Engine Replacement (South America)

Engine Replacement (South America)

Special Tools

* J-43828 - Ball Joint Removal.

* J-24319-B - Steering Linkage and Tie Rod Puller.

* L-0906001 - Engine support bracket.

* L-0806003 - Engine Support Table.

* J-9703386 - Engine Support Table.

* J-9703392 - Engine Support Table.

* J-0906003 - Engine Support Table

* L-0906004 - Engine Support Table

* DT-50396 - Torque Converter Holding Tool.

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

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. 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. Remove the air cleaner outlet duct (1). Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.




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




7. Remove the oil cap (1).

8. Remove the intake manifold cover (2).




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

10. Disconnect the fuel feed line (1).




11. Disconnect the EVAP pipe (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.




12. Disconnect heater inlet hose (1). Refer to Heater Inlet Hose Replacement (LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (LFW) Heater Inlet Hose Replacement.

13. Disconnect heater outlet hose (2). Refer to Heater Outlet Hose Replacement (LFW) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (LEA) Heater Outlet Hose Replacement.

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




15. Remove the Air Conditioning compressor hose to evaporator outlet hose nut (1).

16. Disconnect the Air conditioning compressor hose to evaporator outlet hose (2). Refer to Air Conditioning Compressor Hose Replacement (V6) Air Conditioning Compressor Hose Replacement (V6)Air Conditioning Compressor Hose Replacement (L4) Air Conditioning Compressor Hose Replacement (L4).

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

18. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Base) Bumper.




19. Use paint in order to place match marks on the steering shaft coupling and on the steering column shaft.

20. Remove the steering shaft coupling bolt (1) at the steering column. Refer to Steering Shaft Coupling Replacement (NVH) Service and Repair




21. Remove the exhaust muffler nuts (1) and gasket (2) from the catalytic converter. Refer to Catalytic Converter Replacement (LEA) Catalytic Converter Replacement.




22. 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.

23. Remove the nut (1) and separate the stabilizer link from the strut assembly. Refer to Steering Knuckle Replacement Service and Repair.




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

25. Remove the starter. Refer to Starter Replacement (LFW) Service and RepairStarter Replacement (LEA) Service and Repair




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

Note: Use DT-50396 - Torque Converter Holding Tool before removing the flywheel fasteners.

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




28. Remove the headlamp bolts (1).

29. Remove the radiator bolts (2).

30. Raise the vehicle.





Note: The L-0906001 - Engine support Bracket will support the engine when the engine mounts and brackets are removed.

31. Lower the vehicle.




32. Remove the transmission mount bolts (1).




33. Remove the engine mount bolts (1).

34. Disconnect electoral connector as necessary.

35. Disconnect coolant hoses as necessary.

36. Raise the vehicle.




37. Remove the lower transmission bolts (1).





Note: During the powertrain removal support the vehicle body by placing a jack at the rear of the vehicle.

38. Install the powertrain removal and transmission devise J-9703386 - (1)to the J-9703392 - Hydraulic Jack(2).





Note: When lifting the powertrain removal and installation devise into position, Ensure proper location of the engine support bracket is installed.

39. Position the powertrain removal and installation devise to the vehicle and lift it by using hydraulic jack.




40. Remove the frame bolts (1).





Note: Ensure the vehicle is support by strapping the body to the hoist.

41. Lower the powertrain as complete assembly




42. Remove the transmission brace (1).




43. Remove the lower trans bolts (1)




44. Remove the upper transmission bolts (1)

45. Separate the engine from the transmission.

46. 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.





Caution: Refer to Fastener Caution Fastener Caution.

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. Carefully raise the powertrain.

7. Slowly lower the body onto the powertrain.





Note: For installation of the front suspension frame/ transmission/ and engine assembly. Refer to Frame Replacement (Except South America) FrameFrame Replacement ((LAF, LEA or LUK Engines) South America Only) FrameFrame Replacement ((LF1, LFW or LFX Engines) South America Only) Frame.

8. Install the frame bolts (1) and tighten to 155 Nm(114 lb ft).

9. Install frame reinforcement bolts (1) and tighten to 100 Nm(74 lb ft).

10. Lower and remove the powertrain lift devise from the vehicle.

11. lower the vehicle




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




13. Install the NEW right side engine mount bolts (1) and tighten to 58 Nm(43 lb ft).




14. Install radiator support bolts (2) and tighten to 22 Nm(16 lb ft).

15. install headlamp bolts (1) and tighten 8 Nm(66 lb in).

16. Raise and support the vehicle.




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




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

19. Install the starter. Refer to Starter Replacement (LFW) Service and RepairStarter Replacement (LEA) Service and Repair.




20. Align the match marks and connect the steering shaft coupling to the steering column.

21. Install the NEW steering shaft coupling bolt (1) at the steering column and tighten to 30 Nm(22 lb ft).




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

23. 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

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




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

26. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Base) Bumper.




27. Install A/C compressor hose to evaporator outlet hose (2). Refer to Air Conditioning Compressor Hose Replacement (V6) Air Conditioning Compressor Hose Replacement (V6)Air Conditioning Compressor Hose Replacement (L4) Air Conditioning Compressor Hose Replacement (L4).




28. Connect heater inlet hose (1). Refer to Heater Inlet Hose Replacement (LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (LFW) Heater Inlet Hose Replacement.

29. Connect heater outlet hose (2). Refer to Heater Outlet Hose Replacement (LFW) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (LEA) Heater Outlet Hose Replacement.

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




31. Connect the EVAP pipe (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.




32. Install the fuel feed line (1).




33. Install intake manifold cover (2).

34. install the oil cap (1).




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




36. Install the air cleaner outlet duct (1). Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

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

38. 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).

39. charge the refrigerant system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

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