Engine Replacement (South America)

Engine Replacement (South America)

Special Tools

* J-9703386 - Powertrain Removal and Installation Device

* J-9703392 - Hydraulic Jack

* L-0806003 - Engine Support Bracket

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




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

7. Remove the air cleaner assembly (2). Refer to Air Cleaner Assembly Replacement Service and Repair.

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




9. Remove the power brake booster vacuum sensor (1) from the power vacuum brake booster.




10. Remove the evaporator outlet hose nut (1).

11. Remove the evaporator outlet hose (2). Refer to Evaporator Outlet Hose Replacement Evaporator Outlet Hose Replacement.

12. Disconnect fuel feed line. Refer to Fuel Feed Intermediate Pipe Replacement (LF1 or LFW) Fuel Feed Intermediate Pipe Replacement.




13. Remove the air conditioning compressor hose bolt (1) from the electronic control module bracket.




14. Remove the heater inlet hose (1). Refer to Heater Inlet Hose Replacement (LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (LFW) Heater Inlet Hose Replacement.

15. Remove the heater outlet hose (2). Refer to Heater Outlet Hose Replacement (LFW) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (LEA) Heater Outlet Hose Replacement.

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




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

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

19. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement.




20. 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.

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




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

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




24. Remove the torque converter bolts (1).

25. Remove the lower transmission bolts.





Note: The engine support bracket will support the engine when the engine mounts and brackets are removed.

26. For all models, install the L-0806003 - engine support bracket (1) to the engine oil crankcase. Support it on the suspension frame, paying attention to the correct location of guide pin to the suspension frame hole.

27. Lower the vehicle.




28. Remove the headlamp bolts (1).

29. Remove the radiator bolts (2).




30. Remove the transmission mount bolts (1).




31. Remove the engine mount bolts (1).

32. Disconnect electoral connectors as necessary.

33. Disconnect coolant hoses as necessary.

34. Lift the vehicle.




35. Install the J-9703386 - powertrain removal and installation device (1) to the J-9703392 - hydraulic jack (2).





Note: When lifting the powertrain removal and installation device into position, ensure proper location of engine support bracket installed previously.

36. Position the powertrain removal and installation to the vehicle and lift it by using a hydraulic jack.





Note: The illustration shows the front suspension frame without the tools installed which provides a better view of the bolts that will be removed.

37. Remove the frame bolts (1).





Note: Ensure the vehicle is secured on the lift. The powertrain assembly is very heavy, use care when raising or lowering the powertrain assembly or vehicle. Inspect for interference with powertrain assembly to body, hoses, cables, and wiring harnesses during the removal process.

38. Remove the powertrain assembly from the vehicle by carefully and slowly lowering the telescopic jack and raising the vehicle.




39. Remove the transmission brace (1).




40. Remove the lower transmission bolt (1).




41. Remove the upper transmission bolts (1).

42. Separate the engine from the transmission.

43. 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).





Note: Ensure the vehicle is secured on the lift. The powertrain assembly is very heavy, use care when raising or lowering the powertrain assembly or vehicle. Inspect for interference with powertrain assembly to body, hoses, cables, and wiring harnesses during the removal process.

5. Carefully install the powertrain assembly in the vehicle.




6. Ensure the correct location of the front suspension frame is correct. Refer to Drivetrain and Front Suspension Frame Alignment Check.




7. Install the transmission brace (1) and tighten to 58 Nm (43 lb ft).




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




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




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




13. Remove the engine support bracket (1).




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

15. Install the headlamp bolts (1) and tighten to 88 Nm (66 lb in).

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




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

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




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

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




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

22. Inspect the stabilizer link seals for damage and replace the link as necessary.




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




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

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




26. 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).




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

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

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

30. Connect the fuel feed line.




31. Install the air cleaner assembly (2). Refer to Air Cleaner Assembly Replacement Service and Repair.

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




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

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

35. 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).

36. Charge the refrigerant system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

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