Note. Below is given only the procedure for disassembling and assembling the power unit, a detailed description of each of the operations is given in the relevant sections of the manual.
Disassembly
Dismantle the power unit in the following order:
1. Mount the power unit on a bench or workbench.
2. On models with manual transmission:
- remove the clutch housing cover (installed on car parts).
- unscrew the bolts securing the starter to the clutch housing and remove the starter. When dismantling the starter, take care not to damage the starter guide pins;
- unscrew the gearbox mounting bolts and carefully disconnect it from the engine, being careful not to rest the gearbox input shaft on the clutch pressure spring petals.
Note. The gearbox mounting bolts are different and must be installed in the same places during assembly.
3. On models with automatic transmission:
- unscrew the bolts securing the starter to the clutch housing and remove the starter. When dismantling the starter, take care not to damage the starter guide pins;
- through the opening for the starter gear in the cylinder block, turning the crankshaft to the desired angle (about 120°), unscrew the torque converter fastening nuts one by one;
- fix the torque converter with a bolt and a strap for one of the holes for the starter mounting bolts;
- unscrew the bolts and remove the automatic transmission, taking into account that its weight should not be taken by the torque converter before it is removed from the drive plate.
Note. The gearbox mounting bolts are different and must be installed in the same places during assembly.
Assembly
Assemble the power unit in the following order:
1. Install the clutch cover with the driven disk on the flywheel along the three centering pins and secure it with bolts.
2. Install the centering sleeves in the lower paws of the cylinder block (if they filmed) and put the top cover of the clutch housing over them.
Pic. 3.2. Drift for centering clutch disc
3. On models with manual transmission, center with drift 0213 (pic. 3.2) clutch disc. Apply a light coat of MOLYKOTE BR2 PLUS grease to the outer surface of the clutch release bearing guide bushing.
Note. Do not apply grease to the splined end of the gearbox input shaft.
4. On automatic transmission models, apply a light coat of MOLYKOTE BR2 PLUS grease to the center of the torque converter shaft. Replace the torque converter mounting nuts with new ones and evenly tighten the nuts in two stages, as described in subsection «Automatic transmission».
5. Connect the gearbox to the engine without resting the gearbox input shaft on the petals of the clutch pressure spring. Attach the gearbox to the engine with bolts.
6. Replace the clutch housing cover and secure it with bolts.
7. Install and secure the starter.
8. Replace the axle shaft seals.