1 - front wheel 2 - mudguard 6 - battery holder 7 - speedometer shaft 8 - reversing light plug 9 - neutral position switch plug 10 - starter motor 11 - shift rod I 12 - shift rod II 13 - engine/transmission beam 14 - front engine/gearbox mount 15 - clutch slave cylinder 16 - tie rod end 17 - stabilizer bar 18 - drive shaft 19 - rear engine/gearbox mount 20 - gearbox
The gearbox is removed downward. This requires a platform hoist or 4 strong supports, as well as a hoist with a suitable wooden spacer to lower the gearbox. A crane is required to suspend the engine remaining on the vehicle.
Removing
1. Disconnect the ground cable from the battery.
Attention! This erases the data from the engine fault memory or the radio's security code. Before disconnecting the battery, read the instructions in Section Removing and installing the battery.
2. Disconnect the positive battery cable, loosen the fastener and remove the battery.
3. Unscrew and remove the battery holder.
4. Carburetor engine: Remove air filter, see chapter Power system, carburetor, fuel injection system, Chapter Removal and installation of the air filter.
5. Injection and diesel engine: Remove the intake pipe and intake manifold prechamber by loosening the clamps and removing the air hose.
6. Diesel engine: Remove fuel filter, see chapter Maintenance.
7. Unscrew the union nut of the speedometer shaft. Remove the speedometer shaft. On cars from 9/89, issue. unscrew the speedometer shaft gear bolt.
8. Gasoline front-wheel drive models up to 9/89, issue. and all models "station wagon": Disconnect the cable on the clutch release lever and unscrew the counter support on the gearbox.
9. Hydraulic drive: Unscrew the clutch slave cylinder from the gearbox housing (2 bolts). Do not loosen hydraulic lines! Pull the supply line out of the holder. Hang the working cylinder on the wire to the side of the body.
10. Disconnect the reversing light cable at the gearbox.
11. To unscrew a cable of weight on the top party of a transmission.
12. If present, unscrew the fasteners of the guide cables and the fastening of the coolant pipe on the gearbox housing.
13. Remove the starter by loosening the bolts for this. Disconnect the cable and plug on the starter beforehand, see also Chapter Electrical system.
14. Loosen the front wheel bolts without unscrewing.
15. Raise the front of the car.
16. Remove the front wheels and unscrew the left side mudguard in the wheel arch.
17. Drain transmission oil, see Chapter Maintenance.
18. Unscrew both shift rods on the gearbox and hang on the wire to the bottom.
19. Remove the left and right drive shafts. To do this, the tie rod ends must be removed first, then the lower wishbones on both sides. In conclusion, squeeze out the drive shafts on the internal hinges, see Chapter Suspension and steering system, Chapter Removal and installation of a power shaft.
20. Remove (if available) front stabilizer, see chapter Suspension and steering system.
21. Attach a cable to the engine earrings and pull it a little, i.e. raise the engine a little.
22. To unscrew a transmission from an average beam of a suspension bracket of the engine. Then unscrew the beam from the body and remove it.
23. Unscrew the clutch cover.
All wheel drive only
1. Remove cotter pins and remove shift rods from gear levers. Remove the brackets on the counter supports.
2. Unscrew the bolts of the supporting console of the intermediate shaft of the drive shafts.
3. Remove the exhaust pipe of the muffler, as well as the cross beam on the propeller shaft tunnel.
4. Remove the cardan shaft, before loosening the bolts, mark the position of the flanges in front and behind with a felt-tip pen so that the shaft can be installed in its previous position.
5. Only BP - SOHC engines (motor identification see chapter Gasoline engines): Unscrew the differential lock (4 bolts), having previously turned the switching rod with a screwdriver (performed in the workshop).
6. Unscrew the rear engine mount on the body.
7. Lower the engine/gearbox using a hoist on the left side.
8. To unscrew a forward support of the engine on a transmission.
9. Place a hoist under the gearbox, using suitable wood shims.
10. Unscrew the 2 flange bolts accessible from above connecting the engine and gearbox. On models up to 87, issue. (engines E) instead of 2 there are 4 upper bolts.
11. To turn out from the bottom party the lower bolts of fastening of the engine and a transmission. On diesel engines, additionally unscrew the 2 corners between the gearbox and the engine from the bottom left and right.
12. Slightly lift the gearbox by hand and press it away from the engine with a pry bar.
13. Lower the gearbox using a hoist and roll it out with the help of an assistant.
Installation
1. Before installing the gearbox, check the clutch and release bearing, see Chapter Clutch.
2. Clean input shaft spline and lightly coat with molybdenum paste or spray.
Attention! If too much grease is applied, during operation, it may get on the friction lining of the driven disk, which will lead to malfunctions.
3. Roll the gearbox on a lift under the car.
4. If, when installing the gearbox, the input shaft does not fit into the clutch disc, turn the gearbox shaft slightly (turn on the transmission), or ask an assistant to turn the engine crankshaft a little.
5. Align the gearbox. In most cases, there are guide pins on the engine flange that must fit into the holes in the clutch housing.
6. Insert all mounting bolts and screw the gearbox to the engine. Tighten the bolts 90 Nm.
Attention! In this case, never tighten the gearbox to the engine by tightening the bolts. Tighten all bolts evenly and then tighten with a torque wrench.
7. Screw the front engine support on the gearbox housing, tighten the bolts with force 50 Nm.
8. Set the motor with a hoist to the correct installation position.
9. Screw the middle beam of the engine mount on the gearbox, tighten the 4 bolts -A- with force 50 Nm.
10. Screw the middle beam to the body with force 80 Nm, bolts -B-.
11. Screw the rear engine mount to the body with force 80 Nm.
12. Remove the lift and engine holder.
13. All-wheel drive only: Align the flanges of the cardan shaft according to the marks, insert the bolts with washers, tighten the nuts with force 30 Nm.
14. Four-wheel drive: Install the shift rods and exhaust pipe, if necessary, install the differential lock actuator (performed in the workshop), see paragraph Removal.
15. Four-wheel drive: Screw in the bolts of the support console of the intermediate shaft of the drive shafts in the sequence shown with a force 50 Nm.
16. Insert the clutch cover and screw it on. For diesel engines, additionally screw on the side reinforcement plates.
17. Insert the starter and tighten the 3 bolts with force 40 Nm.
18. Connect the plug and cable to the starter.
19. Install both drive shafts with new circlips, see Chapter Suspension and steering system, Chapter Removal and installation of a power shaft.
20. Install the stabilizer and tie rod ends, see Chapter Suspension and steering system.
21. Screw the shift rods on the gearbox. Tighten the so-called extension rod firmly 40 Nm, shifting rod with force 20 Nm.
22. Screw the mudguard in the left wheel arch.
23. If available, screw on the bottom motor shield.
24. Fill in transmission oil, see Section Current service.
25. Install the speedometer shaft on the gearbox and screw on with a union nut. On cars from 9/89, issue. Pre-insert speedometer gear and secure with bolt -arrow-.
26. Screw the clutch slave cylinder onto the gearbox housing, tighten the bolts to 20 Nm. Lay the hydraulic lines in the mounting on the gearbox. In the version with cable drive, connect and adjust the clutch cable, see Chapter Clutch, Chapter Clutch pedal/cable adjustment.
27. Screw on the front wheels and lower the car.
28. Tighten the wheel nuts crosswise with force 100 Nm.
29. Connect the plug to the reversing light switch.
30. Screw the gearbox ground cable.
31. If equipped, screw the cable holder and the coolant pipe mount to the gearbox housing.
32. Install the air filter and air inlet hose, see Chapter Power system, carburetor, fuel injection system, Chapter Removal and installation of the air filter.
33. Diesel engine: Install fuel filter.
34. Insert and screw the battery holder.
35. Install and connect the battery, first positive, then ground cable.
36. If available, set the clock and set the radio security code.
37. Measure wheel alignment as soon as possible.