Before disconnecting hoses and electrical wires, it is recommended to mark them so as not to confuse them during assembly

The engine is removed from the car upwards.

To remove the engine, a hoist or other lifting device with a lifting capacity of at least 300 kg is required.

The car must be installed on a lift, inspection ditch or overpass. Before removing the engine, it is necessary to prepare a reliable stand on which the engine must stand steadily.

  • 1. Remove the battery.
  • 2. Remove the hood.
  • 3. Remove the front engine mudguard.
  • 4. Drain the liquid from the engine cooling system.
  • 5. Drain the oil from the crankcase.
  • 6. Drain the gearbox oil.
  • 7. Remove the radiator of the cooling system.
  • 8. Disconnect the high voltage center wire and the low voltage wire from the ignition distributor.

Removing and installing the ZMZ-402 engine

Disconnect the wires from the starter by removing the rubber protective caps 1.

Disconnect fuel line 2 from fuel pump.

Disconnect the wire from the emergency oil pressure switch mounted below the oil filter.

Disconnect the oil cooler supply hose from the cock located at the bottom of the unit on the left side.

Removing and installing the ZMZ-402 engine

Disconnect wire 1 from coolant temperature sensor 2.

Loosen clamp 3 and disconnect hose 4 from the thermostat housing cover.

Removing and installing the ZMZ-402 engine

Disconnect the wires from the generator by disconnecting the block 1 and unscrewing the screw 2.

Remove the air filter.

Removing and installing the ZMZ-402 engine

Disconnect wires 1 from microswitch 2 on the carburettor.

Disconnect the air damper rod 2 from the carburetor air damper drive lever and, unscrewing the screw 1, remove the rod 2 from the bracket.

Removing and installing the ZMZ-402 engine

Disconnect the accelerator drive link 4 from the throttle valve drive sector, unscrew the nut 3 and remove the link 4 from the bracket.

Removing and installing the ZMZ-402 engine

Disconnect fuel drain hose 1 from the carburetor.

Disconnect the vacuum hose 2 of the EPHX solenoid valve and the vacuum hose from the vacuum supply pipe to the EPHX valve on the other side of the carburetor.

Disconnect the vacuum hose 3 of the brake booster from the fitting on the engine intake pipe by loosening the clamp 4.

Disconnect the oil supply hose from the oil cooler from the fitting at the bottom of the unit on the right side.

Removing and installing the ZMZ-402 engine

Disconnect the wire from the oil pressure indicator sensor on the block on the right side.

Disconnect the heater fluid supply and drain hoses from the heater radiator fittings.

Remove the exhaust system.

Remove the gearbox.

Remove the clutch slave cylinder without disconnecting the hose from it, and leave the cylinder hanging on the hose.

Removing and installing the ZMZ-402 engine

Disconnect the ground wire from the clutch housing.

Remove the bolt securing the engine mount bracket to the cushion on each side.

Check if all hoses and wires are disconnected from the engine.

Carefully lift the motor up.

Install the engine in reverse order.

When installing the engine on the pads, make sure that the mounting pins on the pads fit into the holes on the engine brackets, while the bolt holes on the brackets and pads must be aligned.