Engine Replacement (Volt)
Engine Replacement (Volt)
Removal Procedure
Danger:
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure will perform the following tasks:
* Identify how to disable high voltage.
* Identify how to test for the presence of high voltage.
* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Failure to follow the procedures exactly as written may result in serious injury or death.
1. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.
2. Drain the drive motor generator battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling Drive Motor Battery Cooling System Draining and Filling.
3. Drain the engine cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
4. Drain the drive motor generator cooling system. Refer to Drive Motor Generator Power Inverter Module Cooling System Draining and Filling Drive Motor Generator Power Inverter Module Cooling System Draining and Filling.
5. Recover the air conditioning refrigerant. Refer to Refrigerant Recovery and Recharging (High Voltage Electric Compressor) Refrigerant Recovery and Recharging (High Voltage Electric Compressor).
6. Remove the drive motor generator power inverter module. Refer to Drive Motor Generator Power Inverter Module Replacement Drive Motor Generator Power Inverter Module Replacement.
7. Remove the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement Service and Repair.
8. Disconnect the canister purge hose (2) from the purge solenoid located at the back of the of the valve cover.
9. Disconnect the fuel feed pipe (1) from the fuel rail assembly. Refer to Fuel Feed Pipe Replacement (Engine Compartment) Fuel Feed Pipe Replacement (Engine Compartment)Fuel Feed Pipe Replacement (Chassis) Fuel Feed Pipe Replacement (Chassis).
10. Press the locking tab (1) rearward in order to release the transmission range selector lever cable (2) from the cable bracket.
11. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual pin, then position the cable out of the way.
12. Disconnect the heater water auxiliary pump inlet hose (2) from the coolant reservoir.
13. Disconnect the heater water auxiliary pump inlet hose (2) from the water outlet.
14. Disconnect the heat water shutoff valve inlet hose (2) from the valve assembly. Refer to Heater Water Shutoff Valve Inlet Hose Replacement Heater Water Shutoff Valve Inlet Hose Replacement.
15. Disconnect the heater inlet and outlet pipe. Refer to Heater Inlet And Outlet Pipe Replacement Heater Inlet And Outlet Pipe Replacement.
16. Disconnect the heater outlet hose vapor vent hose (1) from the coolant reservoir (2). Refer to Heater Outlet Hose Vapor Vent Hose Replacement Heater Outlet Hose Vapor Vent Hose Replacement.
17. Separate the air conditioning compressor and evaporator hose (2) at the connection above the valve cover. Refer to Air Conditioning Compressor and Evaporator Hose Replacement Air Conditioning Compressor and Evaporator Hose Replacement.
18. Remove the front wheelhouse front liners. Refer to Front Wheelhouse Front Liner Replacement .
19. Remove the front end panel outer deflectors. Refer to Front End Panel Outer Deflector Replacement .
20. Disconnect the air conditioning evaporator thermal expansion valve tube from the condenser. Refer to Air Conditioning Evaporator Thermal Expansion Valve Tube Replacement Air Conditioning Evaporator Thermal Expansion Valve Tube Replacement
21. Disconnect the electrical connector from the engine coolant temperature sensor on the radiator assembly.
22. Disconnect the electrical connectors from the engine control module (ECM). Refer to Engine Control Module Replacement Engine Control Module Replacement.
23. Disconnect the wiring connectors from the transmission.
24. Disconnect the wheel speed connectors from the steering knuckles and the frame, then position out of the way.
25. Disconnect the drive motor battery coolant cooler inlet hose quick connect at the right frame. Refer to Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement.
26. Disconnect the drive motor generator control module cooling outlet hose. Refer to Drive Motor Generator Control Module Cooling Outlet Hose Replacement Drive Motor Generator Control Module Cooling Outlet Hose Replacement.
27. Disconnect the wiring harness from the accessory wiring junction block. Refer to Accessory Wiring Junction Block Replacement Accessory Wiring Junction Block Replacement.
28. Remove the positive battery cable from the strut tower junction block.
29. Remove the ground wire from the left strut tower.
30. Remove the left headlamp. Refer to Headlamp Replacement Removal and Replacement.
31. Disconnect in-line harness at the left frame rail.
32. Place the ECM, transmission and the accessory wiring junction block wiring harnesses on the top of engine assembly.
33. Remove the strap from the right frame rail and reposition to engine
34. Remove the ground wire from the stud behind the right headlight and reposition harness to the engine.
35. Disconnect A/C compressor electrical connectors.
Note: Do Not disconnect the brake hoses from the calipers.
36. Remove the front brake calipers from the caliper brackets, then suspend the calipers with mechanics wire to the body.
37. Remove the stabilizer link (1) nuts from the strut assemblies. Refer to Stabilizer Shaft Link Replacement Service and Repair.
38. Disconnect the stabilizer links from the strut assemblies.
39. Disconnect the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.
40. Disconnect the front steering knuckles from the strut assemblies. Refer to Steering Knuckle Replacement Service and Repair.
41. Remove the catalytic converter assembly (4) from the vehicle. Refer to Catalytic Converter Replacement Service and Repair.
42. Disconnect the radiator assembly wiring harness connectors from the radiator assembly.
43. Install the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.
44. Use the engine support fixture to slightly raise the powertrain assembly to aid in the removal of the engine and transmission mount bolts.
45. Remove the engine mount to engine mount bracket fasteners. Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.
46. Remove the transmission mount to transmission mount bracket fasteners. Refer to Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side.
47. Using suitable straps or chains, secure the front of vehicle to the hoist arms.
48. Using a suitable engine support table, lower the vehicle until the drivetrain and front suspension frame contacts the engine support table.
49. Position blocks of wood below the oil pan and transmission to stabilize the powertrain on the support table.
50. Using the engine support fixture, lower the powertrain down until it is resting on the engine support table.
51. Remove the engine support fixture.
52. Remove the drivetrain and front suspension frame reinforcements (1) from the rear of the frame.
53. Remove the front drivetrain and front suspension frame retaining bolts.
54. Slowly and carefully raise the vehicle, ensure the engine, transmission, radiator assembly and drivetrain suspension frame are free from wiring, hoses and other engine compartment components.
55. Remove the starter opening cover located below the intake manifold.
56. Remove the four torque dampener to flywheel bolts.
57. Remove the intermediate drive shaft from the engine and transmission. Refer to Front Wheel Drive Intermediate Shaft Replacement Front Wheel Drive Intermediate Shaft Replacement.
58. Remove the nine transmission to engine fasteners.
59. Separate the transmission from the engine assembly.
60. Disconnect engine coolant hoses as necessary.
61. Disconnect electrical connectors as necessary.
62. Transfer components as necessary.
Installation Procedure
1. Position the engine to the transmission assembly.
Caution: Refer to Fastener Caution Fastener Caution.
2. Install the nine transmission to engine fasteners, then tighten to 80 Nm (59 lb ft)
3. Install the four torque dampener to flywheel bolts, then tighten to 62 Nm (46 lb ft).
4. Install the starter opening cover, then tighten to 20 Nm (15 lb ft).
5. Position the engine, transmission, radiator assembly and drivetrain suspension frame under the vehicle.
6. Slowly and carefully lower the vehicle, ensure the engine, transmission, radiator assembly and drivetrain suspension frame are free from wiring, hoses and other engine compartment components.
7. Install the four front drivetrain and front suspension frame retaining bolts, then tighten to the fasteners to 160 Nm (118 lb ft).
8. Install the drivetrain and front suspension frame reinforcements (1) to the rear of the frame, then tighten the reinforcement fasteners (2) to 22 Nm (16 lb ft).
Note: Use the engine support fixture to slightly raise the powertrain assembly to aid in the installation of the engine and transmission mount bolts.
9. Install the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.
10. Install the engine mount to engine mount bracket fasteners. Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.
11. Install the transmission mount to transmission mount bracket fasteners. Refer to Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side.
12. Install the intermediate drive shaft to the engine and transmission. Refer to Front Wheel Drive Intermediate Shaft Replacement Front Wheel Drive Intermediate Shaft Replacement.
13. Connect the right wheel drive shaft to the intermediate shaft.
14. Connect the electronic power steering connectors to the electronic power steering assembly. Refer to FEP Connectors (Steering Gear) FEP Connectors (Steering Gear).
15. Install the catalytic converter assembly (4). Refer to Catalytic Converter Replacement Service and Repair.
16. Connect the front steering knuckles to the strut assemblies. Refer to Steering Knuckle Replacement Service and Repair.
17. Connect the stabilizer link (1) to the strut assemblies. Refer to Stabilizer Shaft Link Replacement Service and Repair.
18. Install the front brake calipers to the caliper brackets. Refer to Step 2 of the installation procedure. Front Brake Caliper Replacement Front Brake Caliper Replacement.
19. Connect the wheel speed connectors to the steering knuckles.
20. Remove the engine support fixture.
21. Install the engine ground strap which is located above the air conditioning compressor on the engine block.
22. Connect the wiring connectors and ground strap to the transmission.
23. Connect the wiring harness to the accessory wiring junction block. Refer to Accessory Wiring Junction Block Replacement Accessory Wiring Junction Block Replacement.
24. Install the left headlamp. Refer to Headlamp Replacement Removal and Replacement
25. Connect the electrical connectors to the ECM. Refer to Engine Control Module Replacement Engine Control Module Replacement.
26. Connect the electrical connector to the engine coolant temperature sensor on the radiator assembly.
27. Connect the air conditioning compressor and evaporator hose (2) located above the valve cover. Refer to Air Conditioning Compressor and Evaporator Hose Replacement Air Conditioning Compressor and Evaporator Hose Replacement.
28. Connect the drive motor generator control module cooling outlet hose. Refer to Drive Motor Generator Control Module Cooling Outlet Hose Replacement Drive Motor Generator Control Module Cooling Outlet Hose Replacement
29. Connect the drive motor battery coolant cooler inlet hose quick connect at the right frame. Refer to Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement
30. Connect the heater outlet hose vapor vent hose (1) to the coolant reservoir (2). Refer to Heater Outlet Hose Vapor Vent Hose Replacement Heater Outlet Hose Vapor Vent Hose Replacement.
31. Connect the heat water shutoff valve inlet hose (2) to the valve assembly. Refer to Heater Water Shutoff Valve Inlet Hose Replacement Heater Water Shutoff Valve Inlet Hose Replacement.
32. Connect the heater inlet and outlet pipe. Refer to Heater Inlet And Outlet Pipe Replacement Heater Inlet And Outlet Pipe Replacement
33. Connect the transmission range selector lever cable terminal (1) to the transmission manual pin.
34. Press the locking tab (1) forward in order to lock the transmission range selector lever cable (2) to the cable bracket.
35. Connect the heater water auxiliary pump inlet hose (2) to the coolant reservoir.
36. Connect the heater water auxiliary pump inlet hose (2) to the heater water shutoff valve.
37. Connect the canister purge hose (2) to the purge solenoid located at the back of the of the valve cover.
38. Connect the fuel feed pipe (1) to the fuel rail assembly. Refer to Fuel Feed Pipe Replacement (Engine Compartment) Fuel Feed Pipe Replacement (Engine Compartment)Fuel Feed Pipe Replacement (Chassis) Fuel Feed Pipe Replacement (Chassis).
39. Connect engine coolant hoses as necessary.
40. Connect electrical connectors as necessary.
41. Install the front end panel outer deflectors. Refer to Front End Panel Outer Deflector Replacement .
42. Install the front wheelhouse front liners. Refer to Front Wheelhouse Front Liner Replacement .
43. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.
Danger:
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure will perform the following tasks:
* Identify how to disable high voltage.
* Identify how to test for the presence of high voltage.
* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Failure to follow the procedures exactly as written may result in serious injury or death.
44. Install the drive motor generator power inverter module. Refer to Drive Motor Generator Power Inverter Module Replacement Drive Motor Generator Power Inverter Module Replacement.
45. Fill the engine cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
46. Fill the drive motor generator battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling Drive Motor Battery Cooling System Draining and Filling.
47. Fill the drive motor generator cooling system. Refer to Drive Motor Generator Power Inverter Module Cooling System Draining and Filling Drive Motor Generator Power Inverter Module Cooling System Draining and Filling.
48. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging (High Voltage Electric Compressor) Refrigerant Recovery and Recharging (High Voltage Electric Compressor).
49. Check engine oil level. Refer to Engine Oil and Oil Filter Replacement Service and Repair
50. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.