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Engine Replacement

Engine Replacement



Special Tools

• CH-807 Closure Plug

• CH-904 Base Frame

• CH-49289 Centring Adapter

• CH-49290 Mounting Engine/Transmission

• EN-412 Engine Stand


Removal Procedure


1. Turn the ignition OFF.

2. Remove the intermediate steering shaft fastener. Refer to Intermediate Steering Shaft Replacement .

3. Open hood.

4. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging .

5. Remove the engine control module. Refer to Engine Control Module Replacement (LLU/A16LET) .

6. Remove the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

8. Remove the front wheels. Refer to Tire and Wheel Removal and Installation .

9. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

10. Drain the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .

11. Disconnect the engine wiring harness connectors (1, 2).


12. Remove the engine wiring harness ground connectors (1) from the front end upper tie bar support.


13. Remove the engine wiring harness (1) from the front compartment fuse block housing (2).


14. Remove the wiring harness bracket from the transmission. Disconnect the backup lamp switch electrical connector.

15. Position and secure the wiring harness to the engine.

16. Remove both coolant hoses from the radiator surge tank. Position and secure the surge hoses to the engine.

17. Remove the clutch actuator cylinder hose.

18. Remove the power brake booster pipe (1) from the intake manifold.


19. Remove the manual transmission shift lever cable from the transmission. Refer to Selector Lever Cable Replacement .

20. Remove the heater inlet hose and the heater outlet hose from the heater core. Refer to Heater Inlet Hose Replacement (Diesel) Heater Inlet Hose Replacement (LAU/A28NER) Heater Inlet Hose Replacement (LLU/A16LET) Heater Inlet Hose Replacement (LHU/A20NFT) and Heater Outlet Hose Replacement (Diesel) Heater Outlet Hose Replacement (LAU/A28NER) Heater Outlet Hose Replacement (LLU/A16LET) Heater Outlet Hose Replacement (LHU/A20NFT) .

21. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

22. Disconnect the evaporative emission pipe quick connector. Close the pipe with the CH-807 closure plug.

23. Disconnect the evaporative emission canister purge solenoid valve electrical connector.

24. Disconnect the fuel feed pipe and fuel return pipe. Close the pipes with the CH-807 closure plugs to prevent fuel loss or contamination.

25. Remove the air cleaner outlet duct with the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement (LLU/A16LET) and Air Cleaner Assembly Replacement (LLU/A16LET) .

26. Remove the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LBS/A20DTH) Air Conditioning Compressor and Condenser Hose Replacement (LAU/A28NER) Air Conditioning Compressor and Condenser Hose Replacement (LLU/A16LET) Air Conditioning Compressor and Condenser Hose Replacement (LBY/A20DTR) Air Conditioning Compressor and Condenser Hose Replacement (LHU/A20NFT) and Air Conditioning Evaporator Hose Assembly Replacement (LAU/A28NER) Air Conditioning Evaporator Hose Assembly Replacement (LBS/A20DTH) Air Conditioning Evaporator Hose Assembly Replacement (LLU/A16LET) Air Conditioning Evaporator Hose Assembly Replacement (LBY/A20DTR) Air Conditioning Evaporator Hose Assembly Replacement (LHU/A20NFT) .

27. Raise the vehicle by its full height.

28. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .

29. Disconnect both front wheel speed sensor electrical connectors. Position and secure both wiring harnesses to the vehicle. Refer to Front Wheel Speed Sensor Replacement (GNA) Front Wheel Speed Sensor Replacement (GNB) .

30. Disconnect the engine coolant fan motor wiring harness connectors.

31.
Note

Do NOT remove the exhaust system.


Remove exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LBY/A20DTR) Exhaust Front Pipe Replacement (LLU/A16LET) Exhaust Front Pipe Replacement (LBS/A20DTH) Exhaust Front Pipe Replacement (LHU/A20NFT, LAU/A28NER) .

32. Lower the vehicle by its half height.

33. Remove the front wheel drive shaft fasteners. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) and Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

34. Remove the stabilizer shaft link fasteners. Refer to Stabilizer Shaft Link Replacement (GNA) Stabilizer Shaft Link Replacement (GNB) .

35. Remove the steering linkage outer tie rod fasteners. Refer to Steering Linkage Outer Tie Rod Replacement .

36. Remove both steering knuckles from both front lower control arms. Refer to Steering Knuckle Replacement (GNA) Steering Knuckle Replacement (GNB) .

37. Remove both front wheel drive shafts from both front wheel bearings and hubs. Refer to Front Wheel Bearing and Hub Replacement (GNA) Front Wheel Bearing and Hub Replacement (GNB) .

38. Raise the vehicle by its full height.


Prepare the CH-49290 for Mounting Engine


1. Install the tool components on the CH-49290-1 plate (2).


• CH-49290-16 supporting with CH-49290-15 plate (3) at position 20 and X.

• CH-49290-5 bracket (6) at position 02.

• CH-49290-6 pin (5) at position E on the CH-49290-5 bracket (6).

• CH-49290-14 supporting with CH-49290-12 plate (7) at position 13 and Q.

• Two bolts with 2 CH49290-18 supporting (10) at position 32 and position 40.

• CH-49290-4 bracket (13) at position 01.

• CH-49290-6 pin (14) at position B on the CH-49290-4 bracket (13).

2.
Note

Do NOT install the CH-49290-10 bracket (1), CH-49290-11 bracket (4), CH-49290-7 plate (8), CH-49290-9 bracket (9), CH-49290-7 plate (12) and CH-49290-8 bracket (11) until the tool is in contact with the frame.


Turn the CH-49290-18 supporting (10), CH-49290-14 supporting (7) and CH-49290-16 supporting (3) downward.


Install the CH-49290 for Mounting Engine


1. Install the CH-49290 mounting on the CH-904 frame.

2. Raise the CH-49290 mounting (1) with a jack.


3.
Note

Ensure that the 2 CH-49290-6 pin are fixed in both holes of the sub frame.


Install the CH-49290-9 bracket and CH-49290-8 bracket (2) with 2 CH-49290-7 plates (4).

• CH-49290-8 bracket at position G.

• CH-49290-9 bracket at position H.

4. Install the 4 bolts (3).

5. Install the CH-49290-10 bracket and CH-49290-11 bracket (5).

• CH-49290-10 bracket at position K.

• CH-49290-11 bracket at position N.

6. Install the 4 bolts (6).

7. Lower the jack with CH-904 frame and remove it.

8. Turn the CH-49290-14 supporting (4) upwards until it seats solidly at the transmission front mount (3).


9. Turn the CH-49290-16 supporting (5) upwards until it seats solidly at the transmission rear mount (2).

10. Turn the 2 CH-49290-18 supporting (6) upwards until it seats solidly at the oil pan (1).


Removal Procedure


1. Lower the vehicle.

2. Remove the engine mount bracket from the engine mount support. Refer to Engine Mount Replacement .

3. Remove the transmission mount fasteners. Refer to Transmission Mount Replacement - Left Side .

4. Raise the vehicle by its full height.

5. Raise the CH-904 underframe and CH-49289 adapter with the hydraulic jack until it contact the frame.


6.
Note

Positioning pins (2, 3) of CH-49289 adapter MUST stick into holes of drivetrain frame.


Check if wheel alignment is required.


• Move out position pins (1) and try to insert into underbody holes.

• If guide pins can NOT be inserted, the Wheel Alignment Measurement is required after installation of drive train frame.

7. Remove the front suspension frame fasteners. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

8.
Note

Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.


With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.

9. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) .

10. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

11. Vehicles equipped with LLU/A16LET, remove the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Hose Replacement (LAU/A28NER) Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR) Charge Air Cooler Inlet Hose Replacement (LLU/A16LET) Charge Air Cooler Inlet Hose Replacement (LBS/A20DTH) .

12. Vehicles equipped with LLU/A16LET, remove the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Hose Replacement (Diesel) Charge Air Cooler Outlet Hose Replacement (LAU/A28NER) Charge Air Cooler Outlet Hose Replacement (LLU/A16LET) .

13. Remove the power steering return hose from the power steering pump. Refer to Power Steering Return Hose Replacement (L4) Power Steering Return Hose Replacement (V6) .

14. Remove the power steering pressure pipe/hose from the power steering pump. Refer to Power Steering Pressure Pipe/Hose Replacement (L4) Power Steering Pressure Pipe/Hose Replacement (V6) .

15. Loosen the radiator outlet hose clamp (2).


16. Remove the radiator outlet hose (3) from the water pump (1).

17. Loosen the radiator inlet hose clamp (4).


18. Remove the radiator inlet hose (3) from the engine coolant thermostat (5).

19. Install suitable cables at the 3 engine lift brackets.

20. Install a suitable engine lifting device to the cables.

21. Extend the engine lifting device until the steel cables are slightly tensioned.

22. Remove the front transmission mount fastener (1).


23. Remove the transmission bracket mount fastener (1).


24. Put the engine transmission unit down on a wooden pallet.

25. Loosen the 8 transmission bolts and remove 7 of them.

26.
Note

Two mechanics required.


Remove the last transmission bolt and the transmission.

27. Install the engine to the EN-412 engine stand.

28. Transfer parts as needed.


Installation Procedure


1. Remove the engine from the EN-412 engine stand.

2. Put the engine down on a wooden pallet.

3.
Note

Two mechanics required.


Install the transmission and one transmission bolt.

4. Install the 7 transmission bolts.

5. Tighten the 8 transmission bolts.

6. Place the engine transmission unit into the front frame.

7. Refer to Fastener Caution .

Install the fastener (1) of the transmission mount and tighten up to 100 Nm (74 lb ft) .


8. Install the front fastener (1) for the transmission and tighten to 100 Nm (74 lb ft) .


9. Remove the cables from the 3 engine lift brackets.

10. Install the radiator inlet hose (3) to the engine coolant thermostat (5).


11. Install the radiator inlet hose clamp (4).

12. Install the radiator outlet hose (3) to the water pump (1).


13. Install the radiator outlet hose clamp (2).

14. Install the power steering pressure pipe/hose to the power steering pump. Refer to Power Steering Pressure Pipe/Hose Replacement (L4) Power Steering Pressure Pipe/Hose Replacement (V6) .

15. Install the power steering return hose to the power steering pump. Refer to Power Steering Return Hose Replacement (L4) Power Steering Return Hose Replacement (V6) .

16. Vehicles equipped with LLU/A16LET, install the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Hose Replacement (Diesel) Charge Air Cooler Outlet Hose Replacement (LAU/A28NER) Charge Air Cooler Outlet Hose Replacement (LLU/A16LET) .

17. Vehicles equipped with LLU/A16LET, install the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Hose Replacement (LAU/A28NER) Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR) Charge Air Cooler Inlet Hose Replacement (LLU/A16LET) Charge Air Cooler Inlet Hose Replacement (LBS/A20DTH) .

18. Install the left wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

19. Install the right wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) .

20.
Note

Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.


With the aid of an assistant, raise the table or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.

21. Install the front suspension frame fasteners. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

22.
Note

Positioning pins (1) of CH 49289 adapter MUST be extended in order to guide into underbody holes.


Insert positioning pins (1).


23. Lower the CH-49289 adapter with the hydraulic jack.


24. Lower the vehicle.

25. Install the transmission mount fasteners. Refer to Transmission Mount Replacement - Left Side .

26. Install the engine mount bracket to the engine mount support. Refer to Engine Mount Replacement .

27. Raise the vehicle by its full height.

28. Install the CH-904 frame with a jack to the CH-49290 mounting (1).


29. Remove the 4 bolts (3).

30. Remove the CH-49290-9 bracket and CH-49290-8 bracket (2) with 2 CH-49290-7 plates (4).

31. Remove the 4 bolts (6).

32. Remove the CH-49290-10 bracket and CH-49290-11 bracket (5).

33. Lower the CH-49290 mounting and the CH-904 frame with the jack.

34. Lower the vehicle.

35. Install both front wheel drive shafts to both front wheel bearings and hubs. Refer to Front Wheel Bearing and Hub Replacement (GNA) Front Wheel Bearing and Hub Replacement (GNB) .

36. Install both steering knuckles to both front lower control arms. Refer to Steering Knuckle Replacement (GNA) Steering Knuckle Replacement (GNB) .

37. Install the steering linkage outer tie rod fasteners. Refer to Steering Linkage Outer Tie Rod Replacement .

38. Install the stabilizer shaft link fasteners. Refer to Stabilizer Shaft Link Replacement (GNA) Stabilizer Shaft Link Replacement (GNB) .

39. Install the front wheel drive shaft fasteners. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) and Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

40. Raise the vehicle.

41. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LBY/A20DTR) Exhaust Front Pipe Replacement (LLU/A16LET) Exhaust Front Pipe Replacement (LBS/A20DTH) Exhaust Front Pipe Replacement (LHU/A20NFT, LAU/A28NER) .

42. Connect the engine coolant fan motor wiring harness connectors.

43. Connect both front wheel speed sensor electrical connectors. Refer to Front Wheel Speed Sensor Replacement (GNA) Front Wheel Speed Sensor Replacement (GNB) .

44. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .

45. Lower the vehicle.

46. Install the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LBS/A20DTH) Air Conditioning Compressor and Condenser Hose Replacement (LAU/A28NER) Air Conditioning Compressor and Condenser Hose Replacement (LLU/A16LET) Air Conditioning Compressor and Condenser Hose Replacement (LBY/A20DTR) Air Conditioning Compressor and Condenser Hose Replacement (LHU/A20NFT) and Air Conditioning Evaporator Hose Assembly Replacement (LAU/A28NER) Air Conditioning Evaporator Hose Assembly Replacement (LBS/A20DTH) Air Conditioning Evaporator Hose Assembly Replacement (LLU/A16LET) Air Conditioning Evaporator Hose Assembly Replacement (LBY/A20DTR) Air Conditioning Evaporator Hose Assembly Replacement (LHU/A20NFT) .

47. Install the air cleaner outlet duct with the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement (LLU/A16LET) and Air Cleaner Assembly Replacement (LLU/A16LET) .

48. Connect the fuel feed pipe and fuel return pipe.

49. Connect the evaporative emission canister purge solenoid valve electrical connector.

50. Connect the evaporative emission pipe quick connector.

51. Install the heater inlet hose and the heater outlet hose to the heater core. Refer to Heater Inlet Hose Replacement (Diesel) Heater Inlet Hose Replacement (LAU/A28NER) Heater Inlet Hose Replacement (LLU/A16LET) Heater Inlet Hose Replacement (LHU/A20NFT) and Heater Outlet Hose Replacement (Diesel) Heater Outlet Hose Replacement (LAU/A28NER) Heater Outlet Hose Replacement (LLU/A16LET) Heater Outlet Hose Replacement (LHU/A20NFT) .

52. Install the manual transmission shift lever cable to the transmission. Refer to Selector Lever Cable Replacement .

53. Install the power brake booster pipe (1) to the intake manifold.


54. Install the clutch actuator cylinder hose.

55. Install both coolant hoses to the radiator surge tank.

56. Install the wiring harness bracket to the transmission. Connect the backup lamp switch electrical connector.

57. Install the engine wiring harness (1) to the front compartment fuse block housing (2).


58. Install the engine wiring harness ground connectors (1) to the front end upper tie bar support.


59. Connect the engine wiring harness connectors (1, 2).


60. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

61. Install the front wheels. Refer to Tire and Wheel Removal and Installation .

62. Install the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

63. Install the engine control module. Refer to Engine Control Module Replacement (LLU/A16LET) .

64. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging .

65. Check the oil level and fill NEW engine oil up if necessary.

66. Fill the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .

67. Close the hood.

68. Install the intermediate steering shaft fastener. Refer to Intermediate Steering Shaft Replacement .