Contents: Removal ⤓ Installation ⤓
Note: Read this entire section before proceeding. The engine and transmission are removed as an assembly and then separated outside the vehicle.
Removal
If your vehicle is equipped with an air conditioning system, have it emptied at a service station.
1. Release pressure from the fuel system (see Chapter 4).
2. Cover the front fenders with covers.
3. Remove the hood cover, (see Chapter 11).
4. Disconnect and remove the battery from the vehicle (see Chapter 5).
5. Remove the air filter (see Chapter 4). On turbocharged vehicles, remove the turbocharger inlet hose (see Chapter 4).
6. Drain and remove the radiator (see Chapter 3). Note: On vehicles with automatic transmission, disconnect the coolant hoses from the radiator.
7. Clearly mark and disconnect all vacuum lines, cooling system and emission control system hoses and connectors. You can use masking tape and/or a touch-up applicator for marking (see illustration). If necessary, draw or photograph the location of individual components and brackets.
8. Disconnect the fuel lines from the carburetor or fuel injection system (see Chapter 4) and muffle them.
9. Disconnect the throttle control cable (see Chapter 4).
10. Raise the vehicle and place it on stable stands.
11. On vehicles equipped with a manual transmission, disconnect the clutch cable and cables or the gearshift rod and extension rod as described in Chapters 7 и 8.
Note: On models with a hydraulic clutch release system, disconnect the slave cylinder without disconnecting the hydraulic lines (see Chapter 8).
12. On vehicles equipped with an automatic transmission, disconnect the gear shift cable from the transmission, then remove the clutch housing cover and unscrew the bolts securing the drive disc to the converter (see Chapter 7).
13. Disconnect the speedometer cable from the gearbox.
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14. If installed, remove the air conditioning compressor (see Chapter 3).
15. Remove the power steering pump and reservoir (if equipped) from the brackets without disconnecting the hoses and secure them to the side.
16. Remove the splash guard located on the engine drive belt side.
17. Drain the engine oil and transmission fluid and remove the oil filter (see Chapter 1).
18. Disconnect the intake pipe from the exhaust manifold (see Chapter 2 Part A).
19. Disconnect the drive shafts from the gearbox (see Chapter 8). Cover the holes with rags to prevent foreign objects from getting in.
20. Attach a short chain to the engine brackets and connect the winch. Take up the slack until the chain is slightly loaded.
21. Support the gearbox with a jack. Place a wooden block between the jack and the gearbox to avoid damaging the gearbox.
Warning: Do not place any part of your body under the engine/transmission when it is supported only by a winch or other lifting device.
22. Remove the plugs from the right front inner apron.
23. Check the clearances and, if necessary, remove the master brake cylinder (see Chapter 9) and the gearbox mounting bracket.
6.23 On some models it may be necessary to remove the brake master cylinder and unscrew the transmission mounting bracket (arrow) to remove the engine/transmission assembly (1.5L engine shown)
24. Remove the through bolts.
6.24 Remove the long through bolt from the gearbox mount
25. Make sure that all cables, hoses, wires and other components are disconnected from the engine.
26. While lifting the engine, gently push the gearbox down to clear any obstructions.
27. Raise the engine with gearbox to a sufficient height and move the winch to the side.
28. Lower the winch and place the gearbox on stands without disconnecting the winch.
29. Unscrew the bolts and separate the engine from the gearbox. If necessary, contact Chapter 7.
30. Remove the clutch components and flywheel (or drive disc) (see Chapter 2, Part A) and the rear panel of the engine, then secure the engine to the stand.
Installation
31. Check the engine mounts. If they are worn or damaged, replace them.
32. On vehicles equipped with a manual transmission, inspect the clutch components (see Chapter 8) and apply a small amount of high temperature grease to the gearbox input shaft splines
33. On automatic models, check the converter cuff and bushing.
34. Carefully connect the gearbox to the engine according to the procedure described in Chapter 7.
Caution: Do not attempt to use bolts to align the engine and transmission. This may damage key components.
35. Insert the gearbox-to-engine mounting bolts and tighten them securely.
36. Attach the winch to the engine and carefully lower the engine and gearbox assembly into the vehicle.
37. Install the mounting bolts and tighten them securely.
38. Install the remaining components and fasteners in the reverse order of removal.
39. Fill the coolant, oil, working fluid and oil into the power steering and gearbox (see Chapter 1).
40. Start the engine and check its operation and tightness. Turn off the engine and check the fluid levels.