Table of contents: Removal ↓ Engine installation ↓
Removal
Disconnect the wire from the negative terminal of the battery.
Remove the powertrain compartment hood.
Remove the expansion tank cap.
Disconnect the supply hose from the radiator and drain the coolant.
On vehicles with a cable-operated clutch, remove the clutch cable from the adjusting sleeve.
Disconnect the cooling system hoses from the engine.
Disconnect the ground wire from the left engine mount bracket.
Disconnect the plug connectors of the electrical components installed on the engine and disconnect the high-voltage wires of the ignition system.
Remove the distributor cap.
Depending on the configuration, remove and secure the power steering pump on the left side of the powertrain compartment.
On the engine model "WH"
Remove the air filter.
Remove the crankcase ventilation hoses.
Disconnect the vacuum hose from the receiver.
Disconnect the throttle cable.
Disconnect the fuel supply and return hoses from the fuel pump and carburetor.
Remove the fuel pump.
On engines of the models "WC", "KR", "KU", "RT", "NF"
Disconnect the fuel injector line bundle and the injection nozzles.
Disconnect the vacuum hoses from the throttle body.
Remove the air duct connecting the air flow meter to the throttle body.
On engines of all models
Disconnect the throttle control cable and route it to the left side of the powertrain compartment.
Remove the crankcase ventilation hose.
Loosen the gearbox-to-engine mounting bolt located behind the clutch release fork.
Remove the right engine mount bracket protective shield.
Remove the upper gearbox mounting bolts from the engine block.
Remove the starter.
Remove the alternator drive belt.
Remove the generator without disconnecting the electrical wires. Secure the generator to the body at the point where the right engine mount bracket is attached.
Disconnect the exhaust pipe from the exhaust manifold and from the transmission bracket.
Remove the lower bolts securing the gearbox to the engine.
Place a support under the gearbox and raise the gearbox slightly.
Loosen the nuts securing the right engine mount support to the body and the left support to the engine.
Hang the engine
Remove the left engine mount bracket.
Engine installation
Place the engine in the powertrain compartment, after checking the alignment of the clutch driven disc, the degree of wear of the clutch release bearing and lightly lubricating the splines of the gearbox input shaft with consistent grease.
Tighten the upper transmission-to-engine mounting bolts and place onto the engine mount brackets.
Remove the support from under the gearbox.
Tighten the lower transmission-to-engine mounting bolts
Install the exhaust pipe onto the exhaust manifold and secure the right gearbox bracket.
Install the starter.
Install the generator and its drive belt, adjust the belt tension.
Install the right engine mount bracket protective shield.
Engines of models "WC", "KR", "KU", "RT", "NF"
Install the crankcase ventilation hoses.
Install and adjust the position of the throttle control cable.
Connect the air flow meter to the throttle body with an air duct.
Connect the vacuum hoses to the throttle body.
Connect the fuel lines and install the fuel injection nozzles in place.
Engine model "WH"
Install the fuel pump.
Connect the fuel inlet and outlet hoses to the carburetor and pump.
Install and adjust the position of the throttle control cable.
Connect the vacuum hose to the receiver.
Install the crankcase ventilation hose.
Install the air filter.
On engines of all models
Install the spark plugs, distributor cap, connect the high voltage wires.
Connect the plug connectors of the electrical equipment units on the engine.
Connect the ground wire to the left engine mount bracket.
Connect the cooling system hoses.
Adjust the clutch release drive.
Fill the cooling system with coolant.
Check the oil level.
Connect the negative cable to the battery.
Start the engine and check that the ignition timing, engine idle speed and, on engines of models, are adjusted correctly "WH", "WC", "KR", "RT" thermal clearances of valves.