2. Together with an assistant, unscrew the mounting bolts and remove the hood cover (see chapter 11).
3. Remove the air cleaner ducts and air preheating devices (carburetor models). On injection models, disconnect the air intake duct between the air cleaner and the air manifold.
4. Drain the coolant and remove the radiator (see chapter 2).
5. Disconnect the brake servo cylinder vacuum hose from the intake manifold.
6. Disconnect the throttle valve drive mechanism and choke cable from the carburetor (or automatic choke wire). On injection models, disconnect the electrical plugs and brake servo cylinder tube from the throttle body. Disconnect the fuel pipes, noting that one of them (with white stripe) is attached to the fuel distributor pipe closest to the generator. Disconnect the crankcase ventilation hose and throttle body cooling hoses. Disconnect the injector wiring (harness N4 near clutch housing). Remove throttle body/intake manifold (see chapter 3).
7. Disconnect the fuel supply hose leading to the fuel pump (carburetor models) or fuel manifold. Similarly, disconnect the fuel return lines and plug them to prevent fuel leakage (be prepared for fuel spills).
8. Disconnect the electrical wiring from:
- A. generator
- b. starter
- V. distributor
- d. coolant temperature sensor
- d. oil pressure switch (see photo)
- e. inductive pulse sensor (injection models)
- and. fuel injectors.
Photo 18.8. Engine oil pressure switch wire.
Pull the wires out of the clamps and move them to the side.
9. Raise and support the front of the car or place it in a pit.
10. Disconnect the exhaust downpipe from the manifold and at the spring-loaded ball joint.
11. Unscrew the threaded plug from the end cover of the gearbox housing.
12. Remove the opened retaining ring.
13. You now have access to the 12 socket head screw. A special wrench will be required for this screw (You can try using a hex wrench).
14. Unscrew and remove the screw.
15. As stated in more detail in Chapter 5, the transmission drive shaft can be pulled out of the spline of the clutch driven disc. There is a special tool for this (KM449-1 and 22-1), however, you can do without it by borrowing one of the 4 bolts that secure the gearshift cover to the top of the transmission housing. Screw this bolt into the end of the drive shaft and, grasping its head, pull the shaft out of the lapped hub of the clutch driven disc (do not forget to reinstall the bolt on the gear shift cover afterwards). This method is not always suitable in the case of a 5-speed gearbox, because its shaft is seated very tightly and to disconnect it you need a puller or even a reverse hammer.
16. Connect the hoists to the engine and tighten them so as to remove the weight of the engine from the cushions. Support the gearbox with a jack.
17. Remove the generator with its bracket so that you can get to the right rear engine support bracket.
18. Disconnect the right front engine support bracket from both the engine and the mount.
19. Disconnect the right rear engine support bracket from both the engine and the mount. The same bracket contains mounting supports for the generator.
20. Unscrew the mounting bolts and remove the starter.
21. On engines 1.6 and 1.8, remove the pulley from the front end of the crankshaft (4 bolts). To remove these bolts you will have to block the engine (blocking, for example, the starter ring gear).
22. Remove the screws and remove the cover at the bottom of the flywheel housing (looks towards the camshaft belt) (see photo).
Photo 18.22. Flywheel housing front cover.
23. Support the gearbox with a jack.
24. On the flywheel housing flange, remove all the bolts securing the engine to the box. Note that the top two bolts also secure the starter and clutch cable wiring clamps.
25. Disconnect the wire "masses" engine.
26. Move the engine away from the box so that the locating pins come out and turn it slightly so that the camshaft belt cover moves towards the engine compartment bulkhead.
27. Lift the engine, being careful not to damage anything, and remove it from the engine compartment.
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