Engine: Service and Repair

REMOVAL - ENGINE COVER





1. Remove the retaining screws and remove cover (Fig. 2).

REMOVAL

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING WITH HOT COOLANT. RISK OF POISONING FROM SWALLOWING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHES, AND EYE WEAR.

CAUTION: STORE OR DISCARD ALL FLUIDS IN SUITABLE AND APPROPRIATELY MARKED CONTAINERS.

1. Disconnect the negative battery cable.
2. Remove the hood.
3. Drain cooling system.
4. Evacuate and recover air conditioning system.
5. Disconnect the engine wiring harness at the vehicle side and carefully guide though the cowl into the engine area.





6. Remove the engine cover (Fig. 3).
7. Remove the air cleaner housing.
8. Disconnect the charge air hose at the mixing chamber (Fig. 3).
9. Remove the radiator assembly.
10. Disconnect the high pressure and return hoses at the power steering pump (Fig. 3).
11. Disconnect the fuel lines at the fuel filter (Fig. 3).
12. Disconnect the refrigerant line at the A/C compressor (Fig. 3).
13. Disconnect the vacuum line for the brake booster at the vacuum pump.
14. Disconnect the coolant hose of heating return flow at the water pump.
15. Disconnect the coolant hose of the heater supply at the coolant pipe at the side of the cylinder head (Fig. 3).
16. Disconnect the vacuum hose at the turbocharger (Fig. 3).
17. Disconnect the air inlet hose at the turbocharger (Fig. 3).
18. Raise and support the vehicle.
19. Disconnect the front exhaust at the turbocharger.





20. Disconnect the electrical connector at the transmission (Fig. 4).
21. Disconnect the locking clamp, shifter cable and the security catch for the shifter cable (Fig. 4)
22. Remove the steering gear mounting bolts.
23. Disconnect the transmission cooler lines at transmission.
24. Remove the torque converter access plate.
25. Remove the torque converter bolts.
26. Remove the crank position sensor.
27. Remove the transmission housing to engine mounting bolts.
28. Remove the starter mounting bolts.
29. Support the transmission with a transmission jack.
30. Place a wood block between the transmission housing and the front frame cross over.
31. Remove the transmission jack.
32. Remove the exhaust bracket (right side).
33. Remove the engine ground strap (left side).
34. Lower the vehicle.
35. Remove the heater housing filter and lower housing.





36. Connect the engine lifting fixture to the lifting eyes. (Fig. 5).
37. Remove the engine mount bolts.
38. Remove the transmission oil level indicator tube mounting bolt.

NOTE: After removing the front cross plate, seal metal with anti corrosion protection.





39. Using tin snips, remove the front cross plate at the cutting edges and deburr (Fig. 6).





40. Connect and engine hoist and carefully lift engine assembly from engine bay area (Fig. 7).

INSTALLATION - ENGINE COVER
1. Align cover and install screws. tighten screws to 11 Nm (97 inch lbs.) (Fig. 2).

INSTALLATION

NOTE: Deburr and seal metal from cross plate removal with anti corrosion material.

1. Install the engine support fixture (Fig. 5).
2. Install the engine lifting devise (Fig. 7).
3. Install the engine assembly into the vehicle engine compartment, mating the transmission and the engine (Fig. 7).
4. Lower the engine assembly until the engine brackets align with the mounts.
5. Hand start the engine mount bolts and remove the engine lifting devise.
6. Tighten the engine mount bolts to 83 Nm (62 ft. lbs.).
7. Raise and support the vehicle.
8. Install the transmission housing to engine bolts.
9. Install the torque converter bolts.
10. Install the torque converter access plate.
11. Install the transmission cooler lines to transmission.
12. Install transmission electrical connector and shifter hardware.
13. Install the steering gear and tighten in two stages. 25 Nm (18.5 ft. lbs.), then 45 Nm (33 ft. lbs.) plus 90°.
14. Install the crank sensor.
15. Install the starter.
16. Connect the ground strap (left side).
17. Align and install the exhaust and bracket.
18. Lower the vehicle.
19. Install the air inlet hose at the turbocharger (Fig. 3).
20. Connect the vacuum hose at the turbocharger (Fig. 3).
21. Connect the coolant supply and return hoses (Fig. 3).
22. Connect the brake booster vacuum hose at the vacuum pump (Fig. 3).
23. Connect the refrigerant lines (Fig. 3).
24. Connect the fuel lines at the filter assembly (Fig. 3).
25. Connect the power steering hoses (Fig. 3).
26. Install the radiator/charge air cooler and hose(s) assemblies.
27. Install A/C condenser.
28. Install air cleaner housing, sensors, and hoses.
29. Route the engine wiring harness inside the vehicle and connect.
30. Install the front grill assembly
31. Install and align the hood.
32. Connect the negative battery cable.
33. Check and fill engine oil.
34. Fill cooling system to proper level with the appropriate coolant.
35. Evacuate and recharge air conditioning.
36. Check and refill all ancillary system fluid levels.
37. Start engine and inspect for leaks.