4.2.3. Removal and transmission installation

Remove the case of the air filter in gathering.

Remove the storage battery and a support of the storage battery.

Disconnect a cable of a choice and a gear change in a following order:

Fig. 4.24. A detachment of cables of a choice and a gear change: 1 — a cable finger; 2 — washers; 3 — a choice and gear change cable; 4 — the E-shaped clamp

- Remove a finger of a cable 1 (fig. 4.24);

- Remove washers 2;

- Disconnect a cable of a choice and a gear change 3;

- Remove the E-shaped clamp 4 cables;

- Disconnect cables from an arm of fastening of cables.

Remove a collar of fastening of electroconducting of the engine.

Fig. 4.25. An arrangement of a bolt (1) fastenings of a wire (2) connections with "weight" and an electric socket (3) inclusions of a lantern of a backing

Turn out a bolt 1 (fig. 4.25) and disconnect a wire of 2 connections with "weight".

Disconnect an electric socket of 3 inclusions of a lantern of a backing.

Fig. 4.26. An arrangement of bolts (1), the bottom hose of a radiator (2) and a bolt (3) fastenings of the gauge of position of a cranked shaft

Turn out bolts 1 (fig. 4.26) and disconnect the bottom hose of a radiator 2.

Turn out a bolt 3, disconnect an electric socket and remove the gauge of position of a cranked shaft.

Fig. 4.27. An arrangement of a nut (1) fastenings of a cable of a speedometer (2)

Turn away a nut 1 (fig. 4.27) and disconnect a cable of a speedometer 2.

Disconnect an electric socket and remove the gauge of speed of the car.

Fig. 4.28. An arrangement of bolts (1) fastenings of the engine of a starter (2) to a transmission and a direction of its removal

Turn out 2 top bolts 1 (fig. 4.28) fastenings of the engine of a starter 2 to a transmission and remove it.

Establish the special tool for engine fastening in gathering DW 110—021 in a following order:

- Remove a gutter sealant;

- Remove a thermoprotective casing of a final collector;

- Arrange the tool for engine fastening in gathering DW 110—021 on the centre of a sealant of a gutter and the forward panel.

Fig. 4.29. Installation and fastening of tool DW by 110-021 bolt (1) fastenings of a final collector

Turn out a bolt 1 (fig. 4.29) fastenings of a final collector and this bolt fix tool DW 110—021.

Turn out the top bolts of fastening of a transmission.

Fig. 4.30. An arrangement of bolts (1) fastenings of the top cover (2) transmissions

Turn out bolts 1 (fig. 4.30) and remove the top cover of 2 transmissions.

Remove forward wheels.

Turn away a drain stopper and merge трансмиссионное oil from a transmission.

Disconnect a coupling cable in a following order:

Fig. 4.31. A detachment of a cable of coupling: 1 — an adjusting nut; 2 — a wire clip; 3 — an aperture of fastening of a transmission

- Turn away an adjusting nut 1 (fig. 4.31) a coupling cable;

- Disconnect a cable from a wire clip 2;

- Disconnect a cable from an aperture of 3 fastenings of a transmission.

Remove a longitudinal beam and the stabilizer.

Disconnect from a transmission power shafts.

Fig. 4.32. An arrangement of bolts (1) fastenings of the bottom plate of coupling (2)

Turn out bolts 1 (fig. 4.32) and remove the bottom plate of 2 fastenings of coupling.

Fig. 4.33. An arrangement of nuts (1) fastenings of a reception exhaust pipe (3) and linings (2) to a final collector

Turn away a nut 1 (fig. 4.33) and remove from a final collector a reception exhaust pipe 3 and a lining 2.

Support a transmission the adaptation for removal and installation of transmission DW220—030N.

Fig. 4.34. An arrangement of the bottom bolt (1) and nuts (2) fastenings of a transmission

Turn out bottom a bolt 1 (fig. 4.34) and a nut 2.

Fig. 4.35. An arrangement of bolts of fastening of a support of a transmission

Turn out bolts of fastening of a support of a transmission (fig. 4.35).

Fig. 4.36. Easing of the hinge by the adaptation for engine DW110-021 support

For removal of a lateral cover of a mechanical transmission that the forward top longitudinal panel (left) did not disturb, incline the engine / a transmission, having weakened a key the hinge of the adaptation for support of engine DW 110—021 (fig. 4.36).

Remove a transmission in gathering in a following order:

- Move a transmission from the engine and slowly lower a transmission an adjusting jack;

- Incline a transmission an adjusting jack;

- Slowly lowering, remove a transmission in gathering.

Using adaptation DW110-021, support the engine in normal position.

The note Wrong position of the engine can damage the details interfaced to it or these details can disturb at work. Therefore at transmission removal correctly support the engine.

If there is no possibility to use the special tool, support the engine by means of a garage jack.

Transmission installation spend to sequences, return to removal.

Establish bolts of fastening of a transmission.

Tighten bolts of fastening of a support of a transmission the moment 45—55 Нм.

Screw bottom a bolt 1 (fig. 4.34) and a nut 2 see and tighten their moment 55—65 Нм.

Screw and tighten nuts 1 (fig. 4.33 see) fastenings of a reception exhaust pipe by the moment 25—35 Нм.

Screw and tighten the top bolts of a transmission the moment 55—65 Нм.

Establish a starter and fix its bolts, having tightened their moment 18—28 Нм.

Connect electric sockets.

Establish the bottom hose of a radiator and the gauge of position of a cranked shaft. Tighten bolts 1 (fig. 4.26 see) fastenings of the bottom hose of a radiator by the moment 8—15 Нм and a bolt 3 gauges of position of a cranked shaft the moment 5—8 Нм.

Tighten a drain stopper the moment 25—30 Нм.

Fill in 2,1 l трансмиссионного oils in a transmission.

Tighten a stopper for check of level of oil by the moment 35—54 Нм.

Adjust length of a cable of coupling, rotating an adjusting nut of a cable of coupling.

Establish the bottom casing of a transmission. Tighten bolts of fastening of the bottom casing of a transmission the moment 35—55 Нм.