Removal
Place the vehicle on a two-post lift, apply the parking brake and turn off the ignition (two-post lift type P3.2G with a lifting capacity of 3.2 t).
Open the hood, unscrew nuts 2 and 5, Figure 3-1, fastenings and disconnect terminal 3 of the "ground" wire and terminal 4 of the "+" wire from the battery (spanner 10).
Unscrew the mounting bolt 6 and remove the clamping bar 7 and battery 1 (replacement head 13, extension, ratchet).
Figure 3-20 - Air cleaner with air supply pipe and intake pipe hose assembly: 1 - throttle pipe; 2 - intake pipe hose clamp; 3 - inlet pipe hose; 4 - upper crankcase ventilation hose; 5 - Upper crankcase ventilation hose clamp; 6 - crankcase ventilation pipe
Loosen the spring clamp 5, Figure 3-20, of the fastening and disconnect the upper hose 4 of the crankcase ventilation from the branch pipe 6 of the cylinder head cover (pliers).
Loosen clamp 2 and disconnect hose 3 of the intake pipe from throttle pipe 1 (phillips screwdriver).
Figure 3-21 - Removing the intake resonator: 1 - bolt; 2 - spacer sleeve; 3 - resonator mounting bracket; 4 - intake resonator
Unscrew the two bolts 1, Figure 3-21, securing the intake resonator 4 to the bracket 3 (replacement head 10, ratchet).
Loosen the air filter mounting bolt and remove the air filter with the intake pipe hose and resonator assembly (replacement head 10, ratchet).
Unscrew nut 2, Figure 3-4, securing bracket 1 of the engine wiring harness to bracket 3 of the air filter and remove the wiring harness from the work area (replacement head 10, extension, ratchet).
Unscrew three nuts 1, Figure 3-5, and remove the air filter mounting bracket 2 (replacement head 10, extension, ratchet).
Disconnect the ends 2 and 3, Fig. 3-6, of the shift and gear selection cables from the ball heads of the levers 1 of the gear shift mechanism (wedge 67.7812-9707-000, hammer).
Squeeze the tabs 5 of the retainer, remove the gear shift cables from the slots of the bracket 4 of the mount and remove the cables from the work area.
Figure 3-22 - Transmission Breather: 1 - heater supply hose; 2 - mounting bracket; 3 - breather tube valve; 4 - breather tube
Remove valve 3, figure 3-22, breather tubes from bracket 2
Figure 3-23 - Oxygen Sensor Diagnostic Harness: 1 - oxygen sensor wiring harness mounting bracket; 2 - gearbox control cable mounting bracket; 3 - oxygen sensor wiring harness mounting bracket; 4 - Engine wiring harness connector; 5 - connector of the diagnostic oxygen sensor wiring harness
Disconnect connector 5, Figure 3-23, of the oxygen sensor wiring harness from mounting bracket 3, remove the oxygen sensor wiring harness from mounting bracket 1 and remove the harness from the work area.
Figure 3-24 - Clutch hydraulic line: 1 - clutch working cylinder; 2 - protective cap for air bleed nipple; 3 - retainer; 4 - clutch hydraulic tube mounting bracket; 5 - bracket; 6 - clutch hydraulic tube with damper assembly
Remove tube 6, Figure 3-24, of the clutch hydraulic drive from the mounting bracket 4.
Press the lock 3 and remove the tube 6 of the clutch hydraulic drive from the working cylinder 1. Install technological plugs on the tube and in the opening of the clutch working cylinder. Remove the tube from the work area (technological plugs).
Figure 3-25 - Disconnecting the bracket securing the radiator outlet hose from the gearbox: 1 - Engine wiring harness to reverse sensor; 2 - bracket mounting bolt; 3 - bracket; 4 - hole for fastening the radiator outlet hose
Unscrew two bolts 2, Figure 3-25, and disconnect bracket 3 securing the radiator outlet hose from the gearbox (replaceable head 13, ratchet).
Remove the front wheels in accordance with the requirements of TI 3100.25100.20594.
Remove the engine mudguard, remove 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.
Unscrew plug 2, Figure 3-8, and drain the oil from the gearbox (plug wrench with 5/16 inch (8 mm) square, installation type 24164 f. "ALFA" (Italy) for collecting used oil).
Screw plug 2 into the oil drain hole in the clutch housing. Tightening torque of the plug 1.9...25 N·m (1.9...2.5 kgf·m) (head with 5/16 inch (8 mm) square, ratchet, torque wrench).
Figure 3-26 - Disconnecting the wiring harnesses from the gearbox: 1 - "ground" wire terminal; 2 - bolt; 3 - fifth gear cover; 4 - mounting bracket; 5 - Engine wiring harness connector to reverse light switch; 6 - Reverse light switch
Disconnect connector 5, Figure 3-26, of the engine wiring harness from switch 6 of the reverse light, disconnect bracket 4 of the wiring harness from cover 3 of the fifth gear and remove the harness from the work area.
Loosen bolt 2 securing terminal 1 of the ground wire to the gearbox and remove the ground wire from the work area (replaceable head 13, ratchet).
Figure 3-27 - Removing the starter: 1 - starter; 2 - mounting bolt
Unscrew the three bolts 2, Figure 3-27, securing the starter and hang the starter 1 on the technological hook (technological hook, replaceable head Torx E10, extension, ratchet wrench).
Figure 3-28 - Removing the rear engine mount bracket: 1 - rear suspension support bracket spacer; 2 - rear suspension support bracket; 3 - rod mounting bolt; 4 - rear suspension support rod; 5 - bracket mounting bolt
Unscrew two bolts 5, Figure 3-28, and remove bracket 2 of the rear engine mount with rod 4 assembled and spacer 1 (replaceable head 18, ratchet).
Knock out and remove the inner joints of the front wheel drives from the differential axle gears and install transport plugs in their place (transport plug - 2 pcs., mounting blade).
Install a crossbar on the engine compartment to support the engine, place a textile loop sling behind the engine tray, hook the crossbar hook onto the loops of the sling and support the engine (crossbar for hanging the engine, textile loop sling with a lifting capacity of 500 kg, sling length 2.0 meters).
Figure 3-29 - Removing the left engine mount bracket: 1 - left engine mount bracket; 2 - left engine mount support; 3 - nuts for fastening the bracket to the support; 4 - bolts for fastening the left support to the gearbox
Unscrew the two nuts 3, Figure 3-29, securing bracket 1 to the left support 2 of the engine mount (replacement head 18, extension, ratchet).
Loosen and remove three bolts 4 securing bracket 1 of the left engine mount to the gearbox and remove the bracket (replacement head 16, extension, ratchet).
Lower the power unit on the engine support beam so that the rear cover of the gearbox drops slightly below the side member (engine support beam).
Figure 3-30 - Disconnecting the gearbox from the engine: 1 - wiring harness mounting bracket; 2 - upper bolt for fastening the gearbox to the engine; 3 - lower bolt for fastening the gearbox to the engine; 4 - bolt for fastening the gearbox to the engine crankcase
Unscrew and remove the two upper bolts 2, Figures 3-30, 3-31, together with the spring washers securing the gearbox to the engine and remove the bracket 1 together with the wiring harness from the work area (replaceable head 19, extension, ratchet wrench).
Figure 3-31 - Disconnecting the gearbox from the engine: 1 - wiring harness mounting bracket; 2 - upper bolt for fastening the gearbox to the engine; 3 - nut for fastening the gearbox to the engine; 4 - bolt for fastening the gearbox to the engine crankcase
Bring the support part of the hydraulic transmission strut up to the stop against the gearbox (hydraulic transmission strut type SG-1 "GARO").
Loosen and remove two bolts 4, Figures 3-30, 3-31, together with spring washers securing the gearbox to the engine crankcase (replaceable head 17, ratchet wrench).
Unscrew and remove bolt 3, Figure 3-30, complete with spring washer and nut 3, Figure 3-31, with spring washer (replaceable head 19, extension, ratchet wrench).
Remove the primary shaft of the gearbox from the splines of the driven clutch disc, lower the hydraulic strut with the gearbox down and remove it from under the vehicle (hydraulic transmission strut type SG-1 "GARO").
Caution: When performing the gearbox removal/installation operation, do not rest the input shaft on the clutch pressure spring petals to prevent damage to them.
Figure 3-32 - Removing the lower clutch housing cover: 1 - upper clutch housing cover; 2 - hook; 3 - lower clutch housing cover
Remove cover 1 from hooks 2, Figure 3-32, cover 3 of the lower clutch housing.
Figure 3-33 - Removing the upper clutch housing cover: 1 - engine; 2 - centering sleeve; 3 - upper clutch housing cover
Remove the upper clutch housing cover 3 from engine 1, Figure 3-33.
Install the gearbox on a workbench, unscrew the two bolts 1, Figure 3-19, and remove the clutch release coupling 2 together with the clutch slave cylinder (replacement head 10, extension, ratchet).
Installation
Check the condition of the front wheel drive seals and replace if necessary (flat screwdriver, mandrel 67.7853-9721 L, hammer).
Install the clutch release coupling 2, Figure 3-19, together with the clutch slave cylinder on the gearbox and tighten the two mounting bolts 1. Tightening torque of bolts 18...24 Nm (1.8...2.4 kgf·m) (replaceable head 10, extension, ratchet, torque wrench).
Attention. Before installing the clutch release sleeve, it is necessary to pre-fill the clutch slave cylinder with brake fluid (technological syringe, brake fluid according to the current "Codifier of the main and auxiliary materials used in the maintenance and repair of LADA vehicles" K 3100.25100.00018).
Install the upper clutch housing cover 3 on engine 1, Figure 3-33.
Install the lower clutch housing cover 3 on hooks 2, Figure 3-32.
Install the gearbox on the transmission stand and place it under the vehicle (hydraulic transmission stand type SG-1 "GARO").
Raise the support part of the transmission rack with the gearbox, insert the splined part of the primary shaft into the splines of the driven clutch disc and align the mounting holes on the gearbox and engine.
Screw in bolt 3, Figure 3-30, complete with spring washer and nut 3, Figure 3-31, with spring washer, without tightening (replaceable head 19, extension, ratchet wrench).
Screw in, without tightening, two bolts 4, figures 3-30, 3-31, together with spring washers for fastening the gearbox to the engine crankcase (replaceable head 17, ratchet wrench).
Install bracket 1, figures 3-30, 3-31 for fastening the wiring harness and tighten the two bolts 2 for fastening the gearbox to the cylinder block with spring washers. Tightening torque of bolts 36...52 Nm (3.6...5.2 kgf·m) (replaceable head 19, ratchet, extension, torque wrench).
Finally tighten bolt 3, Figure 3-30, and nut 3, Figure 3-31, of the gearbox mounting stud to the cylinder block. Tightening torque of bolt and nut 36...52 Nm (3.6...5.2 kgf·m) (replaceable head 19, ratchet, extension, torque wrench).
Finally tighten the two bolts 4, Figures 3-30, 3-31, securing the gearbox to the engine crankcase. Tightening torque of bolts 36...52 Nm (3.6...5.2 kgf·m) (replaceable head 17, ratchet wrench, torque wrench).
Install bracket 1, Figure 3-29, of the left engine mount support onto the gearbox and tighten the three mounting bolts 4. Tightening torque of bolts 53...71 Nm (5.3..7.1 kgf·m)
(replaceable head 16, ratchet and extension, torque wrench).
Attach the power unit to the left support 2 of the engine mount and tighten the two fastening nuts 3. Tightening torque of nuts 90...120 Nm (9.0...12.0 kgf·m) (replaceable head 18, ratchet and extension, torque wrench).
Remove the engine support beam from the vehicle.
Fix valve 3, Figure 3-22, of the breather tube in the mounting bracket 2.
Install the gearbox control cables into the slots of bracket 4, Figure 3-6, on the gearbox.
Apply grease to the spherical pins of the levers of the gearshift mechanism 1 on the gearbox and connect the 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).
Attach bracket 3, Figure 3-22, to the radiator outlet hose mount to the gearbox and tighten the two mounting bolts 2. Tightening torque of bolts 7...9 Nm (0.7...0.9 kgf·m) (replaceable head 13, extension, ratchet, torque wrench).
Install bracket 2, Figure 3-5, of the air filter mount in place and tighten the three nuts 1 of the mount. Tightening torque of nuts 7...9 Nm (0.7...0.9 kgf·m) (replaceable head 10, extension, ratchet, torque wrench).
Install bracket 1, Figure 3-4, of the engine wiring harness onto bracket 3 of the air filter mount and tighten the mounting nut. Nut tightening torque 7...9 Nm (0.7...0.9 kgf·m) (replaceable head 10, extension, ratchet, torque wrench).
Remove the old retaining rings from the inner drive joint ends of the wheel drives and install new rings in the groove centers. Reuse of retaining rings is not permitted.
Remove the transport plug from the gearbox 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.
Press the drive into the axle shaft gear with a sharp movement of the rack with the steering knuckle.
Make sure that the drive is fixed in the axle shaft gear using your hands, applying a load to the inner joint towards the steering knuckle.
Perform installation operations for the other wheel drive.
Install starter 1, Figure 3-27, in place and tighten the three mounting bolts 2. Tightening torque of bolts 22...28 Nm (2.2...2.8 kgf·m) (torx E10 socket, extension, ratchet, torque wrench).
Remove the technological plugs from the clutch slave cylinder and the clutch hydraulic drive tube. Check the condition of the sealing rings on the clutch hydraulic tube fitting and replace if necessary. Connect the tube 6, Figure 3-24, of the clutch hydraulic drive to the clutch slave cylinder 1 and make sure that it is securely fastened with the clamp 3.
Fix the clutch hydraulic drive tube 6 in the mounting bracket 4.
Connect block 5, Figure 3-26, of the engine wiring harness to switch 6 of the reverse light and secure bracket 4 of the wiring harness in the hole in cover 3 of the fifth gear of the gearbox.
Connect connector 5, Figure 3-23, of the oxygen sensor wiring harness to mounting bracket 3 and secure the harness in mounting bracket 1.
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.
Connect terminal 1, Figure 3-26, of the ground wire to the gearbox and tighten the mounting bolt 2. Bolt tightening torque 18...24 Nm (1.8...2.4 kgf·m) (replaceable head 13, extension, ratchet, torque wrench).
Attach rod 4, Figure 3-28, together with bracket 2 of the rear suspension support to the subframe, insert the bolt and tighten the fastening nut without tightening it (replacement head 18, ring spanner 16, ratchet).
Loosen bolt 3 securing rod 4 to bracket 2 of rear suspension support (replaceable head 18, ratchet).
Install spacer 1 on bracket 4 of the rear suspension support and tighten two bolts 3 to secure the bracket to the gearbox. Tightening torque of bolts 90...120 Nm (9.0...12.0 kgf·m) (replaceable head 18, ratchet and extension, torque wrench).
Finally tighten the bolts securing the rear suspension support rod to the subframe and to the rear suspension support bracket. Tightening torque of bolts 90...120 Nm (9.0...12.0 kgf·m) (ring spanner 16, replaceable head 18, ratchet, torque wrench).
Unscrew plug 1, Figure 3-8, to fill with oil.
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 GL-4 according to API classification in accordance with the current "Codifier of main and auxiliary materials used in maintenance and repair of LADA vehicles" K 3100.25100.00018, consumption rate - 2.34 l).
Screw plug 1 into the oil filler hole in the gearbox housing.
Remove air from the clutch hydraulic system in accordance with the requirements of Section 12 of this TI.
Install the engine mudguard in accordance with the requirements of TI 3100.25100.20594.
Install the front wheels in accordance with the requirements of TI 3100.25100.20594.
Install the air filter with the intake pipe hose and resonator assembly on the vehicle.
Attach resonator 4, Figure 3-21, to the intake bracket 3, make sure that there are spacer bushings 2 and tighten the two mounting bolts. Tightening torque of bolts 7...9 Nm (0.7...0.9 kgf·m) (replaceable head 10, ratchet, torque wrench).
Connect hose 3, Figure 3-20, of the intake pipe to the throttle pipe 1, install and tighten clamp 2 of the fastening (phillips screwdriver).
Connect the upper hose 4 of the crankcase ventilation to the branch pipe of the cylinder head cover and secure it with the spring clamp 5 of the fastening (pliers).
Tighten the air filter mounting bolt. Bolt tightening torque 7...9 Nm (0.7...0.9 kgf·m) (replaceable head 10, ratchet, torque wrench).
Install battery 1 on the vehicle, Figure 3-1, install clamping bar 7 and tighten mounting bolt 6. Bolt tightening torque 11...13 Nm (1.1...1.3 kgf·m) (replaceable head 13, extension, ratchet, torque wrench).
Connect terminal 3 of the ground wire and terminal 4 of the positive wire to the battery and tighten nuts 2 and 5. Tightening torque of nuts 4...6 Nm (0.4...0.6 kgf·m) (replaceable head 10, torque wrench).
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 1.19.8, 1.19.15, 1.19.16, 1.19.17, 1.19.21.3.