Installation
Operations are common for all vehicle configurations
Install the transport trolley with the engine and gearbox assembly under the vehicle (trolley type 67.50.004).
Lower the vehicle to the level of the transport trolley.
Bring the crane 1, Figure 3-38, hydraulic to the vehicle, insert the hooks of the lifting clamp 2 into the eyes of the lifting eyes 3 of the power unit and lift the power unit 4. Perform the operation with an assistant (hydraulic crane type OMA-587, grip TCO 3/379.000).
Install two nuts 1, Figure 3-39, securing the power unit to the left support 2 (replacement head 18, extension, ratchet).
For vehicles with H4M engine
Install three bolts 1, Figure 3-40, securing the power unit to the right support 2 (replacement head 16, extension, ratchet).
For cars with engines 21129 and 21179
Install two bolts 1, Figure 3-41, securing the power unit to the right support 2 (torx E12 replaceable head, extension, ratchet).
Operations are common for all vehicle configurations
Tighten the power unit mounting bolts and nuts to the specified torques.
Tightening torques for power unit mounting bolts and nuts:
- to the left support of the power unit suspension 90... 120 N·m (9...12 kgf·m) (replaceable head 18, extension, torque wrench);
- to the right support of the powertrain suspension 54.70 N·m (5.4...7.0 kgf·m) (replaceable head 16 or Torx E12, extension, torque wrench).
Remove the hooks of the lifting clamp from the eyes of the power unit lifting eyes.
Remove old and install new retaining rings on the inner drive joint ends of the wheel drives. Reuse of retaining rings is not permitted (flat head screwdriver).
Remove one transport plug from the transmission differential. Insert the splined part of the inner joint of one of the drives into the axle shaft seal, turn the drive shaft and align the joint splines with the axle shaft gear recesses. Using a sharp movement of the strut with the steering knuckle, press the drive into the axle shaft gear.
Make sure that the drive is locked in place by moving the inner joint with your hands towards the steering knuckle.
Perform installation operations for the second wheel drive.
Install the front suspension subframe with the front suspension arms, anti-roll bar, steering rack and electric power steering pump as an assembly in accordance with the requirements of TI 3100.25100.20594.
Install the rear support of the powertrain suspension in accordance with the requirements of Section 11 of this TI.
For cars with air conditioning system
Remove plugs from compressor openings and pipelines.
Install new sealing rings on the pipes. Apply PAG K-105 compressor oil to the sealing rings, connect pipelines 2, Figure 3-35, to compressor 3 and install two bolts 1 to secure the pipelines. Tightening torque of bolts 7.9 Nm (0.7...0.9 kgf·m) (8 mm socket, extension, ratchet wrench, torque wrench).
For cars of all trim levels
Install the exhaust system in accordance with the requirements of Section 9 of this TI.
For vehicles with manual transmission
Fix the clutch hydraulic tube in the mounting bracket.
Remove the technological plugs from the holes in the pipeline and the working cylinder of the clutch hydraulic drive and connect the pipeline to the working cylinder on the gearbox and secure it by pressing the lock, Figures 3-20 and 3-21.
Remove air from the clutch hydraulic circuit in accordance with the requirements of TI 3100.25100.20593.
For cars of all trim levels
Unscrew plug 2, figure 3-36, oil filler holes on the gearbox housing (for AMT 2182 replaceable head 17, ratchet).
Fill the gearbox with oil. The oil level should be at the lower edge of the filler hole (filling unit C-223-1 for transmission oils, transmission oil according to the current "Codifier of the main and auxiliary materials used in the maintenance and repair of LADA vehicles" K 3100.25100.00018, consumption rate: for AMT 2182 - 2.25 l; for manual transmission JH3 - 2.46 l; for manual transmission JR5 - 2.34 l).
For cars with AMT 2182
Degrease the threads in the gearbox housing and on the plug, apply sealant to the threaded part of the plug (white spirit, consumption rate 2 g; sealant PS-1 according to the current "Codifier of main and auxiliary materials used in maintenance and repair of LADA vehicles" K 3100.25100.00018, consumption rate 1 g).
Install the oil filler plug into the gearbox housing. Tightening torque of the plug 29...46 N·m (2.9...4.6 kgf·m) (replaceable head 17, ratchet, torque wrench).
For vehicles with manual transmission
Install the oil filler plug into the gearbox housing.
For cars of all trim levels
Install the left side mudguard and inner lining in accordance with the requirements of TI 3100.25100.20599.
Install the front wheels in accordance with the requirements of TI 3100.25100.20594.
For vehicles with manual transmission
Install the gear shift cables into the slots of bracket 4, Figure 3-19, on the gearbox.
Apply grease to the spherical pins of levers 1 of the gear shift mechanism and connect ends 2 and 3 of the cables to the levers (AZMOL LSC-15 grease according to the current "Codifier of the main and auxiliary materials used in the maintenance and repair of LADA vehicles" K 3100.25100.00018, consumption rate 1 g).
For cars of all trim levels
Attach in the reverse order of removal:
- brake booster hose or tube end to intake module;
- electrical equipment wiring harness pads;
- heater hoses, cooling system radiator, filling.
When installing wire harnesses, replace cut clamps with new ones.
Tightening torques:
- nuts 1, figure 3-12, fastening terminal 2 of the wiring harness to the starter traction relay 10.13 N·m (1.0...1.3 kgf·m);
- nuts for fastening terminal 4, figure 3-30, wiring harness to the generator 10.13 N·m (1.0...1.3 kgf·m);
- bolt 2, figure 3-31, or nut 1, figure 3-32, fastening the terminal of the ground wire to the gearbox 18.24 N·m (1.8...2.4 kgf·m);
- nuts and bolts for fastening the wire harness brackets 7.9 N·m (0.7...0.9 kgf·m);
- air filter bracket mounting nuts (replaceable heads 10, 13, extension, ratchet wrench, torque wrench).
Connect the fuel line tube tip until you hear a characteristic click. The tip must be securely fixed in the connection. Check the reliability of fixation by trial moving the tip along the tube axis with a little force.
Fix the fuel pipes in the bracket 3, Figure 3-25, pipeline fastenings on the intake module 4 (for engine 21129).
Install the air filter 8, Figure 3-3, with the hose 7 of the intake pipe assembly on the three mounting supports and secure with bolt 9. The tightening torque of the mounting bolt is 7.9 N·m (0.7...0.9 kgf·m) (replaceable head 13, ratchet, torque wrench).
For vehicles with H4M engine
Connect the air supply pipe 1, Figure 3-3, to the air intake.
For cars with engines 21129 and 21179
Attach resonator 4, Figure 3-4, of the intake to the air filter housing and air intake and secure to the body with two bolts 1. Tightening torque of the mounting bolts 7.9 N·m (0.7...0.9 kgf·m) (replaceable head 10, ratchet, torque wrench).
For cars of all trim levels
Connect the canister valve tube to the intake module, Figures 3-7 and 3-15.
Connect hose 7, Figure 3-3, of the intake pipe to the throttle pipe 4 and tighten clamp 5 of the fastening (phillips screwdriver).
Place the upper crankcase ventilation hose 2 onto the intake module pipe (for engine H4M) or cylinder head covers (for engines 21129 and 21179) and secure with clamp 3 (pliers).
Check and, if necessary, bring the oil level in the engine crankcase up to standard (installation type 24065 for filling with engine oil from the company "Alfa" (Italy), engine oil according to the current "Codifier of the main and auxiliary materials used in the maintenance and repair of LADA cars" K 3100.25100.00018).
The oil level should be in the grooved area of the level indicator.
Fill the engine cooling system with coolant in accordance with the requirements of Section 10 of this TI (coolant in accordance with the current "Codifier of main and auxiliary materials used in maintenance and repair of LADA vehicles" K 3100.25100.00018).
Install the battery 1, Figure 3-2, and connect the terminals of the "+" and "ground" wires to the battery in accordance with the requirements of TI 3100.25100.20587.
Install the intake module screen.
For cars with air conditioning
Perform a vacuum degassing of the air conditioning system and load the refrigerant into the system in accordance with the requirements of the operating instructions for the service equipment and TI 3100.25100.20600 (refrigerant R134a according to the current "Codifier of the main and auxiliary materials used in the maintenance and repair of LADA vehicles" K 3100.25100.00018, the mass of the refrigerant filled into the system is 390±20 g).
For cars of all trim levels
Start the engine and let it idle for 2-3 minutes to remove air pockets in the cooling system.
Check the heater's functionality.
After stopping the engine, check the coolant level and the absence of signs of leakage; if necessary, bring the fluid level up to normal. The coolant level should be between the "min" and "max" marks on the expansion tank (exhaust reel with fan type SERF/SP).
When the engine is running, the "Check Engine" indicator light on the instrument panel should not light. When the lamp lights up, switch the electronic engine control system to the diagnostic display mode in accordance with the requirements of TI 3100.25100.12056 (for engines 21129 and 21179), TI 3100.25100.12060 (for engine H4M), identify the fault code and eliminate the cause.
Place the vehicle on a four-post lift, apply the parking brake and lift it off the ground (four-post electromechanical lift type P-178D-03 with a lifting capacity of 3.5 tons).
Press the front suspension with your hands 2-3 times to adjust its components, applying a force of 400-500 N (40-50 kgf) in the area of the front bumper.
Finally tighten the front suspension arm hinge bolts in accordance with the requirements of TI 3100.25100.20594.
Install the engine mudguard in accordance with the requirements of TI 3100.25100.20594.
Check and, if necessary, adjust the front wheel alignment angles in accordance with the requirements of TI 3100.25100.13070.
Present the vehicle to the Quality Control Department. The Quality Control Department will check the vehicle for compliance with the requirements of TU 017200-254-00232934, paragraphs 1.19.5, 1.19.6, 1.19.9, 1.19.10, 1.19.14, 1.19.15, 1.19.19.6, 1.19.21.3, 1.19.21.6.