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).
Figure 3-1 - Battery: 1 - battery; 2, 5 - nut; 3 - "ground" wire terminal; 4 - terminal of the "+" wire; 6 - bolt; 7 - pressure bar
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 3-2 - Air cleaner with air supply pipe and intake pipe hose assembly: 1 - air supply pipe; 2 - Upper crankcase ventilation hose; 3 - Upper crankcase ventilation hose clamp; 4 - throttle pipe; 5 - intake pipe hose clamp; 6 - brake booster hose; 7 - Inlet pipe hose; 8 - air filter; 9 - air filter mounting bolt
Loosen clamp 3, Figure 3-2, of the fastening and disconnect the upper hose 2 of the crankcase ventilation from the branch pipe of the cylinder head cover (pliers).
Loosen clamp 5 and disconnect hose 7 of the intake pipe from throttle pipe 4 (flat head screwdriver).
Remove hose 6 of the brake booster from the clamps on hose 7 of the inlet pipe.
Loosen bolt 9 of the air filter mount (replacement head 10, ratchet).
Figure 3-3 - Disconnecting the air supply pipe from the air intake: 1 - Upper radiator frame crossbar; 2 - air intake; 3 - air supply pipe
Disconnect the air supply pipe 3, Figure 3-3, from the air intake 2 and remove the air filter with the air supply pipe and the intake pipe hose as an assembly.
Figure 3-4 - Engine Wiring Harness Bracket: 1 - Engine wiring harness bracket; 2 - nut; 3 - air filter mounting bracket
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).
Figure 3-5 - Air filter mounting bracket: 1 - nut; 2 — air filter mounting bracket
Unscrew three nuts 1, Figure 3-5, and remove the air filter mounting bracket 2 (replacement head 10, extension, ratchet).
Figure 3-6 - Shift Cables: 1 - gear shift levers; 2 - gear shift cable tip; 3 — gear selection cable tip; 4 — gear shift cable mounting bracket; 5 - retainer antennae
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 3-7 — Clutch hydraulic line: 1 — clutch working cylinder; 2 — protective cap for air bleed nipple; 3, 4 — retainer; 5 — clutch hydraulic tube with damper assembly; 6 — left engine support bracket; 7 — clutch hydraulic tube mounting bracket; A, B - rib, limiter of the latch stroke
Raise the retainer 3, Figure 3-7, up until the retainer's antennae rest against the ribs "A", remove the clutch hydraulic drive tube 5 from the working cylinder 1 and install technological plugs on the tube and in the opening of the clutch working cylinder. When performing this operation, the lock 4 must remain in the recessed position; the lock 4 is used when performing the "air removal" procedure (technological plugs).
Remove the clutch hydraulic drive tube 5 from the mounting bracket 7 and remove the tube from the work area.
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.
Figure 3-8 - Gearbox oil change plugs: 1 - oil fill plug; 2 - oil drain plug
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 3-9 - Disconnecting the engine wiring harness from the cable mounting bracket: 1 - gear shift cable mounting bracket; 2 - mounting bracket; 3 - Engine wiring harness
Disconnect the bracket 2, Figure 3-9, securing the engine wiring harness 3 from the bracket 1 securing the gearbox control cables.
Figure 3-10 - 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 3-10, 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 3-11 - Removing the starter: 1 - starter; 2 - mounting bolts
Unscrew the three bolts 2, Figure 3-11, fastenings and hang the starter 1 on the technological hook (technological hook, replaceable head 13, ratchet).
Figure 3-12 - Disconnecting the front wheel drives from the gearbox: 1 - inner joint of the left wheel drive; 2 - gearbox; 3 - inner joint of the right wheel drive
Knock out and remove the inner joints 1 and 3, Figure 3-12 of the front wheel drives from the differential axle gears and install transport plugs in their place (transport plug - 2 pcs., mounting blade).
Figure 3-13 — Removing the rear engine mount bracket: 1 — rear suspension support rod; 2 — rod mounting bolt; 3 - bracket mounting bolts; 4 — rear suspension support bracket
Unscrew two bolts 3, Figure 3-13, and remove bracket 4 of the rear engine mount support with rod 1 as an assembly (replaceable head 18, ratchet).
Figure 3-14 - Removing the wiring harness mounting bracket: 1 - clip; 2 - wiring harness mounting bracket; 3 - bolt
Unscrew clip 1, Figure 3-14, and bolt 3, remove the breather tube from the groove of bracket 2 and remove the bracket assembly with the wiring harness from the work area (torx T15 screwdriver, 13mm replaceable head, ratchet wrench).
Figure 3-15 - Removing the breather: 1 - bracket; 2 - breather tube valve; 3 - breather tube
Remove valve 2, Figure 3-15, breather tubes from mounting bracket 1.
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 3-16 - 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 3-16, 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).
Figure 3-17 - Disconnecting the gearbox from the engine: 1 - nut for fastening the gearbox to the engine; 2 - bolts for fastening the gearbox to the engine
Unscrew nut 1, Figure 3-17, and bolt 3, Figure 3-18, securing the gearbox to the engine (replacement head 13, 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).
Bring the support part of the hydraulic transmission strut up to the stop against the gearbox (hydraulic transmission strut type SG-1 "GARO").
Figure 3-18 - Disconnecting the gearbox from the engine: 3, 4, 6, 7 - bolts for fastening the gearbox to the engine; 5 - nut for fastening the gearbox to the engine
Unscrew two bolts 2, Figure 3-17, bolts 4, 6, 7 and nut 5, Figure 3-18, securing the gearbox to the engine (replacement head 13, extension, ratchet).
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 3-19 - Removing the clutch release sleeve: 1 - mounting bolts; 2 - clutch release sleeve assembled with clutch slave cylinder
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 into 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).
[Material was taken from the website Ladaman.ru]
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.
Tighten, without tightening, two bolts 2, Figure 3-17, bolts 4, 6, 7 and nut 5, Figure 3-18, securing the gearbox to the engine (replaceable head 13, ratchet).
Tighten nut 1, Figure 3-17, and bolt 3, Figure 3-18, securing the gearbox to the engine. Tightening torque of bolt and nut 36.52 N·m (3.6...5.2 kgf·m) (replaceable head 13, ratchet, extension, torque wrench).
Finally tighten bolts 2, 4, 6, 7, figures 3-17, 3-18, and nut 5 securing the gearbox to the engine. Tightening torque of bolts and nuts 36.52 N·m (3.6...5.2 kgf·m) (replaceable head 13, ratchet, extension, torque wrench).
Install bracket 1, Figure 3-16, of the left engine mount support onto the gearbox and tighten the three mounting bolts 4. Tightening torque of bolts 53.71 N·m (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 N·m (9.0. 12.0 kgf·m) (replaceable head 18, ratchet and extension, torque wrench).
Remove the engine support beam from the vehicle.
Install bracket 2, Figure 3-14, for fastening the wiring harness, insert the breather tube into the bracket groove and tighten bolt 3 and clip 1 for fastening. Bolt tightening torque 18...24 Nm (1.8...2.4 kgf·m) (torx T15 screwdriver, 13 mm replaceable head, ratchet wrench, torque wrench).
Fix valve 2, Figure 3-15, of the breather in the mounting bracket 1.
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).
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 3-11, in place and tighten the three mounting bolts 2. Tightening torque of bolts 36...52 Nm (3.6...5.2 kgf·m) (replaceable head 13, 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 5, Figure 3-7, of the clutch hydraulic drive to the clutch slave cylinder 1 and make sure that it is securely fixed with the clamp 3 (brackets 3 and 4 must be in the extreme lower position).
Fix the clutch hydraulic drive tube 5 in the mounting bracket 7.
Connect block 5, Figure 3-10, 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.
Attach bracket 2, Figure 3-9, for fastening harness 3 of the engine wires to bracket 1 for fastening the transmission control cables.
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 3-10, 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 1, Figure 3-13, together with bracket 4 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 2 securing rod 1 to bracket 4 of rear suspension support (replaceable head 18, ratchet).
Attach bracket 4 of the rear suspension support to the gearbox and tighten the two mounting bolts 3. 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. Bolt tightening torque 90. 120 N·m (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 - 2.46 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 air supply pipe assembly onto the vehicle.
Connect the air supply pipe 3, Figure 3-3, to the air intake 2.
Connect hose 7, Figure 3-2, of the intake pipe to the throttle pipe 4, install and tighten the clamp 5 of the fastening (flat head screwdriver).
Connect the upper hose 2 of the crankcase ventilation to the branch pipe of the cylinder head cover and secure it with the spring clamp 3 of the fastening (pliers).
Tighten bolt 9 of the air filter mounting. Bolt tightening torque 7...9 Nm (0.7...0.9 kgf·m) (replaceable head 10, ratchet, torque wrench).
Install hose 6 of the brake booster into the clamps on hose 7 of the inlet pipe.
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.