Engine Replacement (LUK)

Engine Replacement (LUK)

Special Tools

* BO-38185 - Hose Clamp Pliers.

* J-39580 - Engine Support Table.

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).

4. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.





6. Remove the intake manifold cover (1). Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement





7. Remove the air cleaner outlet duct assembly (1). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.





8. Remove the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement Service and Repair





9. Disconnect the evaporative emission (EVAP) line quick connect fitting (1) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.





10. Release the clamp (1) and remove the power brake booster vacuum pipe (2) from the intake manifold vacuum port.

11. Release the power brake booster vacuum pipe from the routing clips and remove the vacuum pipe.





12. 10. Disconnect the fuel feed line (1). Refer to Metal Collar Quick Connect Fitting Service Service and Repair.





13. Remove the radiator surge tank inlet hose (1). Refer to Radiator Surge Tank Inlet Hose Replacement (LEA) Radiator Surge Tank Inlet Hose Replacement (LEA).





14. Remove the radiator inlet hose (1). Refer to Radiator Inlet Hose Replacement (LUK) Radiator Inlet Hose Replacement (LUK)Radiator Inlet Hose Replacement (LHU) Radiator Inlet Hose Replacement (LHU)Radiator Inlet Hose Replacement (LEA) Radiator Inlet Hose Replacement (LEA).

15. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LUK) Radiator Outlet Hose Replacement (LUK)Radiator Outlet Hose Replacement (LHU) Radiator Outlet Hose Replacement (LHU)Radiator Outlet Hose Replacement (LEA) Radiator Outlet Hose Replacement (LEA).





16. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.





17. Disconnect the heater inlet hose. Refer to Heater Inlet Hose Replacement.





18. Disconnect the heater outlet hose. Refer to Heater Outlet Hose Replacement.





19. Remove the A/C compressor hose to evaporator outlet hose nut (1).

20. Disconnect the A/C compressor hose to evaporator outlet hose (2).





21. Remove the transmission fluid cooler inlet (1) and outlet (5) hoses from the retainer (2) on the control valve body cover.

22. Remove the transmission fluid cooler inlet hose nut (3) from the transmission.

23. Remove the transmission fluid cooler inlet hose (1) from the transmission.

24. Remove the transmission fluid cooler outlet hose nut (4) from the transmission.

25. Remove the transmission fluid cooler outlet hose (5) from the transmission.

26. Plug and/or cap the hose and transmission to prevent contamination.

27. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair

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

29. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LHU) Service and RepairExhaust Front Pipe Replacement (LDK or LHU) Service and Repair.





30. Remove the frame reinforcements bracket bolts (1) and (2).

31. Remove the frame reinforcements bracket (3).

32. Remove the starter. Refer to Starter Replacement (LDK Or LHU) Starter Replacement (LDK Or LHU)Starter Replacement (LEA) Starter Replacement (LEA)





33. Remove the steering linkage outer tie rod nut (1) and tie rod (2). Refer to Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement.





Note:
Do not allow the stabilizer link ball stud to rotate while removing the link nut.

34. Remove the nut (1) and separate the stabilizer link from the strut assembly. Refer to Stabilizer Shaft Link Replacement Front Suspension.





35. Remove the steering knuckle to strut bolts (1) and nuts (2). Refer to Strut Assembly Removal and Installation (GNA) Strut Assembly Removal and Installation (GNA).





36. Mark the relationship of the flywheel to the torque converter for reassembly.

37. Remove the torque converter to flywheel bolt (1).





38. Remove the lower transmission bolts (1).

Note:
Blocks of wood can be used between the front of the frame and the oil pan to table in order to level the powertrain during the removal.

39. Position a engine support table under the powertrain assembly.





40. Remove the frame bolts (1).

41. Lower the vehicle on the engine support table.





42. Remove the transmission mount bolts (1).





43. Remove the engine mount bolts (1).

44. Disconnect electoral connector as necessary.

45. Disconnect coolant hoses as necessary.

Note:
When lowering the engine/transaxle assembly, verify all brake lines, shiftier cables and other components are free during removal

46. Lower the engine table and raise the body on the hoist until the engine/transaxle and cradle are free from the vehicle





47. Remove the transmission brace (1





48. Remove the lower trans bolts (1)





49. Remove the upper transmission bolts (1).

50. Separate the engine from the transmission.

51. Install the engine to a suitable engine stand.

Installation Procedure

1. Remove the engine from the engine stand.

2. Install the transmission to the engine.

3. Install the upper transmission bolts (1) and tighten to 75 Nm (55 lb ft).





4. Install the upper transmission bolts (1) and tighten to 75 Nm (55 lb ft).





5. Install the transmission brace (1) and tighten to 58 Nm (43 lb ft).

6. Slowly lower the body onto the powertrain.





7. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 Nm (37 lb ft).





8. Install the NEW right side engine mount bolts (1) and tighten to 62 Nm (46 lb ft).





9. Install the frame retaining bolts then tighten the bolts to 160 Nm (118 lb ft)





10. Install the lower transmission bolts (1) and tighten to 75 Nm (55 lb ft).





11. Install the torque converter to flywheel bolts (1) and tighten to 62 Nm (46 lb ft)

12. Install the starter. Refer to Starter Replacement (LDK Or LHU) Starter Replacement (LDK Or LHU)Starter Replacement (LEA) Starter Replacement (LEA).

13. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LHU) Service and RepairExhaust Front Pipe Replacement (LDK or LHU) Service and Repair.





14. Install the frame reinforcements bracket (3) then tighten the bolts (1) and (2) to 42 Nm (31 lb ft).





15. Install the NEW strut to the steering knuckle using new bolts (1) and nuts (2) and tighten to 185 Nm (136 lb ft).

16. Inspect the stabilizer link seals for damage and replace the link as necessary.





Note:
Use the proper size allen wrench to keep the stabilizer link ball stud from rotate while installing the nut.

17. Install the stabilizer link to the strut nut (1) and tighten to 65 Nm (48 lb ft)





18. Install the steering linkage outer tie rod (2). Refer to Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement

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





20. Install the air conditioning compressor and condenser hose (2). Refer to Air Conditioning Compressor and Condenser Hose Replacement Air Conditioning Compressor and Condenser Hose Replacement.





21. Connect the heater outlet hose. Refer to Heater Outlet Hose Replacement.





22. Connect the heater inlet hose. Refer to Heater Inlet Hose Replacement.





23. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.





24. Install the radiator inlet hose (1). Refer to Radiator Inlet Hose Replacement (LUK) Radiator Inlet Hose Replacement (LUK)Radiator Inlet Hose Replacement (LHU) Radiator Inlet Hose Replacement (LHU)Radiator Inlet Hose Replacement (LEA) Radiator Inlet Hose Replacement (LEA).

25. Install radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LUK) Radiator Outlet Hose Replacement (LUK)Radiator Outlet Hose Replacement (LHU) Radiator Outlet Hose Replacement (LHU)Radiator Outlet Hose Replacement (LEA) Radiator Outlet Hose Replacement (LEA).





26. Install the fuel feed line (1).





27. Connect the EVAP pipe (1).





28. Install the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement Service and Repair





29. Install the air cleaner outlet duct assembly (1). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.





30. Install the intake manifold cover (1). Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

31. Fill the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

32. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).

33. Refill the refrigerant system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

34. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.