Engine Replacement

Engine Replacement

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

Removal Procedure





1. Disconnect the negative battery cable (3). Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection





2. Remove the battery (7) and battery tray (8). Refer to Battery Tray Replacement (Except Diesel) Battery Tray Replacement (Except Diesel)Battery Tray Replacement (Diesel) Battery Tray Replacement (Diesel).





3. Remove the engine control module (1). Refer to Engine Control Module Replacement Service and Repair.





4. Remove the relay box (1).

5. Position and secure the relay box to the engine.





6. Remove the intermediate steering shaft fastener (1). Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.





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

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





9. Remove the air cleaner outlet duct (2). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.





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

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

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





13. Disconnect the engine wiring harness connectors (1, 2, 3).





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





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

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





17. Remove the radiator surge tank hose (2).

18. Position and secure the surge tank hose to the engine.





19. Remove the engine coolant air bleed hose (1).





20. Remove the range selector lever cable (2) from the transmission. Refer to Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement.

21. Position and secure the automatic transmission range selector lever cable to the vehicle.





22. Remove the power brake booster pipe (1) from the power brake booster (2).

23. Remove the heater inlet hose and the heater outlet hose from the heater core. Refer to Heater Inlet Hose Replacement (L4) Heater Inlet Hose Replacement (L4)Heater Inlet Hose Replacement (V6) Heater Inlet Hose Replacement (V6) and Heater Outlet Hose Replacement (V6) Heater Outlet Hose Replacement (V6)Heater Outlet Hose Replacement (L4) Heater Outlet Hose Replacement (L4).

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

25. Disconnect the fuel feed pipe. Refer to Fuel Pump Fuel Feed Hose Replacement Fuel Pump Fuel Feed Hose Replacement.





26. Remove the air conditioning hose assembly (3) from the evaporator. Refer to Air Conditioning Evaporator Hose Assembly Replacement Air Conditioning Evaporator Hose Assembly Replacement.

27. Install the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.





28. Remove the right engine mount (4). Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.





29. Remove the transmission mount fasteners (1).

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

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

32. If equipped, remove the engine shield from the front suspension frame.





33. Remove the both front wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.

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





35. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LFW) Exhaust Front Pipe Replacement (LFW)Exhaust Front Pipe Replacement (LE9) Exhaust Front Pipe Replacement (LE9)

36. Position a suitable powertrain lift table below the frame, engine and transmission.

37. Slowly lower the vehicle onto the lift table until the frame contacts the lift table.

38. Using wood blocks, support the engine and transmission.

39. Remove the engine support fixture hooks from the engine lift brackets.

40. Raise the lift table or lower the vehicle to support the frame, engine and transmission.

41. Remove the front suspension frame fasteners. Refer to Drivetrain and Front Suspension Frame Front Insulator Replacement Drivetrain and Front Suspension Frame Front Insulator Replacement.

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

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

43. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.

44. Remove the starter motor. Refer to Starter Replacement (LF1) Starter Replacement (LF1)Starter Replacement (LE9) Starter Replacement (LE9)





45. Remove the engine from the transmission. Refer to Transmission Replacement Transmission Replacement.

Installation Procedure





1. Install the transmission to the engine. Refer to Transmission Replacement Transmission Replacement.

2. Install the starter motor. Refer to Starter Replacement (LF1) Starter Replacement (LF1)Starter Replacement (LE9) Starter Replacement (LE9)

3. With the aid of an assistant, position the lift table and powertrain assembly under the vehicle.

4. Carefully lower the vehicle onto the engine, transmission, front frame and front suspension assembly.

5. Install the front suspension frame fasteners. Refer to Drivetrain and Front Suspension Frame Front Insulator Replacement Drivetrain and Front Suspension Frame Front Insulator Replacement.

6. Connect the engine support fixture hooks to the engine lift brackets.

7. Lift the engine assembly into the approximate running position.

8. Remove the engine lift table.

9. Lower the vehicle.





Caution:
Refer to Fastener Caution Fastener Caution.

10. Install the transmission mount fasteners (1) and tighten to 50 Nm (37 lb ft). Refer to Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side.





11. Install the right engine mount (4). Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side

12. Remove the engine support fixture.

13. Connect the fuel feed pipe. Refer to Fuel Pump Fuel Feed Hose Replacement Fuel Pump Fuel Feed Hose Replacement.





14. Install the air conditioning hose assembly (3). Refer to Air Conditioning Evaporator Hose Assembly Replacement Air Conditioning Evaporator Hose Assembly Replacement.

15. Connect the heater inlet hose and the heater outlet hose to the heater core. Refer to Heater Inlet Hose Replacement (L4) Heater Inlet Hose Replacement (L4)Heater Inlet Hose Replacement (V6) Heater Inlet Hose Replacement (V6) and Heater Outlet Hose Replacement (V6) Heater Outlet Hose Replacement (V6)Heater Outlet Hose Replacement (L4) Heater Outlet Hose Replacement (L4).





16. Connect the power brake booster pipe (1) to the power brake booster (2).





17. Connect the range selector lever cable (2) to the transmission. Refer to Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement.





18. Install the engine coolant air bleed hose (1).





19. Install the radiator surge tank hose (2).





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





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





22. Connect the engine wiring harness connectors (1, 2, 3).

23. Raise the vehicle.

24. Install both drivetrain and front suspension frame transmission protectors.





25. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LFW) Exhaust Front Pipe Replacement (LFW)Exhaust Front Pipe Replacement (LE9) Exhaust Front Pipe Replacement (LE9)





26. Install both front wheel drive shafts.
27. Connect the engine coolant fan motor wiring harness connectors.

28. If equipped, install the engine shield to the front suspension frame.

29. Install the front wheels. Refer to Tire and Wheel Removal and Installation (South America) Tire and Wheel Removal and Installation (South America)Tire and Wheel Removal and Installation (Europe) Tire and Wheel Removal and Installation (Europe).

30. Lower the vehicle.

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





32. Connect the intermediate steering shaft and install the fastener (1). Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.





33. Install the relay box (1).





34. Install the engine control module (1). Refer to Engine Control Module Replacement Service and Repair.





35. Install the air cleaner (10. Refer to Air Cleaner Assembly Replacement Service and Repair.





36. Install the air cleaner outlet duct (2). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.





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





38. Install the battery (7) and battery tray (8). Refer to Battery Tray Replacement (Except Diesel) Battery Tray Replacement (Except Diesel)Battery Tray Replacement (Diesel) Battery Tray Replacement (Diesel).

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

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

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