Engine Replacement (1.4L LUJ - 6T40)
Special Tools
• |
CH-49289
Centering Frame |
• |
CH-49290
Engine Support Tool |
• |
EN-34730-91
Pressure Tester |
For equivalent regional tools, refer to
Special Tools .
Removal Procedure
5. |
Remove the windshield washer
solvent container filler tube (1). |
6. |
Remove the front compartment
fuse block cover (1). |
7. |
Loosen the 3 front compartment
fuse block bolts (1). |
8. |
Unclip the 4 front compartment
fuse block retainer clips (2) and (3) and lift the front
compartment fuse block slightly up. |
|
Note: The wiring
harness plugs should remain in the lower part (4) of the front
compartment fuse block.
|
9. |
Entirely loosen the 3 front
compartment fuse block bolts (1) while lifting the front
compartment fuse block until it can be removed from the 3 wiring
harness plugs (3), (5) and (6). |
10. |
Remove the ECM wiring harness
plug (1) from the lower part of the front compartment fuse
block. |
11. |
Disconnect the ECM wiring
harness plug (2) and unclip it from the retainer clip (3).
|
12. |
Remove the 3 ground cable nuts
(1) and put the 3 ground cables (2) aside. |
13. |
Unclip the ECM wiring harness
from body. |
14. |
Unclip the back up lamp switch
wiring harness from body. |
21. |
Put the radiator surge tank
aside. |
24. |
Place collecting basin
underneath the vehicle. |
|
Warning:
Gasoline or gasoline vapors are highly flammable.
A fire could occur if an ignition source is present. Never drain or
store gasoline or diesel fuel in an open container, due to the
possibility of fire or explosion. Have a dry chemical (Class B)
fire extinguisher nearby. |
25. |
Remove fuel injector rail cap
(1). |
26. |
Relieve fuel pressure. Use
EN-34730-91 pressure tester (1). |
27. |
Remove fuel feed pipe (4) from
fuel injector rail. |
28. |
Unclip fuel feed pipe from
retainer clip (1). |
29. |
Remove fuel ventilation pipe
(2) from evaporative emission canister purge solenoid valve.
|
30. |
Unclip fuel ventilation pipe
from retainer clip (1). |
31. |
Close the vents with the
EN-6015 closure plugs . |
32. |
Disconnect the brake booster
vacuum pipe (3) from intake manifold. |
33. |
Remove the lower condenser
hose nut (3). |
34. |
Remove the lower condenser
hose (1) and the seal ring (2). |
35. |
Remove the A/C compressor and
the condenser hose nut (1) from the air conditioning evaporator
hose. |
36. |
Remove the A/C compressor and
the condenser hose (2) and the seal ring (3) from the air
conditioning evaporator hose. |
43. |
Disconnect the wheel speed
sensors on both sides and unclip it from the suspension
frame. |
44. |
Remove the wheel speed sensor
wiring harness retainers from the frame. |
45. |
Disconnect the engine coolant
fan wiring harness plug (1) an unclip it from the suspension frame
(2). |
46. |
Disconnect the EPS wiring
harness plug (3). |
47. |
Disconnect the EPS main wiring
harness plug from the EPS unit. |
|
Note: Do not confuse
with three way warm up catalytic converter.
|
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to
www.spxtools-shop.com.
|
49. |
Assemble the CH-49290
engine support tool (1) according to the details provided in
the SPX installation manual. |
50. |
Support the CH-904
base frame on a jack. |
51. |
Support the CH-49290
engine support tool on the CH-904 base frame
. |
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to
www.spxtools-shop.com.
|
52. |
Install the CH-49290
engine support tool (1) according to the details provided in
the SPX installation manual. |
53. |
Remove and DISCARD the 3
engine mount bolts (2) from the engine mount (1) and the engine
mount bracket (3). |
54. |
Remove and DISCARD the 3
transmission mount bolts (2) from the transmission mount (3) and
the transmission mount bracket (1). |
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to
www.spxtools-shop.com.
|
55. |
Assemble the CH-49289
centering frame (1) according to the details provided in the
SPX installation manual. |
56. |
Support the CH-904
base frame on a jack. |
57. |
Support the CH-49289
centring frame on the CH-904 base frame
. |
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to
www.spxtools-shop.com.
|
58. |
Install the CH-49289
centering frame (1) according to the details provided in the
SPX installation manual. |
|
Note: Simplified
graphic. The engine/transmission unit is fixed with the engine
support tool to the suspension frame. The suspension frame is
supported by the centering adapter and the underframe.
|
59. |
Remove the frame front bolts
(1). |
60. |
Remove the frame rear bolts
(2). |
61. |
Remove the frame
reinforcements (3). |
62. |
Lower the suspension frame (4)
carefully with the engine transmission unit off the vehicle with
the hydraulic jack about 7 cm (2.76 in) .
|
63. |
Remove the 2 wiring harness
bracket bolts from the EPS unit. |
64. |
Remove the 2 wiring harness
bracket from the EPS unit. |
65. |
Remove the suspension frame
carefully with the engine transmission unit from the vehicle with
the hydraulic jack. |
66. |
Drain the transmission
fluid. |
69. |
Remove the engine coolant air
bleed hose (3) from the water outlet. |
70. |
Remove the heater inlet hose
(1) from the water pump. |
71. |
Remove the heater outlet hose
(2) from the water outlet. |
72. |
Remove the radiator surge tank
(4) in compound with the engine coolant air bleed hose and the 2
heater hoses. |
73. |
Remove the A/C compressor and
the condenser hose (9) from the condenser. |
74. |
Remove the radiator coolant
feed hose (10) from the engine coolant thermostat housing.
|
75. |
Remove the radiator coolant
return hose (5) from the water outlet. |
76. |
Remove the charger air cooler
inlet air hose (8) from the turbocharger. |
79. |
Remove the complete radiator
assembly (7) from the suspension frame. |
80. |
Install a suitable cable at
the 3 engine lift brackets. |
81. |
Install a suitable engine
lifting device to the cable. |
82. |
Extend the engine lifting
device until the steel cable are slightly tensioned. |
83. |
Remove the front transmission
mount through bolt (1). |
84. |
Remove the transmission
bracket mount to mount through bolt (1). |
85. |
Lower and remove the
frame. |
87. |
Put the engine transmission
unit down on a wooden pallet. |
|
Note: Two mechanics
are required.
|
89. |
Remove the last 2 transmission
bolts and the transmission. |
90. |
Install the engine to a
suitable engine stand. |
91. |
Transfer parts as needed.
Refer to Off-Vehicle. |
Installation Procedure
1. |
Remove the engine from the
engine stand. |
2. |
Put the engine down on a
wooden pallet. |
|
Note: Two mechanics
are required.
|
3. |
Install the transmission and 2
transmission bolts. |
4. |
Install the 6 transmission
bolts. |
7. |
Install a suitable cable at
the 3 engine lift brackets. Install a suitable engine lifting
device to the cable. Raise the engine transmission unit and extend
the engine lifting device until the steel cable are slightly
tensioned. |
8. |
Raise the CH-904
underframe and CH-49289 centring frame with
the hydraulic jack until it contacts the frame. |
9. |
Place the engine transmission
unit into the front frame. |
10. |
Install the rear transmission
bracket mount to mount through bolt (1) and tighten to 100
N·m (74 lb ft) . |
11. |
Install the front transmission
mount through bolt (1) and tighten to 100 N·m (74 lb
ft) . |
12. |
Remove the cable from the 3
engine lift brackets. |
13. |
Install the complete radiator
and condenser assembly to the suspension frame. |
14. |
Install the complete radiator
assembly (7) to the suspension frame. |
16. |
Install the charger air cooler
inlet air hose (8) to the turbocharger. |
17. |
Install the radiator coolant
return hose (5) to the water outlet. |
18. |
Install the radiator coolant
feed hose (10) to the engine coolant thermostat housing.
|
19. |
Install the A/C compressor and
the condenser hose (9) to the condenser. Tighten the condenser hose
nut to 19 N·m (14 lb ft) . |
20. |
Install the radiator surge
tank (4) in compound with the engine coolant air bleed hose and the
2 heater hoses. |
21. |
Install the heater outlet hose
(2) to water outlet. |
22. |
Install the heater inlet hose
(1) to water pump. |
23. |
Install the engine coolant air
bleed hose (3) to the water outlet. |
|
Note: Positioning
pins (1) of CH-49289 centring frame MUST be
extended in order to guide into underbody holes.
|
28. |
Move the frame (1) with the
engine transmission unit to the vehicle upward until the wiring
harness bracket can be fixed to the EPS unit. |
29. |
Install the wiring harness
bracket to the EPS unit. |
30. |
Tighten the 2 wiring harness
bracket bolts and tighten to 9 N·m (80 lb
in) . |
|
Note: Simplified
graphic. The engine/transmission unit is fixed with the engine
support tool to the suspension frame. The suspension frame is
supported by centering the adapter and the underframe.
|
31. |
Install the frame (4).
|
32. |
Install the frame
reinforcements (3). |
33. |
Install the frame rear bolts
(2). Handtighten ONLY. |
34. |
Install the frame front bolts
(3). Handtighten ONLY. |
35. |
Tighten the rear frame bolts
(2) and tighten to 160 N·m (118 lb ft)
. |
36. |
Tighten the front frame bolts
(1) and tighten to 160 N·m (118 lb ft)
. |
37. |
Lower the CH-49289
centring frame (1) with CH-904 base frame
and a jack. |
38. |
Remove the CH-49289
centring frame from the CH-904 base frame
. |
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to
www.spxtools-shop.com.
|
39. |
Disassemble the
CH-49289 centering frame (1) according to the
details provided in the SPX installation manual. |
40. |
Install the 3 transmission
mount bolts (2) to the transmission mount (3) and the transmission
mount bracket (1) and tighten to 50 N·m (37 lb ft) +
60° - 70° . |
41. |
Install the 3 engine mount
bolts (2) to the engine mount (1) and the engine mount bracket (3)
and tighten to 50 N·m (37 lb ft) + 60° -
70° . |
42. |
Lower the CH-49290
engine support tool (1) with CH-904 base
frame and a jack. |
43. |
Remove the CH-49290
engine support tool from the CH-904 base
frame . |
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to
www.spxtools-shop.com.
|
44. |
Disassemble the
CH-49290 engine support tool (1) according to the
details provided in the SPX installation manual. |
46. |
Connect the engine coolant fan
wiring harness plug (1) and clip it to the suspension frame
(2). |
47. |
Connect the EPS wiring harness
plug (3). |
48. |
Connect the EPS main wiring
harness to the EPS unit. |
49. |
Install the wheel speed sensor
wiring harness retainers from the frame. |
50. |
Connect the wheel speed sensor
on both sides. |
57. |
Install the A/C compressor and
the condenser hose (2) and the seal ring (3) to the air
conditioning evaporator hose. |
58. |
Install the A/C compressor and
the condenser hose nut (1) to the air conditioning evaporator hose
and tighten to 19 N·m (14 lb ft) .
|
59. |
Install the lower condenser
hose (1) and the seal ring (2). |
60. |
Install the lower condenser
hose nut (3) and tighten to 19 N·m (14 lb
ft) . |
61. |
Remove the EN-6015
closure plugs . |
62. |
Connect fuel feed pipe (4) to
the fuel injector rail. |
63. |
Clip the fuel feed pipe to the
retainer clip (1). |
64. |
Connect the fuel ventilation
pipe (2) to the evaporative emission canister purge solenoid
valve. |
65. |
Clip the fuel ventilation pipe
to the retainer clip (1). |
66. |
Connect the brake booster
vacuum pipe (3) to the intake manifold. |
67. |
Install the fuel injector rail
cap (1). |
76. |
Install the ECM wiring harness
plug (1) to the lower part of the front compartment fuse
block. |
77. |
Connect the ECM wiring harness
plug (2) and clip it to the retainer clip (3). |
78. |
Install the 3 wiring harnesses
(2). |
79. |
Install the 3 ground nuts (1)
and tighten to 9 N·m (80 lb in) .
|
|
Note: Ensure that the
3 wiring harness plugs (3), (5) and (6) fit clearly to the front
compartment fuse block.
|
80. |
Install the front compartment
fuse block (2) to the lower part (4) and loosely install the bolts
(1). |
81. |
Clip in the front compartment
fuse block to the 4 retainer clips (2) and (3). |
82. |
Tighten the 3 front
compartment fuse block bolts (1) to 22 N·m (16 lb
ft) . |
83. |
Install the front compartment
fuse block cover (1). |
84. |
Install the windshield washer
solvent container filler tube (1). |
87. |
Check the oil level and fill
NEW engine oil up if necessary. |
|