15.2. Removal and installation of a mechanical box

Removal
Before a detachment of the rechargeable battery find out whether you have a code of turning on of the radio receiver.
Switch off ignition and disconnect a wire of "weight" from the rechargeable battery.
Unscrew four screws and remove an engine casing (see fig. 3.1 – 41).
Weaken collars and remove the air branch pipe which is connecting a flowmeter of air and soaking up the pipeline.
Disconnect electric sockets a lambda sensors.
Unscrew nuts of fastening of the right and left reception exhaust pipes.
Unscrew the top bolts of fastening of the transmission to the engine.

Fig. 3.1-1. Arrangement of clamps of fastening of the lower mudguard of a motor compartment



Release clamps and remove the lower mudguard of a motor compartment (see fig. 3.1-1).

Fig. 3.1-2. Arrangement of bolts of fastening of an arm of the lower mudguard of a motor compartment



Unscrew two bolts and remove an arm of the lower mudguard of a motor compartment (see fig. 3.1-2)
Unscrew bolts and remove the protection covers located over the left and right shaft of the drive.
Unscrew bolts and disconnect internal hinges of shaft of the drive from the transmission. Using a soft wire, suspend the internal ends of shaft of the drive to a body.

Fig. 9-1. An arrangement of bolts of fastening of a reception exhaust pipe to catalytic converter



Unscrew bolts of fastening of the left and right reception exhaust pipes to catalytic converter (fig. 9-1).
Release connecting clips of exhaust pipes and remove reception exhaust pipes and catalytic converter.

Fig. 9-2. Arrangement of a bolt of fastening of the sensor of frequency of rotation of the engine



Turn out the sensor of frequency of rotation of the engine (fig. 9-2) from the forward left side of the transmission.
Disconnect the electric socket

Fig. 9-3. An arrangement of electric sockets of the sensor of a speedometer (A) and the switch of a backing (In)


And (see fig. 9-3) from the speedometer sensor.
Disconnect the electric socket B (see fig. 9-3) from the backing switch (the multipurpose sensor).
Disconnect other sockets and a wire of connection with "weight" from the transmission.
Unscrew bolts of fastening of a starter, remove it and fix on the engine, without disconnecting from it wires.

Fig. 9-4. Fastening of thirst for a gear shifting rod: 1 – draft; 2 – bolt



Unscrew a bolt and remove draft from a rod of gear shifting (fig. 9-4).
Unscrew the lower bolts of fastening of the transmission to the engine, except for the bolts located on each side a transmission flange.
Fix special adaptation on a stationary jack, establish under the transmission and lift a jack so that the weight of the transmission was perceived by a jack.
In the absence of special devices for removal of the transmission support the transmission by a jack through wooden whetstone.

Fig. 9-5. Arrangement of bolts of fastening of the left and right support of the transmission



Unscrew bolts of fastening of the left and right support of the transmission (fig. 9-5).
Unscrew the remained two lower bolts of fastening of the transmission to the engine.
Move the transmission from the engine and lower it by 15 cm in order that access to the working cylinder of the drive of coupling opened.

Fig. 9-6. Arrangement of a bolt of fastening of the working cylinder of the drive of coupling



Unscrew the working cylinder and a soft wire attach it to a body (fig. 9-6). Do not disconnect a hydraulic hose from the working cylinder and do not press a coupling pedal.
Being careful, lower the transmission and take it from under the car.

Installation
Installation is carried out to the sequences, the return to removal, taking into account the following.
Check a condition of coupling.
Clear a shlitsevy part of the leading shaft of the transmission and grease with a thin layer of special G 000 100 lubricant. The layer of lubricant has to be thin and uniform, otherwise during the coupling work excessive lubricant will be rejected on the working surfaces of coupling that can break its work.
Apply a thin film of lubricant on the pusher head interfaced to the coupling switching off lever.
Make sure that the directing plugs for centering of the transmission are installed in the block of cylinders of the engine.
Having raised, attach the transmission to the engine and install the working cylinder of the drive of coupling.
Move the transmission to the engine so that the leading shaft of the transmission entered vents of the conducted clutch plate. For combination of shliyets of an entrance shaft of the transmission with vents of the conducted clutch plate, perhaps, it is necessary to turn a bent shaft of the engine slightly. At installation of the transmission the leading shaft should not hang on a clutch plate.
Having moved the transmission forward, install a coupling case on the directing plugs of the block of cylinders.
Insert bolts of fastening of the transmission to the engine and at this stage tighten their moment 25 N · m.
Establish a starter.
Tighten bolts of fastening of the transmission to the engine the required moment.
Connect a wire of connection with "weight" to the transmission.
Screw in bolts of fastening of support of the transmission (see fig. 9-5).
Remove the device for a transmission raising.
Connect drive shaft to the transmission.
Install protection covers of shaft of the drive and fix them by bolts.
Establish and screw draft of management on the transmission.
Connect electric sockets of a tachometer and light of a backing to the transmission.
Establish a reception exhaust pipe.
Check and if necessary bring to norm oil level in the transmission.
Connect a wire of "weight" to the rechargeable battery.
Turn on the radio receiver and enter into it a code.
Lift glasses power windows up to an emphasis. Then press all switches of a window regulator once again, at least for 1 second, in the provision of closing for activation of the control unit of window regulators.
Determine time on hours.
Before launch of the engine check existence and level of engine oil in the engine.

Moments of an inhaling, N · m
Selector cable arm to the transmission
23
Selector cable to the lever 
5,6
Selector cable cover to an arm 
12
The hydrotransformer to a press disk
85
Emphasis of the compensator of torque of the engine to a frame
40
Torque compensator support to the engine
42
Transmission support to the lower frame
40
Drive shaft to the leading flange of the transmission
77
The drive shaft thermofilter to the transmission
23
The generator to the engine:

M8
22
M10
45


Fig. 9-7. An arrangement and numbering of bolts of fastening of the mechanical transmission to the petrol engine of 2,8 l: And – an installation site of the aligning plug

                       Bolte Moment's position
                                           inhalings, N · m
                                   1 M10x135 45
                                   2 M12x110 65
                             3, 4, 5 M12h67 65
                                     6 M12x90 65
                                     7 M12x80 65
                                     8 M10x50 45
                                     9 M10x38 45
                                     10 M8x40 20

Fig. 9-8. An arrangement and numbering of bolts of fastening of the mechanical transmission to petrol engines 3,7 and 4,2 of l: And – an installation site of the aligning plug

                       Bolte Moment's position
                                          inhalings, N · m
                                  1 M12x75 65
                                2 M12x110 65
                                  3 M10x45 45
                                  4 M12x90 65