum hoses, valves and crankcase ventilation hoses mounted on the intake manifold. 18. Remove the intake manifold support bracket. 19. Remove the front exhaust pipe. Injection engine with direct fuel injection 20. injection engines with direct fuel injection, perform the following actions remove the air filter duct. 21. Perform actions on the decompression of the fuel system, disconnect from the chamber throttle valve fuel hose and fuel return hose (all apertures muffle to exclude losses of fuel and dirt). 22. Disconnect the accelerator cable. 23. Disconnect from the chamber throttle body, intake manifold and other parts of the wiring connectors. Take conducting aside from the manifold and the cylinder head so that it does not interfere with the removal of the engine. 24. Disconnect the brake booster vacuum hose, coolant hose, vacuum hose valve (1), and the crankcase ventilation hose from the intake manifold (2 - bolts of connection with weight). 25. Remove the intake manifold support bracket. 26. Loosen the clamps and disconnect the hoses from the engine heater and other coolant hoses, pre-marking the original location of each hose. 27. On vehicles equipped with air conditioning, unscrew the bolts of the compressor and take the compressor aside. Tie up the compressor to the body so that its weight is not perceived pipes and hoses, line conditioner. Hoses not to disconnect from the air conditioner. 28. Following the description (see. Subsection 7.7.4), disconnect all the wiring connectors from the ignition distributor, ignition coil and power transistor unit. Release the sleeve of the wiring terminals on the cylinder head and take aside. Loosen the bolts and remove all cables connected to the mass of the cylinder head and intake manifold. 29. Remove the bolts and remove all cables connected to the mass of the cylinder head 30. Remove the half-axis assembly with universal joints (see. Subsection 10.2). 31. Disconnect from the PPC the clutch cable (see. Subsection 8.3). 32. Remove the stem from the checkpoint inclusion of transfers (1), traction gear (2), the speedometer cable and wiring connectors. 33. Move the hoist lift and secure the bracket on the cylinder head, pull hoist, it was perceived that the weight of the power unit. 34. paint or put labels location marker coupling bolt (arrow) in the front support bracket of the power unit to the assembly to install the bolt into position. 35. Loosen and remove the nut of a coupling bolt (arrow), remove the bolt from the support. Remove the nut and get a coupling bolt of a back support of the power unit. 36. Remove the four screws on the central spar, spar remove, to get it out of the power unit. 37. Remove the nut and get a coupling bolt of the right support of the power unit, then remove the mounting bolts and remove the support from the engine compartment. 38. If weakened planting rubber pads mounted on both sides of the support bracket from the body, remove the cushions. 39. Loosen and remove the coupling bolt of the left support of the power unit. Then loosen the three mounting bolts to the checkpoint and move towards support. If weakened planting rubber pads mounted on both sides of the support bracket, remove the cushions. 40. Once again, make sure that all the parts, wires and hoses that may prevent the dismantling of the power unit, disconnected or removed. Also make sure that when dismantling the unit will not be sdeformirovany or damaged other parts of the car (eg traction control rod and PPC). 41. If there is a low cart, then Roll it under the engine to facilitate the extraction of aggregate removed from under the car. Lower the power unit, taking care not to damage or hook located next to the items. This operation is advisable to perform an assistant, because you need a little tilt the unit so as not to hurt the body panels. When lowering the motor, be extremely careful. 42. Roll out the power unit out of the car.

Remove the transaxle from the engine

Setting

PERFORMANCE ORDER

1. If the check point shot from the engine, then follow the steps below Nos. 2-6. If CPR is not removed, then follow the guided installation and beyond. 2. On the input shaft splines, apply a thin layer of refractory greasing. Excess grease is not allowed, otherwise possible lubrication of the friction disk. 3. Install the pins on the engine or PPC (if possible), make sure that the release bearing is securely fixed to the clutch fork. 4. Carefully set the PPC engine on the guide pins. When installing weight CPR should not be perceived primary shaft when the shaft comes into slots on the clutch disc. 5. Tighten the transaxle housing bolts, ensuring proper installation of brackets, tighten the bolts to the specified torque. 6. Install the starter and tighten the bolts. 7. Place the power unit under the car and attach the brackets to the engine hoist lift. 8. Working with an assistant, lift the power unit in the engine compartment, taking care not to touch the parts nearby. 9. Replace the left support bracket of the power unit rubber cushions, making sure the cushion to pin into the holes in the bracket. Replace the bearing, tighten the mounting bolts to the checkpoint, and tighten them to the specified torque. Insert the coupling bolt and tighten the nut by hand. 10. Install the rubber pads on the right arm of the suspension from the body, making sure the pin cushions into the holes in the bracket. Establish a support and tighten bolts with the set moment. Insert the coupling bolt and tighten the nut by hand. 11. Ensure that all rubber pads are in place. On the back support, set the stop ring. Install a central spar, tighten the bolts previously wearing them washer and tighten by hand. Tighten bolts spar with the set moment. 12. Insert a coupling bolt of a back support and tighten the nut by hand. 13. Insert the coupling bolt of the front support. Align the power unit so that the coupling bolt of the front support precisely aligned with the labels put before dismantling, and then tighten the bolt to the specified torque. 14. Shake the powertrain, laid siege to the place, and then tighten to specified torque tightening bolts front, right and left legs. 15. Next, the installation of the power unit in reverse order. When installing, make sure the wiring is laid on the same routes and fixed clips and staples, and that all the connectors are connected. 15. Replace the seals semi-axes and set the half-line at the checkpoint. 16. Connect all coolant hoses and secure with hose clamps. 17. Adjust the accelerator cable. 18. Attach and adjust the clutch cable (see. Subsection 8.3). 19. Install and adjust drive belts. 20. Change the oil in the engine and gearbox, recommended grade of oil and gas volumes (see. Subsection 1.12.7). 21. Fill the coolant. 22. After start the engine and check for leaks.