If your vehicle's radio is equipped with an anti-theft system, make sure you know the correct activation code before disconnecting the battery.
If, after connecting the battery, an unreadable message appears on the display of the instrument panel of the radio, then refer to Section Anti-theft audio system and instrument panel language for details on how to set the display operation.
Withdrawal
1. Depressurize the fuel system (see chapter Supply system), then disconnect the negative cable from the battery.
2. Cover the fenders and front panel and remove the hood (see chapter Body). There are special mats to protect the wings, however, an old bed cover or blanket will also work.
3. Remove the air cleaner housing and intake ducts (see chapter Supply system).
4. Drain the cooling system (see chapter Car maintenance).
5. Label the vacuum lines, emission control hoses, cable connectors, ground rails, and fuel lines for proper connection, then disconnect them. It is convenient to use pieces of adhesive tape with numbers or letters.
If there is some possibility of error, sketch the engine compartment and clearly label the lines, hoses and wires.
6. Mark and disconnect from the engine all hoses of the cooling system (see chapter Cooling system).
7. Remove the cooling fan, shroud and heatsink (see chapter Cooling system).
On the M40 engine, only the cooling fan and casing need to be removed; however, protect the radiator from damage with a board or cardboard.
8. Remove drive belts (see Chapter Car maintenance).
9. Disconnect the fuel lines from the fuel supply pipe (see Chapter Supply system).
Fuel is extremely flammable so take extra precautions when working on any part of the fuel system. Do not smoke, use open flames or light fixtures without shades near the work area, and do not work in a garage with natural gas equipment (such as a water heater or clothes dryer), which has a wick.
10. When performing any work on the fuel system, wear safety goggles and have a fire extinguisher ready.
11. Disconnect the accelerator cable from the engine (see Chapter Supply system) and reset link/speed control cable, if applicable (see chapter automatic transmission (AT)).
12. If installed, remove the power steering pump (see Chapter Steering). Leave the pipes/hoses connected and make sure the pump in the engine compartment is held in the correct position (tie it aside with rope or wire).
13. On models with air conditioning, remove the compressor (see Chapter Cooling system) and take aside or tie outside the working area. Do not disconnect hoses.
14. Drain the engine oil (see chapter Car maintenance) and remove the oil filter. Remove the splash guard under the engine.
15. Remove the starter (see chapter Onboard electrical system).
16. Remove the generator (see chapter Onboard electrical system). This is not necessary on all models, but in any case it is advisable to avoid damage.
17. Disconnect the exhaust system from the engine (see chapter Supply system).
18. If the car is equipped with an automatic transmission, unscrew the bolts and nuts securing the rotation converter to the drive disk (see chapter automatic transmission (AT)). On the M40 engine, unscrew the bolts of the automatic transmission fluid cooling pipes from the sump.
19. Install a jack under the transmission. Place a block of wood between them to prevent damage to the transmission. There are special transmission jacks with safety chains - use one if possible.
20. Attach a lifting sling or piece of chain to the engine lifting eyes. If the eyelets are removed, the chain can be directly attached to the intake manifold studs, however, install a flat washer between the chain and the nut and tighten the nut until the chain is fully pressed to avoid possible bending of the studs.
21. Roll up the winch and attach a sling to it. Take up some slack in the sling or chain, but do not lift the engine.
Do not crawl under the engine when it is only supported by a winch or other lifting device.
22. On the M10, M20 and M30 engines, remove the rear cross member of the transmission mount and lower its rear slightly.
23. Using a socket head, remove the bolts securing the transmission to the cylinder block.
To loosen the bolts securing the clutch housing to the cylinder block, you will need a swivel wrench with a very large extension, which must be directed towards the rear of the transmission.
24. Remove the nuts securing the engine mounts to the frame brackets. On the M40 engine, unscrew the damper bolts from the supports.
25. Again check up, whether there are still other connections of the engine with transmission or the car. If left, then disconnect them.
26. Raise the engine slightly. Gently push it forward to disengage from the transmission. If you are working with an automatic transmission engine, the rotation converter may move forward with the engine. If it remains in the transmission, then do not touch it, however, you may find it easier to let it move forward to further grab it with your hands and remove it from the crankshaft.
Before installing the rotation converter in the transmission, when returning the engine to its place, make sure that the front oil seal of the transmission pump is replaced with a new one, since the old one is usually damaged when the engine is removed along with the converter. Either method is acceptable, however, be prepared for some fluid to leak out as the rotation converter exits the transmission. If you are operating a manual transmission engine, move the engine forward until the input shaft is completely disengaged from the clutch. Slowly lift the engine out of the engine compartment. Check carefully that everything is disconnected.
27. Remove flywheel/drive plate (and rear engine cover, if applicable)...
...and install the engine on a special stand. Do not overturn the M40 engine (see Section Engine Removal Methods and Precautions).
Installation
1. Check engine and transmission mounts. If they are worn or damaged, replace them.
2. Install flywheel or drive plate (see Part Repair work carried out without removing the engine from the car). On a manual transmission engine, install the clutch and pressure plate (see chapter Manual gearbox (RKPP)). This is the right time to replace the clutch.
3. If, when removing the engine, the rotation converter came out with it, then carefully install the converter into the transmission before lowering the engine into the car.
4. Carefully lower the engine into the engine compartment; make sure the motor mounts match.
5. On a car with automatic transmission, install a rotation converter on the crankshaft, following the instructions in Chapter automatic transmission (AT).
6. On a manual transmission vehicle, apply some high temperature grease to the input shaft and insert it into the clutch and crankshaft auxiliary bearing until the clutch housing is flush with the cylinder block. Do not allow the weight of the motor to rest on the input shaft.
It may be necessary to rock the engine slightly or turn the crankshaft to align the clutch disc input shaft splines.
7. Install the transmission-to-engine bolts and tighten them.
Do not use bolts to tighten the transmission to the engine.
8. Reinstall other components in reverse order.
9. Fill with coolant, oil, power steering fluid and, if necessary, transmission fluid.
10. Start the engine and check for leaks and correct operation of all units, then install the hood and check the car on the go.
11. If necessary, charge the air conditioning system and check for leaks.