Access Cover: Service and Repair

REMOVAL - ENGINE COVER





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

REMOVAL

WARNING: NO SPARKS, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.

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.

1. Disconnect the negative battery cable.

NOTE: REPLACE THE AIR CONDITIONING DRIER WHEN EVER THE AIR CONDITIONING SYSTEM IS OPENED.

2. Drain cooling system.
3. Evacuate and recover air conditioning system.
4. Remove the front grille and fascia assembly.
5. Disconnect the engine wiring harness at the cabin side and carefully guide though the cowl into the engine area.





6. Remove the turbocharger heat shield (Fig. 3).
7. Remove the engine cover (Fig. 3).
8. Remove the air cleaner and hose at the turbocharger and air cleaner assembly.
9. Disconnect the transmission lines at the radiator.
10. Disconnect the upper and lower radiator hoses.
11. Disconnect the A/C lines at the condenser.
12. Disconnect the condenser fan harness connector.
13. Disconnect the power steering cooler lines at the cooler.
14. Disconnect the charge air cooler hose at the intake manifold (Fig. 3).
15. Remove charge air hose fasteners at the radiator closure panel.
16. Remove the fasteners retaining the radiator to the front crossmember.
17. Remove the change air cooler, A/C condenser and fan as an assembly.
18. Disconnect the charge air hose at the intake manifold (Fig. 3).
19. Remove the radiator assembly.
20. Disconnect the high pressure and return hoses at the power steering pump.
21. Disconnect the fuel lines at the fuel filter.
22. Disconnect the refrigerant line at the A/C compressor.
23. Disconnect the vacuum line for the brake booster at the vacuum pump (Fig. 3).
24. Disconnect the coolant hose of heating return flow at the water pump.
25. Disconnect the coolant hose of the heater supply at the coolant pipe at the side of the cylinder head.





26. Disconnect the air inlet, CCV breather hoses and CCV heater at the turbocharger (Fig. 4).
27. Raise and support the vehicle.
28. Disconnect the front exhaust at the turbocharger (Fig. 4).
29. Disconnect the electrical connector at the transmission.





30. Disconnect the engine valley drain hose fastener from the transmission (Fig. 5).
31. Remove the steering gear mounting bolts.
32. Disconnect the transmission cooler lines at transmission and oil pan.
33. Remove the torque converter access plate.
34. Remove the torque converter bolts.
35. Remove the crank position sensor.
36. Remove the transmission housing to engine mounting bolts.
37. Remove the starter mounting bolts (Fig. 5).
38. Support the transmission with a transmission jack.
39. Place a wood block between the transmission housing and the front frame cross over.
40. Remove the transmission jack.
41. Remove the exhaust bracket (right side).
42. Remove the engine ground strap (left side).
43. Lower the vehicle.
44. Remove the heater housing filter and lower housing.
45. Connect the engine lifting fixture #9308 to the engine lifting eyes.
46. Remove the engine mount bolts.
47. Remove the transmission oil level indicator tube mounting bolt.

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





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





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

INSTALLATION - ENGINE COVER

CAUTION: Care must be taken when installing the engine cover. Assure the proper routing of the fuel injector return fuel hose to the banjo bolt fitting in the left rear corner of the cover. Failure to do so may pinch or damage the hose causing fuel leakage or a driveability concern.

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

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

NOTE: Replace the air conditioning drier any time the air conditioning system is opened to the atmosphere.

1. Install the engine lifting fixture, special tool #9308 to the engine lifting eyelets.
2. Attach the engine hoist.
3. Install the engine assembly into the vehicle engine compartment, mating the transmission and the engine.
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. Refer to correct sequence and torque specification.
9. Install the torque converter bolts.





10. Install the crank sensor (Fig. 8).
11. Install the torque converter access plate.
12. Install the transmission cooler lines to transmission.
13. Connect the engine valley drain hose to the transmission (Fig. 5).
14. Install transmission electrical connector and shifter hardware.
15. Install the steering gear and tighten in two stages. 25 Nm (18.5 ft. lbs.), then 45 Nm (33 ft. lbs.) plus 90°.
16. Install the starter.
17. Connect the ground strap (left side).
18. Align and install the exhaust and bracket.
19. Lower the vehicle.
20. Install the lower heater housing and filter.
21. Install the air inlet hose, CCV breather and CCV heater at the turbocharger (Fig. 4).
22. Connect the coolant supply and return hoses.
23. Connect the brake booster vacuum hose at the vacuum pump.





24. Connect the fuel lines at the filter assembly (Fig. 9).
25. Connect the power steering hoses.
26. Install the radiator/charge air cooler and hose(s) assemblies.
27. Install A/C condenser and fan assemblies Connect the fan harness connector.
28. Connect the refrigerant lines.
29. Install a air conditioning receiver/drier.
30. Connect the upper and lower radiator hoses.
31. Connect the transmission lines at the radiator.
32. Install air cleaner housing and connect the air inlet duct and air flow sensor.
33. Connect the charge air cooler hose at intake manifold.
34. Route the engine wiring harness inside the vehicle and connect.
35. Install the turbocharger heat shield.
36. Install the front grille and fascia assembly.
37. Connect the negative battery cable.
38. Check and fill engine oil
39. Fill cooling system to proper level with the appropriate coolant.
40. Evacuate and recharge air conditioning.
41. Check and refill all ancillary system fluid levels.
42. Start engine and inspect for leaks.