Since some connections are also required to be removed under the vehicle, it must be lifted and placed on reliable stands. Before assembly work in the engine compartment, the front fenders must be covered.
Electrical wires, as well as vacuum and water hoses, can be routed differently in the engine compartment, depending on the year of manufacture and the composition of the equipment. Since it is not possible to provide a detailed description of each of the routing options, it is recommended that wires and hoses be marked when they are disconnected.
Withdrawal
Remove engine compartment hood (see section «Removal and installation of a cowl of a motor compartment»).
Disconnect the wires from the battery.
Remove gearbox (see section «Removal and installation of a transmission»).
Lower the car.
Vehicles with power steering: remove the V-belt, remove the power steering pump and, without disconnecting the hoses, set aside.
Attention: If you have to open the hydraulic system, after installing it (see section «Checking the oil level in the hydraulic steering»).
Vehicles with air conditioning: Unbolt air conditioning compressor and place to one side with connections connected.
Caution: Never open the cooling circuit.
Model 316: remove air filter (see section «Removal and installation of the air filter»).
Drain coolant (see section «Coolant replacement»).
Remove radiator (see section «Removal and installation of a radiator»).
Attention: If the water hoses are fastened with clamps, cut the clamps and use screw clamps for installation.
Remove protective cap -A- from ignition coil. Pull out high voltage wire -C- and unscrew low voltage wires -B- and -D-. Cut the cable tie in the suspension strut tunnel.
Disconnect the alternator connector.
Disconnect connector -2- and vacuum hoses -1- and -3- from electric changeover valve.
Lift up the plastic protective cap. Remove changeover relay and unplug connector -1-.
Disconnect connector -2- of switching unit for transistorized ignition.
Open glove box and unscrew cap -F-. To do this, turn the rear screw -E- 90°to the left, unscrew the front screws (arrows). Then detach the right side of the cover and pull out the cover.
Disconnect connectors -G- and -H- from control unit.
After that, pull the control unit wiring harness out of the engine compartment.
Remove throttle cable (see section «Throttle cable adjustment»).
If present, remove the cable from the Tempomat (speed stabilization).
Mark with adhesive tape and disconnect all vacuum hoses that fit the engine.
Model 316: Detach fuel hose -E- from fuel pump and from mounting -F-. First loosen and slide back the clamp.
6 cylinder engine
Disconnect connector -U- from air mass meter.
On the air flow meter, loosen and slide back the clamp.
Unscrew the air mass meter bracket and pull out the air filter housing together with the air mass meter.
Disconnect the fuel hoses and close them with plugs so that no fuel flows out.
Remove the expansion tank of the cooling system. To do this, disconnect two water and one ventilation hoses, as well as a connector for the coolant level sensor and unscrew the two screws securing the expansion tank.
Disconnect the heating system hoses from the bulkhead, after releasing and pulling back the clamps.
Unscrew the earth jumper from the oil sump.
If there are engine shock absorbers, unscrew and pull out.
Loosen both engine mounts by unscrewing nuts -G-.
Hook up the engine with a rope. To do this, pass through the lifting eyes of the engine (arrow) appropriate cable or chain. Raise the engine with a crane.
Check that all hoses and wires connecting the engine to the body have been removed. Then remove the engine.
Attention: To avoid damage to the body, very carefully guide the engine when removing it.
Installation
Check engine mounts, water, oil and fuel hoses for ruptures and cracks and replace if necessary.
Check engine dampers. To do this, hold the shock absorber in the working position and pull out and sink the shock absorber rod. In this case, the shock absorber rod must move smoothly and with the same resistance throughout the entire working stroke. If there is a large oil leak, replace the shock absorber.
Check the ease of rotation of the crankshaft radial bearing and the clutch release bearing, as well as the ease of movement of the clutch fork.
Check the thickness and condition of the clutch disc friction lining.
Carefully guide the engine into the engine compartment. To avoid damage to the drive shaft, clutch and body, use the engine very carefully when lowering.
Screw, without tightening, the nuts of the engine mounts.
Raise the car.
Install gearbox (see section «Removal and installation of a transmission»).
Lower the car.
Push the engine to level it. Then tighten the engine mounts to 45 Nm.
If the engine shock absorbers were removed, insert and secure them.
Screw the earth jumper onto the oil sump.
Connect the heating system hoses to the bulkhead and secure with clamps.
Insert and secure the expansion tank of the cooling system. Connect ventilation and water hoses. Connect the coolant level sensor connector.
Engine with fuel injection device: check the air filter element, shake it out or replace it if necessary. Secure the air hose with a clamp.
Install and adjust throttle cable (see section «Throttle cable adjustment»).
Install, if present, the Tempomat cable.
Engine with fuel injection device: pull the wiring harness of the control unit into the passenger compartment and connect the connector to the control unit. Insert and screw the cover.
Connect both connectors of the switching unit of the transistorized ignition system.
Insert the switching relay into the additional relay socket. Connect connector.
Connect the electrical wires to the electrical switching valve. Connect vacuum hoses -1- to distributor and -3- to throttle valve.
By connecting the electrical wires to the ignition coil. Put the protective cap on the coil.
Connect the connector to the generator.
Install radiator (see section «Removal and installation of a radiator»).
If removed, mount the A/C compressor and power steering pump and mount them. Apply and tighten the V-belt (see section «Replacing and tensioning the V-belt of the power steering pump»).
Connect all electrical wires, vacuum, water and fuel hoses in accordance with the marking made during removal. Secure hoses with clamps. Fix the wires with cable ties.
Check the oil level in the engine and gearbox and top up if necessary.
Check the frost resistance of the coolant and add it if necessary (see section «Checking the coolant level»).
Clean the air filter element or, if necessary, replace it.
Install air filter (see section «Removal and installation of the air filter»).
Connect the wires to the battery.
Check ignition timing and adjust if necessary (see section «Checking and adjusting the ignition timing»).
Check and, if necessary, adjust the idle speed settings.
Warm up the engine to operating temperature, check the coolant level and the tightness of all hose connections.
Check valve clearances (see section «Checking and adjusting valve clearances»).
Install engine compartment hood (see section «Removal and installation of a cowl of a motor compartment»).