Engine Assembly Replace
J340100
Remove
Important: Observe the relevant safety regulations when working on air conditioning systems.
1. Evacuate refrigerant from air conditioning system
2. Remove battery from vehicle
• Remove 2x cover from 2x terminal
• Disconnect negative and positive cable
• Remove clamp
o Release 2x nut
3. Release intake pipe from intake manifold
• Release clip
• Disconnect breather hose
o Release clip, then pull off
4. Remove intake pipe with air cleaner assembly from engine compartment
• Disconnect harness from mass air flow meter
• Release air cleaner assembly from inner wing
o Remove 2x bolt
o Release from locator
5. Remove engine cover
• Remove 2x bolt, 2x nut
6. Disconnect 2x connector from engine control unit (ECU)
7. Remove ECU and support bracket from battery tray
• Remove 2x nut
8. Release power steering reservoir from coolant expansion tank, then move to one side
• Remove 2x bolt, slide off locator
• Release transmission breather hose from coolant expansion tank
o Release from clip
9. Disconnect 2x harness connector from 2x cooling fan, then release clip
10. Disconnect harness connector from air conditioning pressure sensor
11. Release mass air flow meter harness from engine
• Release 3x clip
12. Disconnect fuse box harness connector from engine harness
13. Release earth lead for fuse box from engine
• Remove bolt
14. Release fuse box harness from engine
• Release 5x clip
15. Disconnect harness from transmission shift selector
• Disconnect 2x connector
16. Disconnect gear shift cable from transmission
• Prise off, using suitable tool
17. Release gear shift cable from support bracket
• Press clip, then pull off
18. Release harness from top of transmission, then move to one side
• Disconnect from input speed sensor
• Release from 2x clip
19. Release 2x battery lead from engine
• Release clip
• Remove bolt
20. Remove cap from coolant expansion tank
21. Raise vehicle
22. Remove engine and transmission undershield from vehicle
• Remove 2x clip, 5x bolt
Important: Observe the relevant environmental regulations when disposing of used coolant.
23. Drain cooling system
• Place collecting container below
• Open radiator drain plug
• Allow coolant to drain into collecting container
• Close radiator drain plug
24. Remove front exhaust pipe
• Disconnect 2x oxygen sensor
• Remove 2x bolt
• Remove 7x nut, gasket
• Release from rubber mount
Important: Observe the relevant environmental regulations when disposing of used transmission oil.
25. Drain oil from transmission
• Place collecting container below
• Remove drain plug from transmission
• Remove sealing washer
26. Install drain plug to transmission 40 Nm
• Install new sealing washer
27. Release 2x oil cooler pipe from transmission, then move to one side
• Place collecting container below
• Remove bolt
• Remove 2x O ring
• Install 4x Blanking Plug KM-6320
28. Disconnect 2x refrigerant pipe from air conditioning compressor
• Remove nut
• Remove 2x O ring
• Install 4x new blanking plug
29. Disconnect 2x power steering hose from 2x power steering pipe
• Place collecting container below
• Release 2x clip
• Install 4x new blanking plug
30. Disconnect radiator lower coolant hose from engine
• Release clip
31. Release oxygen sensor harness from subframe
• Release 3x clip, then move to one side
32. Lower vehicle to suitable working height
33. Remove 2x front wheel from vehicle
• Remove 10x bolt
34. Lower vehicle
35. Release 2x drive shaft from 2x hub/knuckle assembly
• Remove 2x hub nut using Holding Tool KM-468-C
36. Support radiator assembly using a suitable strap to the bonnet landing panel
37. Disconnect radiator upper coolant hose from engine
• Release clip
38. Disconnect return hose for coolant expansion tank from engine
• Release clip
39. Disconnect lower hose from coolant expansion tank
• Release clip
40. Disconnect fuel feed pipe from fuel rail
• Release integral clip
• Install 2x new blanking plug
41. Disconnect 2x heater matrix coolant hose from engine
• Release 2x clip
42. Disconnect harness connector from output speed sensor at rear of transmission
43. Disconnect brake servo hose from intake manifold
• Release clip
44. Raise vehicle to suitable working height
45. Remove wheelarch splash shield, right side
• Remove 3x clip
46. Release tie rod end from steering knuckle, right side
• Remove nut
• Use Remover KM-507-C
47. Release lower control arm fulcrum, right side
• Release nut and nut, bolt
48. Release lower ball joint from hub assembly, right side
• Remove split pin
• Remove nut
• Use Remover KM-507-C
49. Remove drive shaft, right side
• Lever out using a suitable tool
50. Remove wheelarch splash shield, left side
• Remove 3x clip
51. Disconnect harness for power steering gear from body harness
52. Disconnect intermediate shaft from steering gear
• Remove bolt
53. Disconnect fuel evaporation hose from fuel rail
• Release integral clip
• Install 2x new blanking plug
54. Release tie rod end from steering knuckle, left side
• Remove nut
• Use Remover KM-507-C
55. Release lower control arm fulcrum, left side
• Release nut and nut, bolt
56. Release lower ball joint from hub assembly, left side
• Remove split pin
• Remove nut
• Use Remover KM-507-C
57. Remove drive shaft, left side
• Lever out using a suitable tool
58. Raise vehicle
59. Remove front primary catalytic converter from engine
• Remove 2x nut, gasket
60. Release harness from starter
• Disconnect connector
• Remove nut
61. Release harness for alternator from starter
• Remove nut
62. Install Engine Support Tool CH-48492 to engine and subframe
63. Lower vehicle
64. Release mount from transmission
• Remove 3x bolt
65. Release mount from engine
• Remove 3x bolt
66. Raise vehicle
67. Release 2x stabiliser link rod from stabiliser bar, left side, right side
Note: If ball joint turns when removing nut, counter-hold centre of stabiliser rod using suitable allen key.
• Remove 2x nut
68. Release propeller shaft from transfer box
• Apply alignment marking
• Remove 6x bolt with 3x washer, then secure to vehicle
69. Install Subframe Support Tool CH-48491 to Base Frame KM-904 and hydraulic lift
Note: 2x technician are required.
70. Position Subframe Support Tool CH-48491 with Base Frame KM-904 and hydraulic lift to subframe
71. Remove engine with subframe from vehicle
• Remove 8x bolt, 2x triangular plate
• Lower and remove
Install
72. Install engine with subframe to vehicle
• Raise and position
• Install 2x triangular plate, 8x bolt; do not tighten at this stage
73. Secure subframe to vehicle
Tighten
• Secure 4x bolt for subframe 150 Nm
• Secure 4x bolt for 2x triangular plate 50 Nm
74. Remove Subframe Support Tool CH-48491 with Base Frame KM-904 and hydraulic lift from subframe
75. Remove Subframe Support Tool CH-48491 from Base Frame KM-904 and hydraulic lift
Note: 2x technician are required.
76. Secure propeller shaft to transfer box
• Release from vehicle
• Align marking
Tighten
• Install 6x bolt with 3x washer 25 Nm
77. Secure 2x stabiliser link rod to stabiliser bar, left side, right side
Note: If ball joint turns when installing nut, counter-hold centre of stabiliser rod using suitable allen key.
Tighten
• Install 2x nut 60 Nm
78. Secure mount to engine
Tighten
• Install 3x bolt 50 Nm
79. Lower vehicle
80. Secure mount to transmission
Tighten
• Install 3x bolt 90 Nm
81. Raise vehicle
82. Remove Engine Support Tool CH-48492 from engine and subframe
83. Connect intermediate shaft to steering gear
Tighten
• Install bolt 30 Nm
84. Connect harness for power steering gear to body harness
85. Connect fuel evaporation hose to fuel rail
• Remove 2x blanking plug
• Secure integral clip
86. Secure harness to starter
Tighten
• Install nut 15 Nm
• Connect connector
87. Secure harness for alternator to starter
Tighten
• Install nut 15 Nm
88. Install front primary catalytic converter to engine
• Install new gasket
Tighten
• Install 2x nut 40 Nm
89. Install front exhaust pipe
• Install new gasket
Tighten
• Install 7x nut 40 Nm
• Install 2x bolt
• Secure to rubber mount
• Connect 2x oxygen sensor
90. Secure oxygen sensor harness to subframe
• Secure 3x clip
91. Connect radiator lower coolant hose to engine
• Secure clip
92. Secure 2x oil cooler pipe to transmission
• Place collecting container below
• Remove 4x Blanking Plug KM-6320
• Install 2x new O ring
Tighten
• Install bolt 10 Nm
93. Connect 2x power steering hose to 2x power steering pipe
• Place collecting container below
• Remove 4x blanking plug
• Secure 2x clip
94. Lower vehicle to suitable working height
95. Install drive shaft, right side
• Push in
• Install hub nut; do not tighten at this stage
96. Secure lower ball joint to hub assembly, right side
Tighten
• Install nut 10 Nm
• Install new split pin
97. Secure tie rod end to steering knuckle, right side
Tighten
• Install nut 50 Nm
98. Install wheelarch splash shield, right side
• Install 3x clip
99. Install drive shaft, left side
• Push in
• Install hub nut; do not tighten at this stage
100. Secure lower ball joint to hub assembly, left side
Tighten
• Install nut 10 Nm
• Install new split pin
101. Secure tie rod end to steering knuckle, left side
Tighten
• Install nut 50 Nm
102. Install wheelarch splash shield, left side
• Install 3x clip
103. Lower vehicle
104. Secure 2x drive shaft to 2x hub/knuckle assembly using Holding Tool KM-468-C
Tighten
• Secure 2x nut 200 Nm
105. Connect brake servo hose to intake manifold
• Secure clip
106. Connect harness connector to output speed sensor at rear of transmission
107. Connect 2x heater matrix coolant hose to engine
• Secure 2x clip
108. Connect return hose for coolant expansion tank to engine
• Secure clip
109. Connect lower hose to coolant expansion tank
• Secure clip
110. Connect fuel feed pipe to fuel rail
• Remove 2x blanking plug
• Secure integral clip
111. Connect radiator upper coolant hose to engine
• Secure clip
112. Remove support from radiator assembly
113. Secure 2x battery lead to engine
• Install bolt
• Secure clip
114. Secure gear shift cable to support bracket
• Push on
115. Connect gear shift cable to transmission
• Push on
116. Connect harness to transmission shift selector
• Connect 2x connector
117. Secure harness to top of transmission
• Connect to input speed sensor
• Secure to 2x clip
118. Secure fuse box harness to engine
• Secure 5x clip
119. Secure earth lead for fuse box to engine
Tighten
• Install bolt 25 Nm
120. Connect fuse box harness connector to engine harness
121. Secure mass air flow meter harness to engine
• Secure 3x clip
122. Connect harness connector to air conditioning pressure sensor
123. Connect 2x harness connector to 2x cooling fan, then secure clip
124. Secure power steering reservoir to coolant expansion tank
Tighten
• Slide on locator, install 2x bolt 9 Nm
• Secure transmission breather hose to coolant expansion tank
o Secure to clip
125. Raise vehicle
126. Fill transmission with oil
• Place collecting container below
• Remove bolt
• Remove filler plug from transmission
127. Install filler plug to transmission
Tighten
• Install bolt 10 Nm
128. Connect 2x refrigerant pipe to air conditioning compressor
• Remove 4x blanking plug
• Install 2x new O ring
Tighten
• Install nut 10 Nm
129. Lower vehicle to suitable working height
130. Install 2x front wheel to vehicle
Tighten
• Install 10x bolt 125 Nm
131. Lower vehicle
132. Install ECU and support bracket to battery tray
Tighten
• Install 2x nut 15 Nm
133. Connect 2x connector to ECU
134. Install engine cover
Tighten
• Install 2x bolt, 2x nut 8 Nm
135. Install intake pipe with air cleaner assembly to engine compartment
• Secure air cleaner assembly to inner wing
o Secure to locator
Tighten
o Install 2x bolt 6 Nm
• Connect harness to mass air flow meter
136. Secure intake pipe to intake manifold
• Secure clip
• Connect breather hose
o Push on, then secure clip
137. Settle front suspension
138. Raise vehicle
139. Secure lower control arm fulcrum, right side
Tighten
• Secure nut 70 Nm
• Secure nut, bolt 120 Nm
140. Secure lower control arm fulcrum, left side
Tighten
• Secure nut 70 Nm
• Secure nut, bolt 120 Nm
141. Install engine and transmission undershield to vehicle
Tighten
• Install 5x new bolt 10 Nm
• Install 2x clip
142. Lower vehicle
143. Install battery to vehicle
• Install clamp
Tighten
o Secure 2x nut 10 Nm
• Connect negative and positive cable
• Install 2x cover to 2x terminal
144. Program all volatile memories
145. Refill air conditioning system
Important: The power steering pump must not be allowed to run dry.
146. Fill fluid reservoir for power steering, then allow fluid to settle for at least two minutes
• Remove cap from fluid reservoir
• Use Dexron II D
Important: Do not run the engine at this stage; this procedure primes the hydraulic system.
147. Slowly turn steering wheel to full lock left and right; add fluid if necessary
148. Start engine, then slowly turn steering wheel to full lock left and right
149. Stop engine
150. Check fluid level and refill as required
Note: If the fluid is very foamy, allow to stand for a few minutes, then repeat the procedure.
• Install cap to fluid reservoir
151. Bleed cooling system
• Place collecting container below
• Fill cooling system to maximum level
• Install cap to coolant expansion tank
• Start engine and allow to run until normal operating temperature attained
152. Refill coolant expansion tank to maximum level