Note: A winch and hoist are required for this job. If the torque converter is removed from the transmission (even partially), there may be a significant fluid leak. To prevent this, disconnect the engine from the transmission, carefully support the torque converter by firmly pressing it against the transmission. If the transmission needs to be removed after some time, secure the torque converter by bolting a metal strip across the contact surface of the clutch housing.
Removing
1. Disconnect the negative cable from the battery.
2. Remove the hood (Section 11).
3. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands.
4. Drain the cooling system, remove the radiator and transmission fluid cooler hoses (models with automatic transmission), as described in Section 3.
5. Drain the engine oil as described in Section 1, remove and discard the oil filter.
6. Remove the air filter (or air filter cover), filter line, carburetor or throttle body heater block (depending on the model), guided by Sections 4A or 4B, if it is needed. On carburetor models, disconnect the warm air hose from the air heater chamber on the exhaust manifold and from the air filter, remove the hose. On models with automatic transmission, disconnect additional wiring, hoses, etc. from the carburetor as described in Section 4A.
7. Remove the alternator as described in Section 5.
8. On power steering models, remove the hydraulic pump as described in Section 10.
9. Disconnect the brake booster vacuum hose from the intake manifold.
10. Disconnect the cable from the throttle lever and bracket on the carburetor or intake manifold, depending on the model.
11. On carburetor models, disconnect the coolant hoses from the auto choke housing, and disconnect the wiring from the auto choke heater and pull-down damper coil (see illustrations). Also disconnect the heater block vacuum tube from the carburetor.
12. Disconnect the pressure sensor vacuum tube from the carburetor (see illustration).
13. Remove coolant hoses from intake manifold and/or throttle body, depending on model.
14. Disconnect the fuel supply hoses from the priming pump and vapor separator on carbureted models, or from the fuel lines on the right side of the engine compartment on other models. Seal open ends of pipes and hoses to prevent dirt and fuel from escaping (see illustrations).
15. Disconnect all relevant electrical wiring and connectors, remove the fuel injection harness. Pull the wiring harness shroud, pinch the harness connector retaining clips to release the shroud from the fuel injectors (see illustration).
16. Disconnect the heater coolant hoses from the coolant lubrication port at the rear of the cylinder block.
17. Disconnect the electrical wiring from the following components (where applicable):
- a) Starter
- b) Distributor (note the position of the high voltage wire)
- c) Oil pressure sensor
- d) Oil temperature sensor
- e) VARG sensor
- j) Oil level sensor
- g) Knock sensor
- h) coolant temperature sensor
- i) Temperature gauge sensor
18. Perform a final check that all relevant hoses, pipes and wires are disconnected and that they are not connected to the engine.
19. Remove the front of the exhaust system as described in Section 4C.
20. Unscrew and remove the protective cover of the clutch housing (see illustration).
21. Remove the clutch (depending on the model), as described in Section 6. On models with automatic transmission, before unscrewing the torque converter, mark its location in relation to the drive disk with chalk or a felt-tip pen. See the Note at the beginning of this Chapter and for more information see Section 7B.
22. Remove the crankshaft pulley. Some pulleys are attached with four bolts that need to be unscrewed with a socket wrench. Unscrew in turn and remove all four bolts. On other engines, the pulley is attached with a single bolt, which also secures the crankshaft sprocket. On manual transmission models, if the engine is in the vehicle, the crankshaft can be blocked from rotating by engaging 1st gear and depressing the brake pedal. Or, through the hole in the clutch housing cover, insert a large screwdriver into the teeth of the flywheel (or drive plate, on models with automatic transmission). The easiest way to get to the crankshaft pulley is through the arc of the right wheel, after removing it.
23. Attach the winch to the engine lifting brackets on the cylinder head, slightly raise the engine.
24. Loosen and remove two of the top three engine-to-transmission mounting bolts accessible from the engine compartment, leaving one in place.
25. Unscrew the right engine mounting bracket from the body and from the cylinder block, remove the mounting bracket.
26. Turn off and remove four bottom bolts of fastening of the engine to transmission.
27. Support the transmission by placing a jack with a piece of wood under it. Remove the remaining upper transmission mounting bolt.
28. Manipulating the engine as needed, separate it from the transmission. Please note that the transmission is located on the pins in the cylinder block.
29. Carefully lift the engine out of the vehicle, being careful not to damage the components in the engine compartment.
30. With the engine removed, the transmission can be supported by placing a plank between the clutch housing and the front suspension lower frame. Then remove the jack from under the transmission.
Installation
Note: New left and right engine/transmission bracket bolts must be used for installation.
31. Using an M10x1.25 tap, clean the threads in the torque converter holes and prepare new bolts before assembling.
32. Support the transmission with a jack, remove the board between the clutch housing and the lower frame.
33. Support the engine with a winch lifting device, gently lower it into place in the engine compartment.
34. Connect the engine and transmission together, while making sure that the transmission is put on the pins in the cylinder block. Then install the top three engine-to-transmission bolts.
35. Tighten all nuts and bolts to the specified torque. When compressing the bolts securing the torque converter to the drive plate, a special adapter is required (see illustration).
36. If the clutch is bolted to the flywheel, make sure that the transmission does not hang on the input shaft.
37. Install the four lower engine-to-transmission bolts, but again, do not fully tighten them at this stage.
38. Install the right engine mounting bracket to the cylinder block, tighten the mounting bolts with a tightening force regulated specifications.
39. Moving the engine and transmission as necessary, install new bolts of the right bracket fastening the engine to the body, then tighten them with the tightening force regulated specifications.
40. Tighten all bolts of fastening of the engine to transmission the tightening force regulated specifications, then disconnect the hoist and winch from the engine, remove the tom box from under the transmission.
41. Install the protective cover of the transmission clutch housing.
42. Install the clutch as described Section 6.
43. Install the front exhaust system as described in Section 4C.
44. Install the crankshaft pulley in the reverse order of removal as described earlier in paragraph 22. Tighten the fastening bolts with a tightening torque regulated specifications.
45. Lower the car to the ground.
46. Reinstall all relevant wires, tubes and hoses, etc., in the reverse order of removal as above.
47. Where applicable, install the power steering pump, tension the pump drive belt, bleed the hydraulic circuit as described in Section 10.
48. Install the alternator and tighten the drive belt as described in Section 5.
49. Establish components of the air filter, being guided by Sections 4A or 4B, if it is needed. On carburetor models, reconnect the warm air hose to the air heater chamber on the exhaust manifold.
50. Install a new oil filter if you haven't already), fill the engine with oil as described in Section 1.
51. Install the radiator, fill the cooling system as described in Section 3.
52. Install the hood as described in Section 11.
53. Connect the negative battery cable.
54. Next, go to Chapter 37.
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