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Oil Pan Replacement > < Engine Replacement - 1.6L LDE - 6T40

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Engine Replacement (1.6L LDE - F17-5 MDG)

Special Tools

•  CH-904   Base Frame
•  EN-6015   Closure Plugs
•  EN-49271   Engine Stand
•  CH-49289   Centering Frame
•  CH-49290   Engine Support Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
2. Open the hood.
3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
4. Remove the battery tray. Refer to Battery Tray Replacement .

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5. Remove the windshield washer solvent container filler tube (1).

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6. Remove the front compartment fuse block cover (1).

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7. Remove the 3 front compartment fuse block bolts (1).
8. Remove the front compartment fuse block (2).

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9. Unclip the 3 wiring harness plugs (3).
10. Disconnect the wiring harness plug from the front compartment fuse block.

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11. Remove the 3 ground nuts (1) and put the 3 wiring harnesses (2) aside.

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12. Disconnect the 2 wiring harness plugs (1, 2).
13. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
14. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
15. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
16. Drain the cooling system. Refer to Cooling System Draining and Filling .
17. Disconnect the coolant fill sensor plug.
18. Unclip the radiator surge tank.
19. Put the radiator surge tank aside.
20. Remove the manual transmission shift lever and selector lever cable from the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
21. Remove the heater inlet and outlet hose from the bulkhead. Refer to Heater Inlet and Outlet Hose Replacement .

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22. Disconnect the booster vacuum pipe (1) from the intake manifold.
23. Disconnect backup lamp switch wiring harness electrical connector.
24. Place collecting basin underneath.
25. Disconnect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement .
26. Place collecting basin underneath.
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.


27. Relieve the fuel pressure. Refer to Fuel Pressure Relief .

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28. Clip the evaporative emission canister purge pipe (3) out of the bracket (1).
29. Remove the fuel tank vent pipe (3) from the evaporative emission canister purge solenoid valve (2).
30. Close the vents with the EN-6015   closure plugs .

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31. Unclip the fuel feed pipe (1) from the fuel feed pipe clip (2). Refer to Plastic Collar Quick Connect Fitting Service .
32. Release the fuel feed pipe (1) from the multiport fuel injection fuel rail (3) and remove the fuel feed pipe.
33. Close the vents with the EN-6015   closure plugs .

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34. Remove A/C compressor and condenser hose nut (1) from A/C condenser (2).

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35. Remove A/C compressor and condenser hose nut (1) from refrigerant hose (2).
36. Remove the air conditioning evaporator hose assembly nut from the air conditioning condenser.
37. Unclip the radiator outlet hose from the radiator.
38. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
39. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
40. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
41. Remove steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
42. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement .
43. Remove the right front wheel drive shaft from the wheel hub. Refer to Front Wheel Drive Shaft Replacement - Right Side .
44. Remove the left front wheel drive shaft from the wheel hub. Refer to Front Wheel Drive Shaft Replacement - Left Side .
45. Disconnect the wheel speed sensors on both sides.
46. Remove the wheel speed sensor wiring harness retainers from the frame.

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47. Unclip the 2 engine coolant fan wiring harnesses (1, 2) from the frame.
48. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
49. Install the CH-49290   engine support tool , for the assembly use attached installation manual.
50. Remove the engine mount. Refer to Engine Mount Replacement .
51. Remove the transmission mount. Refer to Transmission Mount Replacement - Left Side .
52. Detach 3 wiring harness plugs from the electronic power steering (EPS).
53. Assemble the CH-49289   centring frame , for the assembly use attached installation manual.

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54. Raise the CH-904   base frame and CH 49289   centring frame with the hydraulic jack until it contacts the frame.

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Note:  Positioning pins (2, 3) of CH-49289   centring frame MUST stick into holes of drivetrain frame.
55. Check if wheel alignment is required.
  •  Move out position pins (1) and try to insert into underbody holes.
  •  If guide pins can NOT be inserted, the Wheel Alignment Measurement is required after installation of drive train frame.

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56. Remove the frame front bolts (1).
57. Remove the frame rear bolts (2).
58. Remove the frame reinforcements (3).
59. Lower suspension frame (4) carefully with the engine transmission unit off the vehicle with hydraulic jack about 7 cm.
60. Remove the 2 wiring harness starter bracket bolts.
61. Remove the wiring harness starter bracket from the electronic power steering (EPS).
62. Remove suspension frame carefully with the engine transmission unit from the vehicle with hydraulic jack.
63. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
64. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .

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65. Loosen the radiator outlet hose clamp (2).
66. Remove the radiator outlet hose (3) from the water pump (1).

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67. Loosen the radiator inlet hose clamp (4).
68. Remove the radiator inlet hose (3) from the engine coolant thermostat (5).
69. Remove the radiator assembly.
70. Install suitable cable at the 3 engine lift brackets.
71. Install a suitable engine lifting device to the cable.
72. Extend the engine lifting device until the steel cable are slightly tensioned.

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73. Remove the front transmission mount through bolt (1).

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74. Remove the transmission bracket mount to mount through bolt (1).
75. Lower and remove the frame.
76. Put the engine transmission unit down on a wooden pallet.
77. Loosen the 8 transmission bolts and remove 6 of them. Refer to Transmission Replacement .

Note:  A second technician is required.
78. Remove the last 2 transmission bolts and the transmission.
79. Install the engine to the EN-49271   engine stand .
80. Transfer parts as needed.

Installation Procedure

1. Remove the engine from the EN-49271   engine stand .
2. Put the engine down on a wooden pallet.

Note:  A second technician is required.
3. Install the transmission and 2 transmission bolts.
4. Install the 6 transmission bolts.

Caution: Refer to Fastener Caution .
5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Install 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.
7. Raise the CH-904   frame and CH-49289   centring frame with the hydraulic jack until it contacts the frame.
8. Place the engine transmission unit into the front frame.

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9. Install the rear transmission bracket mount to mount through bolt (1) and tighten to 100 N·m (74 lb ft) .

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10. Install the front transmission mount through bolt (1) and tighten to 58 N·m (43 lb ft) .
11. Remove the cable from the 3 engine lift brackets.
12. Install the radiator assembly.

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13. Install the radiator inlet hose (3) to the engine coolant thermostat (5).
14. Install the radiator inlet hose clamp (4).

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15. Install the radiator outlet hose (3) to the water pump (1).
16. Install the radiator outlet hose clamp (2).
17. Install the right wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
18. Install the left wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .

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Note:  Positioning pins (1) of CH-49289   centring frame MUST be extended in order to guide into underbody holes.
19. Move the frame with the engine transmission unit to the vehicle upwards, till wiring harness starter can be fixed .
20. Install the wiring harness starter bracket to electronic power steering (EPS).
21. Install and tighten the 2 wiring harness starter bracket bolts.

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22. Install the frame (4).
23. Install the frame reinforcements (3).
24. Install frame rear bolts (2). Handtighten ONLY.
25. Install frame front bolts (1). Handtighten ONLY.
26. Tighten the frame rear bolts (2) and tighten to 160 N·m (118 lb ft) .
27. Tighten the frame front bolts (1) and tighten to 160 N·m (118 lb ft) .

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28. Lower the CH-49289   centring frame with the hydraulic jack until it is removable.
29. Disassemble the CH-49289   centring frame , for the assembly use attached installation manual.
30. Install the engine mount. Refer to Engine Mount Replacement .
31. Install the transmission mount. Refer to Transmission Mount Replacement - Left Side .
32. Remove the CH-49290   engine support tool , for the disassembly use attached installation manual.
33. Connect the 3 wiring harness connectors to the electronic power steering (EPS).
34. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .

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35. Clip the 2 engine coolant fan wiring harnesses (1, 2) into the frame.
36. Install the wheel speed sensor wiring harness retainers from the frame.
37. Connect the wheel speed sensor on both sides.
38. Install the right front wheel shaft to the wheel hub. Refer to Front Wheel Drive Shaft Replacement - Right Side .
39. Install the left front wheel shaft to the wheel hub. Refer to Front Wheel Drive Shaft Replacement - Left Side .
40. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
41. Install the steering linkage outer tie rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
42. Install the upper stabilizer shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
43. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
44. Check the transmission fluid level. Refer to Transmission Fluid Level Inspection .
45. Lower the vehicle.
46. Clip the Radiator outlet hose into the radiator.

Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .
47. Install the air conditioning evaporator hose assembly nut to the air conditioning condenser and tighten to 19 N·m (14 lb ft) .

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Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .
48. Install the A/C compressor and condenser hose nut (1) to the A/C condenser (2). Tighten the nut to 19 N·m (14 lb ft) .

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Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .
49. Install the A/C compressor and condenser hose nut (1) to the refrigerant hose (2). Tighten the nut to 19 N·m (14 lb ft) .
50. Remove the EN-6015   closure plugs .
51. Connect the fuel filler pipe to the multiport fuel injection fuel rail.
52. Remove the EN-6015   closure plugs .
53. Connect the fuel tank vent pipe to the evaporative emission vent valve.
54. Connect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement .
55. Bleed the hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding .
56. Fill the reservoir with clutch/brake fluid up to the MAX level.
57. Connect backup lamp switch wiring harness electrical connector.

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58. Connect the booster vacuum pipe (1) to the intake manifold.
59. Install the heater inlet and outlet hose from the bulkhead. Refer to Heater Inlet and Outlet Hose Replacement .
60. Install the manual transmission shift lever and selector lever cable to the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
61. Connect the coolant fill sensor plug.
62. Clip in the radiator surge tank.
63. Fill the cooling system. Refer to Cooling System Draining and Filling .
64. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
65. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
66. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

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67. Connect the 2 wiring harness plugs (1, 2).

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68. Install the 3 wiring harnesses (2).
69. Install the 3 ground nuts (1) and tighten to 9 N·m(80 lb in) .

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70. Clip in the 3 wiring harness plugs (3).
71. Connect the wiring harness plug to the front compartment fuse block.

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72. Install the front compartment fuse block (2).
73. Install the 3 front compartment fuse block bolts (1) and tighten to 22 N·m (16 lb ft) .

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74. Install the front compartment fuse block cover (1).

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75. Install the windshield washer solvent container filler tube (1).
76. Install the battery tray. Refer to Battery Tray Replacement .
77. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
78. Check the oil level and fill NEW engine oil up if necessary.
79. Close the hood.
80. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .

Oil Pan Replacement > < Engine Replacement - 1.6L LDE - 6T40