For removal of KP execute:

a) preparatory operations:

— open a cowl;

— disconnect a negative wire of the rechargeable battery;

— uncover the engine;

Fig. 5.13. Fastening of an inlet hose of the air filter: 1 and 3 — places of fastening of a hose of ventilation of a case of the engine; 2 and 6 — collars; 4 — the socket of the air sensor; 5 — a hose of the air pump; 7 — a hose of the air filter

b) remove an inlet air hose from the air filter (see subsection. "Replacement of the working cylinder of coupling" and fig. 5.13);

c) remove the air filter assembled;

Fig. 5.18. Screws of fastening of the air filter (are shown by shooters)

— turn out two fixing screws (fig. 5.18);

— lift the filter and remove it rotary motion;

d) remove the working cylinder of coupling (see subsection. "Replacement of the working cylinder of coupling");

e) remove the sensor of a flywheel which is in the top part of coupling, having turned out two screws of the sensor, and remove the sensor aside;

e) disconnect a starter:

Fig. 5.19. Bolts of fastening of a starter (are shown by shooters)

— turn out three bolts (fig. 5.19) in a forward part;

— remove a starter from the adjustable plug rotary motion;

Fig. 5.20. Bolts of fastening of KP (are specified by shooters)

g) turn out fixing bolts in the top part of the transmission (fig. 5.20);

Fig. 5.21. Installation of a lifting beam

h) establish a lifting beam (fig. 5.21), moor the engine for lifting eyes and slightly raise it;

Fig. 5.22. Details of fastening of KP from a body (are shown by shooters)

i) disconnect transmission support from a body (fig. 5.22):

— turn out three nuts of support of the transmission;

— turn out a support bolt on a body;

— remove both support;

Fig. 5.23. Removal of a forward mudguard of the engine

j) remove a forward mudguard of the engine (fig. 5.23)

k) remove the left mudguard of the engine:

Fig. 5.24. Bolts of fastening of the left mudguard (are shown by shooters)

— turn out three bolts from above (fig. 5.24);

— remove the left mudguard;

Fig. 5.25. A bolt of fastening of a mass wire to KP (it is shown by an arrow)

l) disconnect a wire of connection with "weight" from the transmission, having turned off a bolt (fig. 5.25);

Fig. 5.26. Bolts of fastening of the heat-insulating screen (are shown by shooters)

m) remove the heat-insulating screen of the right half shaft, having turned out three bolts (fig. 5.26);

Fig. 5.27. Details of fastening of support of the engine and the central longitudinal beam (are shown by shooters)

o) remove the central longitudinal beam (fig. 5.27):

— turn off two nuts of support of the engine;

— turn out four bolts of fastening of the central longitudinal beam;

— take out two bolts from rubber plugs;

— remove the central longitudinal beam;

o) disconnect a gear shifting bar from the transmission:

Fig. 5.28. Fastening of a bar of gear shifting to KP: 1 — a bar; 2 — a bolt; 3 — a nut

— turn off a nut of 3 (fig. 5.28) and push out a bolt 2 up;

— bind a gear shifting bar;

Fig. 5.29. Backing light switch socket detachment

p) disconnect the socket of the switch of light of a backing (fig. 5.29);

c) merge oil from the transmission:

— turn out a bolt and remove the pallet;

— substitute capacity;

— turn out a stopper of a drain opening;

— be convinced that oil completely flew down;

— put a stopper of a drain opening with a new sealing ring and tighten the moment 38 N · m;

r) disconnect a flexible shaft of a speedometer from a transmission case:

Fig. 5.30. A speedometer cable junction on KP: 1 — a speedometer cable; 2 — the fixing pin

— clear the place of connection (fig. 5.30);

— take out the fixing pin 2 of the transmission;

— carefully extend a flexible shaft of 1 speedometer from the transmission;

— close a connecting opening;

s) remove forward wheels:

— weaken bolts of fastening of forward wheels;

— you will hang out forward wheels;

— put basic racks;

— remove forward wheels;

t) disconnect the right half shaft:

Fig. 5.31. Detachment of the right half shaft: 1 — a mandrel

— remove two lock pins by means of a mandrel with a diameter of 5 mm (fig. 5.31);

— turn out the top bolt and weaken an inhaling of the lower bolt of a rotary fist;

— wring out a rotary fist outside and take away a half shaft as it is possible further from a transmission shaft;

x) disconnect the left half shaft:

Fig. 5.32. Screws of fastening of a protective cover of a half shaft (are shown by shooters)

— turn out three screws of fastening of a protective corrugated cover (fig. 5.32);

— remove an ABS system wire from an arm;

— remove the fixing bracket and take out the pipeline of the brake system from an arm;

— turn out two adjusting bolts and disconnect the shock-absorber from a rotary fist;

— turn a steering wheel against the stop to the right;

— accurately take out a shaft from the transmission;

— close трехшиповик and a transmission opening;

— turn a steering wheel in the central situation;

v) remove the transmission:

Fig. 5.33. Installation of a support under the transmission

— establish a support 999 5972 and fix it under the transmission (fig. 5.33);

— turn out fixing bolts of connection of the engine with the transmission;

— lower the engine and the transmission so that they did not concern a body from the distributor;

— remove the transmission;

w) remove details from the old transmission:

— support;

— adjusting plugs 1 and 6;

— backing light switch 8;

— bearing 4 switching off of coupling, fork 3 and sealing rubber element 2;

— turn out a hairpin 5;

— clear and check the removed details:

— check the bearing of switching off of coupling and a fork as it is described in subsection. "Coupling";

aa) install details in the new transmission;

Fig. 5.34. Removal of details from KP: 1, 6 — adjusting plugs; 2 — a sealing element; 3 — a fork; 4 — the bearing; 5 — a hairpin; 7 — a bolt; 8 — the backing light switch

— take out caps and remove protective covers, rearrange them on the old transmission;

PREVENTION If the transmission is not replaced, and removed is established, it is necessary to replace the right consolidation and a sealing ring, see. "Replacement of an epiploon of the right half shaft".

— put into place adjusting plugs;

— apply sealant (number according to the catalog 1161099-5) on the backing light switch, install the switch, the moment of an inhaling of 22 N · to m;

— grease a clutch release fork lever support sphere with jellied Volvo number 1161246-2 lubricant;

— install into place the coupling switching off bearing, a fork and a rubber sealing element;

— put a hairpin 5, the inhaling moment

50 N · m

— mount an arm of a tube of the hydraulic drive of coupling, the moment of an inhaling of 48 N · m;

— deliver support, the moment of an inhaling of 40 N · to m.