Basic Engine, 2.0L: Component Locations Saab 9-5 II

Special Tools (LDK, LHU)

Illustration Tool Number/Description CH-49289 Centering Adapter CH-49290 Mounting Engine/Transmission DT-2619-01 J 2619-01 Slide Hammer EN-6105 Assembly Sleeves EN-6151-A Chuck Key EN-7872 J 7872 Magnetic Base Dial Indicator Set EN-8062 J 8062 KM-348/J-8062 Valve Spring Compressor - Head Off EN-8087 J 8087 Cylinder Bore Gauge EN-9666 J 9666 Valve Spring Tester EN-21867-850 J 21867-850 KM-6106 and KM-498-B 83 93 852 Oil Pressure Gauge Adapter J 22738-B Valve Spring Tester EN-28410 J 28410 Gasket Remover EN-28428-E J 28428-E High-Intensity Black Light Kit EN-34115 J 34115 KM-6105 83 96 202 Sprocket Bearing Installer EN-35667-A J 35667-A Cylinder Head Leakdown Tester EN-35749 J 35749 Oil Pressure Sensor Socket EN-36017 J 36017 KM-840 and KM-6152 Valve Seal Remover EN-37281-A J 37281-A KM-6360 Injector Remover EN-38188 J 38188 Cylinder Head Broken Bolt Extractor Kit EN-39358 J 39358 83 94 785 Spark Plug Socket EN-42067 J 42067 KM-J-42067 83 94 975 Rear Main Seal Installer EN-42385-850 J 42385-850 Thread Repair Kit EN-43649 J 43649 Valve Spring Compressor EN-43650 J 43650 Balance Shaft Bearing Remover and Installer EN-43653 J 43653 KM-652 83 94 868 Flywheel Holding Tool EN-43953 J 43953 83 95 113 Piston Ring Compressor EN-43963 J 43963 KM-6149 Valve Spring Compressor (off car) EN-43966-1 J-43966-1 Connecting Rod Guides EN-44217 J-44217 Timing Chain Retention Tool EN-44602 J-43651 KM-J-43651 83 96 103 Water Pump Holder EN-44811 J-44811 KM-6151 83 96 095 Accessory Belt Tensioner Unloader EN-44887 J-44887 KM-6150 83 96 129 Oil Filter Wrench EN-45025 J-45025 Control Main Filter Wrench EN-45027 J 45027 Tensioner Tool EN-45059 J 45059 Angle Meter EN-45299 J 45299 Engine Preluber EN 45680-850 Cylinder Liner Removal and Installation Kit EN 46327 Timing Chain Retention Tool EN-46745 J-43654 Piston Pin Clip Remover/Installer EN-46745-4 Piston Pin Clip Remover/Installer Adapter EN-47635 Installer EN-47909 Injector Bore and Sleeve Cleaning Kit EN-47981 J 38122-A KM-J-38122-A and KM-956-1 83 96 210 Crankshaft Balancer Holder EN-48266 Injector Seal Installer and Sizer EN-48585 Crankshaft Balancer Guide EN-48749 Timing Chain Retention Tool Kit EN-48896 HP Fuel Pump Installation Alignment Gauge EN-48953 Camshaft Actuator Locking Tool EN-49212 Camshaft Fixer J 23951 Valve Manometer

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1. Camshaft Position Actuator Solenoid Valve - Intake
2. Camshaft Position Actuator Solenoid Valve Bolt
3. Camshaft Position Actuator Solenoid Valve Bolt
4. Camshaft Position Actuator Solenoid Valve - Exhaust
5. Upper Intake Manifold Sight Shield Grommet
6. Ball Stud
7. Upper Intake Manifold Sight Shield Grommet
8. Turbocharger Coolant Feed Pipe Fitting
9. Turbocharger Coolant Feed Hose Gasket
10. Turbocharger Coolant Feed Hose Clamp
11. Turbocharger Coolant Feed Hose
12. Turbocharger Coolant Feed Hose Bolt
13. Turbocharger Coolant Feed Hose Gasket
14. Turbocharger Coolant Feed Hose Clamp
15. Upper Intake Manifold Sight Shield Grommet
16. Ball Stud
17. Ignition Coil Bolt
18. Ignition Coil Bolt Retainer
19. Ignition Coil
20. Spark Plug
21. Camshaft Cover Bolt
22. Camshaft Cover Bolt Retainer
23. Oil Filler Cap
24. Oil Fill Cap Seal
25. Camshaft Cover
26. Camshaft Housing Cover Insulator
27. Camshaft Housing Cover Insulator Bolt
28. Camshaft Cover Seal
29. Camshaft Cover Seal
30. Camshaft Bearing Cap Bolt
31. Camshaft Bearing Front Cap
32. Camshaft Bearing Cap
33. Camshaft Bearing Front Cap
34. Camshaft Bearing Rear Cap Bolt
35. Camshaft Bearing Rear Cap - Exhaust
36. Camshaft Bearing Rear Cap Bolt
37. Camshaft Bearing Rear Cap - Intake
38. Power Brake Booster Pump Seal
39. Power Brake Booster Pump
40. Power Brake Booster Pump Bolt
41. Camshaft Position Sensor Bolt
42. Camshaft Position Sensor
43. Camshaft Position Sensor O-Ring
44. $ exhaust camshaft
45. $ intake camshaft
46. Roller Finger Follower
47. Hydraulic Lash Adjusters
48. Cylinder Head Bolt
49. Coolant Air Bleed Fitting
50. Hydraulic Lash Adjusters
51. Roller Finger Follower
52. Valve Keys
53. Valve Stem Seal
54. Valve Spring
55. Valve Spring Retainer
56. Small Cylinder Head Bolt
57. Cylinder Head
58. Timing Chain Guide Bolt Access Hole
59. $ exhaust valve
60. $ intake valve
61. Camshaft Position Sensor Bolt
62. Camshaft Position Sensor - Intake
63. Camshaft Position Sensor O-Ring
64. Cylinder Head Gallery Plug
65. Rear Lift Bracket
66. Rear Lift Bracket Bolt
67. Cylinder Head Cover Plate Seal
68. Cylinder Head Cover Plate
69. Cylinder Head Cover Plate Bolt
70. Fuel Injector Hold Down Clamp
71. Fuel Injector Seal
72. Fuel Injector
73. Fuel Injector O-rings
74. Fuel Rail
75. Fuel Rail Pressure Sensor
76. Fuel Injector Wiring Harness
77. Fuel Rail Bolt

Scheme 372

1. Evaporative (EVAP) Emission Purge Solenoid Valve Bolt
2. EVAP Purge Solenoid Valve
3. Manifold Absolute Pressure (MAP) Sensor Bolt
4. MAP Sensor
5. Fuel Pump Lifter
6. High Pressure Fuel Pump Gasket
7. High Pressure Fuel Pump O-Ring
8. High Pressure Fuel Pump
9. High Pressure Fuel Pump Bolt
10. Fuel Feed Line
11. Fuel Feed Line Bolt
12. High Pressure Fuel Pump Insulator
13. High Pressure Fuel Pump Cover
14. High Pressure Fuel Line
15. Fuel Injector Insulator
16. Oil Indicator Tube
17. Oil Indicator
18. Intake Manifold Brace
19. Intake Manifold Brace Stud
20. Oil Indicator O-Ring
21. Charger AIR Bypass Tube Clamp
22. Charger AIR Bypass Tube Assembly
23. Charger AIR Bypass Valve Tank Assembly Nut
24. Charger AIR Bypass Valve Tank Assembly, Some Models
25. Charger AIR Bypass Valve Solenoid Bolt
26. Charger AIR Bypass Valve Solenoid
27. Throttle Body Bolt
28. Throttle Body
29. Throttle Body Seal
30. Power Brake Booster Fitting
31. Intake Manifold
32. Intake Manifold Gasket

Scheme 373

1. Turbocharger Wastegate Regulator Solenoid Valve Hose
2. Turbocharger Wastegate Regulator Solenoid Hose Clamp
3. Turbocharger Wastegate Regulator Solenoid Valve Hose
4. Turbocharger Wastegate Regulator Solenoid Valve Assembly
5. Turbocharger Wastegate Regulator Solenoid Valve Bracket
6. Turbocharger Wastegate Regulator Solenoid Valve Bracket Bolt/Screw
7. Turbocharger Wastegate Regulator Solenoid Valve Hose
8. Turbocharger Wastegate Regulator Solenoid Hose Clamp
9. Turbocharger Oil Feed Pipe
10. Turbocharger Oil Feed Pipe Bolt
11. Turbocharger Oil Feed Pipe Gasket
12. Turbocharger Oil Feed Pipe Gasket
13. Turbocharger Oil Feed Pipe Bolt
14. Turbocharger Coolant Return Pipe Gasket
15. Turbocharger Coolant Return Pipe Bolt
16. Turbocharger Coolant Return Pipe
17. Turbocharger Coolant Return Pipe Bolt
18. Turbocharger Coolant Return Pipe Gasket
19. Turbocharger Coolant Feed Pipe Gasket
20. Turbocharger Coolant Feed Pipe Bolt
21. Turbocharger Coolant Feed Pipe
22. Turbocharger Coolant Feed Pipe Gasket
23. Turbocharger Coolant Feed Pipe Bolt
24. Exhaust Manifold Heat Shield Bolt
25. Exhaust Manifold Heat Shield Bolt
26. Exhaust Manifold Heat Shield
27. Exhaust Manifold Nut
28. Exhaust Manifold
29. Exhaust Manifold Gasket
30. Exhaust Manifold Stud
31. Exhaust Manifold Nut - Inverted Torx®
32. Oxygen Sensor Fastener
33. Oxygen Sensor
34. Oxygen Sensor Gasket
35. Catalytic Converter Nut
36. Catalytic Converter
37. Catalytic Converter Seal
38. Catalytic Converter Stud
39. Catalytic Converter Bracket
40. Catalytic Converter L-Bracket
41. Catalytic Converter Bolt
42. Catalytic Converter Bracket Bolt
43. Catalytic Converter Stud
44. Turbocharger Air Cooler Outlet Pipe
45. Turbocharger Air Cooler Outlet Pipe Bolt
46. Turbocharger Heat Shield
47. Turbocharger Heat Shield Bolts
48. Turbocharger Air Cooler Outlet Pipe Seal
49. Turbocharger Gasket
50. Turbocharger
51. Turbocharger Air Bypass Valve Spring
52. Turbocharger Air Bypass Diaphragm Assembly
53. Turbocharger Air Bypass Valve Cover
54. Turbocharger Air Bypass Valve Cover Bolt
55. Turbocharger Oil Return Pipe Gasket
56. Turbocharger Oil Return Pipe Bolt
57. Turbocharger Oil Return Pipe
58. Turbocharger Oil Return Pipe O-Ring
59. Turbocharger Brace

Scheme 374

1. Water Pump to Engine Block Seal
2. Water Pump Seal
3. Water Pump
4. Water Pump Bolt
5. Outlet Pipe O-rings
6. Outlet Pipe
7. Coolant Thermostat Housing Bolt
8. Coolant Thermostat Housing
9. Thermostat Housing to Block Gasket
10. Coolant Thermostat Housing Seal
11. Coolant temperature. Sensors
12. Thermostat
13. Coolant Inlet
14. Coolant Inlet Bolt
15. Water Pipe Support Bracket
16. Water Pipe Support Bracket Bolt
17. Water Pipe Support Bracket Bolt Stud
18. Piston Ring Assembly
19. Piston Assembly
20. Connecting Rod Bushing
21. Connecting Rod
22. Connecting Rod Bearing
23. Connecting Rod Cap Bolt
24. Oil Cooler O-ring
25. Oil Cooler
26. Oil Cooler Bolt
27. Front Lift Bracket
28. Front Lift Bracket Bolt
29. Cylinder head gasket
30. Cylinder Bore Liner
31. Cylinder Head Alignment Pin
32. Oil Filter Cap
33. Oil Filter Cap O-ring
34. Oil Filter
35. Engine Block Gallery Plug
36. Engine Block to Transaxle Alignment Pin
37. Crankshaft Position Sensor
38. Crankshaft Position Sensor Bolt
39. Engine Oil Pressure Switch
40. Piston Oil Nozzle Assembly
41. Manual Transaxle Flywheel to Crankshaft Bolt
42. Flywheel - Manual Transaxle
43. Automatic Transaxle Flywheel to Crankshaft Bolt
44. Flywheel - Automatic Transaxle
45. Crankshaft Rear Seal
46. Engine Block
47. Crankshaft Thrust Bearing - Upper
48. Crankshaft Bearing - Upper
49. Crankshaft
50. Crankshaft Thrust Bearing - Lower
51. Crankshaft Bearing - Lower
52. Lower Crankcase
53. Lower Crankcase Perimeter Bolt
54. Oil Level Indicator Plate Bolt
55. Engine Oil Level Sensor Assembly
56. Engine Oil Level Sensor Retainer Ring
57. Engine oil pan dowels
58. Lower Crankcase Main Bearing Bolt
59. Oil Pan Drain Plug
60. Engine Oil Pan Bolt
61. Engine Oil Pan Long Bolt
62. Engine Oil Pan
63. Starter
64. Starter motor bolt
65. Knock Sensor - Front
66. Knock Sensor - Rear

Scheme 375

1. Timing Chain Tensioner Body
2. Timing Chain Tensioner Seal
3. Adjustable Timing Chain Guide
4. Adjustable Timing Chain Guide Bolt
5. Timing Chain
6. Timing Chain Fixed Guide Bolt
7. Fixed Timing Chain Guide
8. Timing Chain Drive Sprocket
9. Friction Washers, if equipped
10. Timing Chain Oil Nozzle Bolt
11. Timing Chain Oil Nozzle
12. Camshaft Position Actuator Bolt
13. Intake Camshaft Position Actuator
14. Camshaft Position Actuator Bolt
15. Exhaust Camshaft Position Actuator
16. Upper Timing Chain Guide
17. Timing Chain Upper Guide Bolt
18. Balance Shaft Drive Sprocket Bolts
19. Exhaust Balance Shaft Drive Sprocket
20. Intake Balance Shaft Drive Sprocket
21. Exhaust Balance Shaft Bearing Carrier
22. Intake Balance Shaft Bearing Carrier
23. Exhaust Balance Shaft
24. Intake Balance Shaft
25. Balance Shaft Rear Bearing
26. Water Pump Drive Sprocket Bolt
27. Water Pump Drive Sprocket
28. Balance Shaft Drive Chain Tensioner Bolt
29. Balance Shaft Drive Chain Tensioner Assembly
30. Adjustable Balance Shaft Drive Chain Guide Bolt
31. Adjustable Balance Shaft Drive Chain Guide
32. Balance Shaft Drive Chain
33. Balance Shaft Drive Chain Guide Bolt
34. Balance Shaft Drive Chain Guide
35. Balance Shaft Drive Sprocket
36. Balance Shaft Drive Chain Guide
37. Balance Shaft Drive Chain Guide Bolt
38. Engine Front Cover Alignment Pins
39. Engine Front Cover Gasket
40. Oil Pump Cover Bolt
41. Oil Pump Cover
42. Oil Pump Gear
43. Oil Pump Inner Rotor
44. Engine front cover
45. Engine Front Cover Bolt
46. Crankshaft Front Oil Seal
47. Crankshaft Balancer
48. Crankshaft Balancer Bolt
49. Engine Front Cover Bolt
50. Oil Pressure Relief Valve
51. Oil Pressure Relief Valve O-Ring
52. Water Pump Sprocket Access Cover Bolt
53. Water Pump Sprocket Access Cover
54. Water Pump Sprocket Access Cover Gasket
55. Belt Tensioner Bolt
56. Belt Tensioner
57. Belt Tensioner Bolt
58. Belt Tensioner Pulley Bolt
59. Belt Tensioner
60. Power Steering Pump Pulley
61. Power Steering Pump Bolt
62. Power Steering Pump Bracket
63. Power Steering Pump Bracket Bolt

Scheme 376

Identification can be made through the use of the broadcast code label (1), identification label (4), and the use of the partial vehicle identification number (VIN) etched in one of two places - the primary location is on the starter motor flange (3). The secondary location is the oil filter bowl (2).

Scheme 377

1. Barcode
2. Sequence Number
3. Julian Day
4. Year
5. Plant Code
6. Suffix Code
7. Component ID
8. Suffix Code

The partial VIN identifies the specific vehicle by sequence number.

Special Tools

EN-28410 Gasket Remover

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

EN-49212 Camshaft Fixer

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

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1. Remove the camshaft cover. Refer to «Camshaft Cover Removal (LDK, LHU)»(ref-653636-S02456269882014090100000) .
2. Rotate the crankshaft balancer mark (1) to the oil pump housing mark (2).
3. Install the EN-49212-1 camshaft fixer (1) and EN-49212-2 camshaft fixer (2) and fix the camshaft.
4. Count the number of the end to end connectors between the marks on EN-49212-1 camshaft fixer (2) and EN-49212-2 (1). The timing chain must have 29 end to end connectors to guarantee a correct adjustment.

Location (pos)

1. 01 - Front
2. 02 - Rear
3. 03 - Left
4. 04 - Right
5. 05 - All
6. 06 - Upper
7. 07 - Centre
8. 08 - Lower
9. 09 - Service Information

1. 01 - Front
2. 02 - Rear
3. 03 - Left
4. 04 - Right
5. 05 - All
6. 06 - Upper
7. 07 - Centre
8. 08 - Lower
9. 09 - Service Information

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1. CH-904 Base Frame
2. CH-49290 Mounting Engine/Transmission
3. CH-49290-4 Right Pin Bracket
4. CH-49290-5 Left Pin Bracket
5. CH-49290-6 Pin
6. CH-49290-7 Adapter Plate
7. CH-49290-8 Adapter Plate
8. CH-49290-9 Front Mounting Bracket Left
9. CH-49290-10 Rear Mounting Bracket Right
10. CH-49290-11 Rear Mounting Bracket Left
11. CH-49290-12 Adapter Plate
12. CH-49290-14 Supporting Stand
13. CH-49290-15 Adapter Plate
14. CH-49290-16 Supporting Stand
15. CH-49290-17 Supporting Stand
16. CH-49290-18 Supporting Stand

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

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1. Install the CH-904 base frame (1) to the hydraulic lift. The distance (A) has to be 40 mm (1.6 in) .
2. Install the CH-49290 mounting engine/transmission (1) to the CH-904base frame (2).
3. Install the CH-49290-4 right pin bracket (1) with CH-49290-6 pin (3) to the CH-49290 mounting engine/transmission.
4. Install the CH-49290-5 left pin bracket (2) with CH-49290-6 pin (3) to the CH-49290 mounting engine/transmission.
5. Vehicles with AWD: Install the CH-49290-17 supporting stand (1) to the CH-49290 mounting engine/transmission. Lower the CH-49290-17 supporting stand.
6. Vehicles with FWD: Install the CH-49290-15 adapter plate (1) to the CH-49290 mounting engine/transmission. Position "X" of the CH-49290-15 adapter plate to "20" of the CH-49290 mounting engine/transmission.
7. Vehicles with FWD: Install the CH-49290-16 supporting stand (2) to "24" of the CH-49290-15 adapter plate. Lower the CH-49290-16 supporting stand.
8. Install the CH-49290-12 adapter plate (1) to the CH-49290 mounting engine/transmission. Position "Q" of the CH-49290-12 adapter plate to "13" of the CH-49290 mounting engine/transmission.
9. Install the CH-49290-14 supporting stand (2) to CH-49290-12 adapter plate. Position "U" of the CH-49290-14 supporting stand to "16" of the CH-49290-12 adapter plate. Lower the CH-49290-14 supporting stand.
10. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
11. NOTE: Do NOT raise the vehicle with the hydraulic lift. Do NOT lower the vehicle. Raise the hydraulic lift with CH-49290 mounting engine/transmission.
12. Install both CH-49290-6 pin (2) into the front suspension frame (1).
13. Install the CH-49290-8 front mounting bracket right (1) with CH-49290-7 adapter plate (2) to CH-49290 mounting engine/transmission and the front suspension frame. Position "G" of the CH-49290-8 front mounting bracket right to "03" and "04" of the CH-49290 mounting engine/transmission. Tighten the fasteners.
14. Install the CH-49290-9 front mounting bracket left (1) with CH-49290-7 adapter plate (2) to CH-49290 mounting engine/transmission and the front suspension frame. Position "H" of the CH-49290-9 front mounting bracket left to "05" and "06" of the CH-49290 mounting engine/transmission. Tighten the fasteners.
15. Install the CH-49290-10 rear mounting bracket right (1) to CH-49290 mounting engine/transmission and the front suspension frame. Position "K" of the CH-49290-10 rear mounting bracket right to "07" and "08" of the CH-49290 mounting engine/transmission. Tighten the fasteners.
16. Install the CH-49290-11 rear mounting bracket left (1) to CH-49290 mounting engine/transmission and the front suspension frame. Position "N" of the CH-49290-11 rear mounting bracket left to "10" and "11" of the CH-49290 mounting engine/transmission. Tighten the fasteners.
17. Install the CH-49290-14 supporting stand (2) to the transmission front mount (1).
18. Vehicles with AWD: Install the CH-49290-17 supporting stand (1) to the transfer case (2).
19. Vehicles with FWD: Install the CH-49290-16 supporting stand (1) to the transmission rear mount (2).
20. Install the CH-49290-18 supporting stand (1) to CH-49290 mounting engine/transmission to support the engine oil pan.
21. Lower and remove the CH-904 base frame with the hydraulic lift from the CH-49290 mounting engine/transmission.

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1. Raise and install the CH-904 base frame with the hydraulic lift to the CH-49290 mounting engine/transmission.
2. Remove the CH-49290-18 supporting stand (1) from the engine oil pan.
3. Vehicles with FWD: Remove the CH-49290-16 supporting stand (1) from the transmission rear mount (2).
4. Vehicles with AWD: Remove the CH-49290-17 supporting stand (1) from the transfer case (2).
5. Remove the CH-49290-14 supporting stand (2) from the transmission front mount (1).
6. Remove the CH-49290-11 rear mounting bracket left (1).
7. Remove the CH-49290-10 rear mounting bracket right (1).
8. Remove the CH-49290-9 front mounting bracket left (1) with CH-49290-7 adapter plate (2).
9. Remove the CH-49290-8 front mounting bracket right (1) with CH-49290-7 adapter plate (2).
10. Lower the hydraulic lift with CH-49290 mounting engine/transmission.
11. Remove the CH-49290 mounting engine/transmission (1) from the CH-904 base frame (2).

1. CH-904 Base Frame
2. CH-49289 Centering Adapter
3. CH-49289-1 Frame
4. CH-49289-2 Safety
5. CH-49289-3 Safety
6. CH-49289-4 Support Right
7. CH-49289-5 Support Left
8. CH-49289-6 Centering Pin
9. CH-49289-7 Arm Right
10. CH-49289-8 Rod Right
11. CH-49289-9 Arm Left
12. CH-49289-10 Rod Left
13. CH-49289-11 Adapter
14. CH-49289-12 Adapter
15. CH-49289-13 Adapter
16. CH-49289-14 Support
17. CH-49290 Mounting Engine/Transmission

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

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1. Install the CH-904 base frame (1) to the hydraulic lift. The distance (A) has to be 40 mm (1.6 in) .
2. Install the CH-49289-2 safety (2) and CH-49289-3 safety (3) into the CH-49289 centering adapter (1).
3. Install the CH-49289 centering adapter to the CH-904 base frame.
4. Install the CH-49289-4 support right (1) to position "01".
5. Install the CH-49289-5 support left (2) to position "02".
6. Install the CH-49289-7 arm right (1) to position "04".
7. Install the CH-49289-9 arm left (2) to position "06".
8. Install the CH-49289-11 adapter (1) to position "08".
9. Install the CH-49289-11 adapter (2) to position "09".
10. Install the CH-49289-12 adapter (1) to position "15".
11. Install the CH-49289-12 adapter (2) to position "18".
12. Install the CH-49289-13 adapter (1) to position "19".
13. Install the CH-49289-13 adapter (2) to position "22".
14. Install the CH-49289-6 (1) centering pin into CH-49289-4 support right (2) to position "B".
15. Install the CH-49289-6 centering pin (3) into CH-49289-5 (4) to position "E".
16. NOTE: For the removal of front suspension frame and/or engine and transmission, lower and secure CH-49289-8 rod right and CH-49289-10 rod left. Install the CH-49289-8 rod right (1) into CH-49289-7 arm right (2) to position "H".
17. Install the CH-49289-10 rod left (3) into CH-49289-9 arm left (4) to position "M".
18. Install both CH-49289-14 support (1) into both CH-49289-11 adapter (2).
19. Install both CH-49289-14 support (3) into both CH-49289-12 adapter (4).
20. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
21. Installation in conjunction with CH-49290 mounting engine: Remove both CH-49290-6 pin (1) from the CH-49290 mounting engine/gearbox (2).
22. NOTE: Do NOT raise the vehicle with the hydraulic lift. Do NOT lower the vehicle. Raise the hydraulic lift with CH-49289 centering adapter (2) to support the front suspension frame (1).
23. Install the CH-49289 centering adapter parallel to the front suspension frame.

Scheme 425

1. Remove the CH-49289 centering adapter (2) from the front suspension frame (1).
2. Lower the hydraulic lift with CH-49289 centering adapter.
3. Remove the CH-49289 centering adapter from the CH-904 base frame.

1. EN-47649 Engine Bridge
2. EN-47649-100 Engine Bridge Feet
3. EN-47650 Retainer Frame
4. EN-47650-30 Extension
5. EN-47650-50 Rail
6. EN-47650-250 Front Adapter
7. EN-47650-300 Rear Adapter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 426

Install the EN-47649-100 engine bridge feet (4) to the EN-47649 engine bridge (1).

1. Tighten the mounting bolt (2) and the nut (6) on both sides. Put the washer (5) under the nut on both sides.
2. Tighten the adjustment screw (3) when the EN-47649 engine bridge is adjusted vertical on both sides.

Scheme 427

1. Pre-assemble of the EN-47650-250 front adapter (1) by the following manufacturer's instructions.
2. NOTE: Pre-assemble the special tool assembly outside the vehicle, in accordance with the table. Pre-assemble the EN-47650 retainer frame off the vehicle.

Scheme 428

1. Install the EN-47650-30 extension bars (1, 6) of the frame set onto the EN-47650 retainer frame.
2. NOTE: The outer bars of the EN-47650 retainer frame MUST be arranged parallel. Tighten the hexagons (2, 7) on both sides.
3. Adjust the height of the EN-47650 retainer frame. Tighten the hexagons (3, 5) on both sides. Adjust the height with the hexagons (4) on both sides.

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1. Remove both wiring harness retainer from both front compartment rails.
2. WARNING: To avoid paint damage, use protective covers on the fenders. Use the long arm (1) of the EN-47650-300 rear adapter for this operation.
3. NOTE: Do NOT tighten fasteners of EN-47650-300 rear adapter. Install the EN-47650-300 rear adapter (1) to the hole (2) in the front compartment rail.
4. Remove the engine wiring harness connectors from the headlamp mount panel reinforcement - left side.
5. With the aid of an assistant, install the EN-47650 retainer frame (1) to the vehicle. If necessary readjust the EN-47650 retainer frame (1) for appropriate fitting.
6. Tighten the rear side of the EN-47650 retainer frame: 6.1. Insert the safety pins (2) through the EN-47650-300 rear adapters and the side bar to prevent movement. 6.2. Tighten the EN-47650 retainer frame to the EN-47650-300 rear adapters with the mounting bolts (1). 6.3. Tighten the bolts (3, 4). 6.4. Tighten the outer bolts (1) of the EN-47650-300 rear adapters. 6.5. Re-tighten ALL the hexagons of the EN-47650 retainer frame.
7. Tighten the front left side of the EN-47650 retainer frame: 7.1. Align the hook (1) with the thumb wheel (4) to the upper tie bar. 7.2. Tighten the hook (1) to the upper tie bar, using the thumb wheel (2). 7.3. Tighten the bolts at the clamping piece (3).
8. Tighten the front right side of the EN-47650 retainer frame: 8.1. Align the hook (1) with the thumb wheel (4) to the upper tie bar. 8.2. Tighten the hook (1) to the upper tie bar, using the thumb wheel (2). 8.3. Tighten the bolts at the clamping piece (3).
9. NOTE: The EN-47650-50 rail is the equipment of the EN-47650 retainer frame and enclosed in the EN-47650 retainer frame tool kit. Install the EN-47650-50 rail (4) to the EN-47650 retainer frame. Secure the EN-47650-50 rail (4) with the safety pins (3).
10. NOTE: Secure the chain boxes with the hook chains on the outside of the engine bridge. With the aid of an assistant, install the EN-47649 engine bridge (5) onto the EN-47650-50 rail (4). Secure the EN-47649 engine bridge (5) with the safety pins (2).
11. When the tool assemble EN-47650 retainer frame and EN-47649 engine bridge is under load, adjust the complete assemble and retighten ALL the fasteners.

Scheme 437

Scheme 438

Scheme 439

Scheme 440

Scheme 441

Scheme 442

Scheme 443

1. NOTE: Secure the chain boxes with the hook chains on the outside of the engine bridge. With the aid of an assistant, remove the EN-47649 engine bridge (5). Remove the safety pins (2).
2. NOTE: The EN-47650-50 rail is the equipment of the EN-47650 retainer frame and enclosed in the EN-47650 retainer frame tool kit. Remove the EN-47650-50 rail (4) from the EN-47650 retainer frame. Remove the safety pins (3).
3. Remove the front right side of the EN-47650 retainer frame: Loosen the bolts from the clamping piece (3). Loosen the hook (1) with the thumb wheel (2) and turn the hook 90° from the upper tie bar.
4. Remove the front left side of the EN-47650 retainer frame: Loosen the bolts from the clamping piece (3). Loosen the hook (1) with the thumb wheel (2) and turn the hook 90° from the upper tie bar.
5. Loosen the rear side of the EN-47650 retainer frame: 5.1. Loosen the EN-47650 retainer frame from the EN-47650-300 rear adapters with the mounting bolts (1). 5.2. Remove the safety pins (2) from the EN-47650-300 rear adapters and the side bars.
6. With the aid of an assistant, remove the EN-47650 retainer frame (1) from the vehicle.
7. Install the engine wiring harness connectors to the headlamp mount panel reinforcement - left side.
8. Remove the EN-47650-300 rear adapter (1) from the front compartment rail.
9. Clean all contact surfaces (1) from the EN-47650 retainer frame on the upper tie bar.
10. Install both wiring harness retainer to both front compartment rails.

Scheme 444

Scheme 445

Scheme 446

Scheme 447

Scheme 448

Scheme 449

1. Remove the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .
2. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
3. Remove the turbocharger coolant feed pipe. Refer to «TURBOCHARGER COOLANT FEED PIPE REPLACEMENT (LHU/A20NFT)»(ref-653648-S24832238872014090100000) .
4. NOTE: Do not damage the camshaft cover and the positive crankcase ventilation retainer of the turbocharger. Remove the retainer of the positive crankcase ventilation. Remove the fastener (1) of the positive crankcase ventilation retainer and remove the retainer (2) out of the turbocharger (3). Remove the seal ring (4). Remove the hose/pipe/tube (5) with a screwdriver.
5. Remove the positive crankcase ventilation hose/pipe/tube (1) with a screwdriver from the camshaft cover (2).

Scheme 450

Scheme 451

1. Install a NEW seal ring (1) to the positive crankcase ventilation retainer (2).
2. Install the positive crankcase ventilation retainer (2) to the turbocharger (3) and tighten the fastener (4) to 10 Nm (89 lb in) .
3. Install the positive crankcase ventilation hose/pipe/tube (1) to the positive crankcase ventilation retainer (2) and the camshaft cover (3).
4. Install the turbocharger coolant feed pipe. Refer to «TURBOCHARGER COOLANT FEED PIPE REPLACEMENT (LHU/A20NFT)»(ref-653648-S24832238872014090100000) .
5. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

1. Raise the vehicle by its full height. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
2. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
3. Remove the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .
4. Remove the turbocharger heat shield. Refer to «TURBOCHARGER HEAT SHIELD, REPLACEMENT»(ref-653636-S02806108982014090100000) .
5. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-653646-S02731215182014090100000) .
6. Release the charge air cooler inlet air tube. Refer to «CHARGE AIR COOLER INLET AIR HOSE REPLACEMENT»(ref-653636-S26871968422014090100000) .
7. Release the turbocharger coolant feed pipe. Refer to «TURBOCHARGER COOLANT FEED PIPE REPLACEMENT (LHU/A20NFT)»(ref-653648-S24832238872014090100000) .
8. Release the turbocharger coolant return pipe. Refer to «TURBOCHARGER COOLANT RETURN PIPE REPLACEMENT (LHU/A20NFT)»(ref-653648-S05047614462014090100000) .
9. Release the turbocharger oil feed pipe. Refer to «TURBOCHARGER OIL FEED PIPE REPLACEMENT»(ref-653636-S19745143222014090100000) .
10. Release the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT (LHU/A20NFT)»(ref-653647-S17749928632014090100000) or «CATALYTIC CONVERTER REPLACEMENT (LHU/A20NFT - AWD)»(ref-653647-S24239191502014090100000) .
11. Disconnect the electrical connector (1) from turbocharger.
12. Release the vacuum pipe (1) from charger air bypass valve (2).
13. Release the positive crankcase ventilation hose.
14. Raise the vehicle by its full height.
15. Remove exhaust front pipe. Refer to «EXHAUST FRONT PIPE REPLACEMENT»(ref-653636-S04493525822014090100000) .
16. Remove the turbocharger brace. Refer to «Turbocharger Stay, Replacement»(ref-653636-S41993401882014090100000) .
17. Remove turbocharger oil return hose. Refer to «TURBOCHARGER OIL RETURN PIPE REPLACEMENT»(ref-653636-S33639686422014090100000) .
18. Remove the 4 fasteners (1) from turbocharger (2).

Scheme 457

Scheme 458

1. Install the turbocharger and tighten to 30 Nm (22 lb ft) , then to 35 Nm (26 lb ft) .
2. Install the turbocharger oil return hose. Refer to «TURBOCHARGER OIL RETURN PIPE REPLACEMENT»(ref-653636-S33639686422014090100000) .
3. Install the turbocharger brace. Refer to «Turbocharger Stay, Replacement»(ref-653636-S41993401882014090100000) .
4. Raise the vehicle by its full height.
5. Connect the positive crankcase ventilation hose.
6. Connect the vacuum pipe (1) to the charger air bypass valve (2).
7. Connect the electrical connector (1) to the turbocharger.
8. Connect the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT (LHU/A20NFT)»(ref-653647-S17749928632014090100000) or «CATALYTIC CONVERTER REPLACEMENT (LHU/A20NFT - AWD)»(ref-653647-S24239191502014090100000) .
9. Connect the turbocharger oil feed pipe. Refer to «TURBOCHARGER OIL FEED PIPE REPLACEMENT»(ref-653636-S19745143222014090100000) .
10. Connect the turbocharger coolant return pipe. Refer to «TURBOCHARGER COOLANT FEED PIPE REPLACEMENT (LHU/A20NFT)»(ref-653648-S24832238872014090100000) .
11. Connect the charge air cooler inlet air tube. Refer to «CHARGE AIR COOLER INLET AIR HOSE REPLACEMENT»(ref-653636-S26871968422014090100000) .
12. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-653646-S02731215182014090100000) .
13. Install the turbocharger heat shield. Refer to «TURBOCHARGER HEAT SHIELD, REPLACEMENT»(ref-653636-S02806108982014090100000) .
14. Install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .
15. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
16. Raise the vehicle by its full lower. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .

Scheme 459

Scheme 460

Scheme 461

Scheme 462

Scheme 463

Scheme 464

Scheme 465

Scheme 466

Scheme 467

Scheme 468

Scheme 469

1. Remove engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .
2. Remove the evaporative emission canister purge solenoid valve. Refer to «EVAPORATIVE EMISSION CANISTER PURGE SOLENOID VALVE REPLACEMENT»(ref-653646-S19439487132014090100000) .
3. Release the power brake booster vacuum pipe. Refer to «POWER BRAKE BOOSTER VACUUM PIPE REPLACEMENT»(ref-653650-S19208644252014090100000) .
4. Remove the manifold absolute pressure sensor. Refer to «MANIFOLD ABSOLUTE PRESSURE SENSOR REPLACEMENT»(ref-653646-S11432377652014090100000) .
5. Remove the turbocharger control solenoid valve. Refer to «TURBOCHARGER CONTROL SOLENOID VALVE REPLACEMENT»(ref-653646-S14724615092014090100000) .
6. Remove the oil level indicator and tube. Refer to «OIL LEVEL INDICATOR TUBE REPLACEMENT»(ref-653636-S30255239332014090100000) .
7. Release the charge air cooler outlet air hose. Refer to «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
8. Remove the intake manifold brace. Refer to «INTAKE MANIFOLD BRACE REPLACEMENT»(ref-653636-S33891934932014090100000) .
9. Remove the fuel feed pipe. Refer to «FUEL FEED PIPE REPLACEMENT (METAL)»(ref-653646-S40817608792014090100000) or «FUEL FEED PIPE REPLACEMENT (PLASTIC)»(ref-653646-S28505209902014090100000) .
10. WARNING: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Remove the fuel feed pipe metal. Refer to «FUEL FEED PIPE REPLACEMENT (METAL)»(ref-653646-S40817608792014090100000) or «FUEL FEED PIPE REPLACEMENT (PLASTIC)»(ref-653646-S28505209902014090100000) .
11. Remove the 7 fasteners (1) from the intake manifold (2).

Scheme 470

1. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the intake manifold and tighten to 25 Nm (18 lb ft) .
2. Install the fuel feed pipe metal. Refer to «FUEL FEED PIPE REPLACEMENT (METAL)»(ref-653646-S40817608792014090100000) or «FUEL FEED PIPE REPLACEMENT (PLASTIC)»(ref-653646-S28505209902014090100000) .
3. Install the fuel feed pipe. Refer to «FUEL FEED PIPE REPLACEMENT (METAL)»(ref-653646-S40817608792014090100000) or «FUEL FEED PIPE REPLACEMENT (PLASTIC)»(ref-653646-S28505209902014090100000) .
4. Install the intake manifold brace. Refer to «INTAKE MANIFOLD BRACE REPLACEMENT»(ref-653636-S33891934932014090100000) .
5. Install the charge air cooler outlet air hose. Refer to «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
6. Install the oil level indicator and tube. Refer to «OIL LEVEL INDICATOR TUBE REPLACEMENT»(ref-653636-S30255239332014090100000) .
7. Install the turbocharger control solenoid valve. Refer to «TURBOCHARGER CONTROL SOLENOID VALVE REPLACEMENT»(ref-653646-S14724615092014090100000) .
8. Install the manifold absolute pressure sensor. Refer to «MANIFOLD ABSOLUTE PRESSURE SENSOR REPLACEMENT»(ref-653646-S11432377652014090100000) .
9. Install the power brake booster vacuum pipe. Refer to «POWER BRAKE BOOSTER VACUUM PIPE REPLACEMENT»(ref-653650-S19208644252014090100000) .
10. Install the evaporative emission canister purge solenoid valve. Refer to «EVAPORATIVE EMISSION CANISTER PURGE SOLENOID VALVE REPLACEMENT»(ref-653646-S19439487132014090100000) .
11. Install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .

Scheme 471

Scheme 472

Scheme 473

Scheme 474

Scheme 475

Scheme 476

Scheme 477

Scheme 478

Scheme 479

Scheme 480

Scheme 481

1. Remove the water pump and balance shaft chain tensioner. Refer to «WATER PUMP AND BALANCE SHAFT CHAIN TENSIONER REPLACEMENT»(ref-653636-S18150887942014090100000) .
2. Remove the balancer chain adjustable guide. Refer to «BALANCER CHAIN ADJUST GUIDE REPLACEMENT»(ref-653636-S02814279592014090100000) .
3. Remove the balancer chain guide - upper. Refer to «BALANCER CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S30258552142014090100000) .
4. Remove the balancer chain guide - lower. Refer to «BALANCER CHAIN GUIDE REPLACEMENT - LOWER»(ref-653636-S03926019162014090100000) .
5. Remove the water pump and balancer shaft chain (1) in direction of arrow.

Scheme 482

1. Adjustment and install the crankshaft and the balancer shaft. Refer to «BALANCE SHAFT TO ENGINE TIMING (LDK, LHU)»(ref-653636-S06062878982014090100000) .
2. Install the water pump and balancer shaft chain (1). Let the setting marks at the chain correspond to the setting marks at the sprockets according to the graphic. Do not rotate the chain after installation.
3. Install the balancer chain guide - lower. Refer to «BALANCER CHAIN GUIDE REPLACEMENT - LOWER»(ref-653636-S03926019162014090100000) .
4. Install the balancer chain guide - upper. Refer to «BALANCER CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S30258552142014090100000) .
5. Install the balancer chain adjustable guide. Refer to «BALANCER CHAIN ADJUST GUIDE REPLACEMENT»(ref-653636-S02814279592014090100000) .
6. Install the water pump and balance shaft chain tensioner. Refer to «WATER PUMP AND BALANCE SHAFT CHAIN TENSIONER REPLACEMENT»(ref-653636-S18150887942014090100000) .

Scheme 483

Scheme 484

Scheme 485

Scheme 486

Scheme 487

EN-49212 Camshaft Fixer

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 488

Scheme 489

1. Remove the timing chain tensioner. Refer to «Timing Chain and Tensioner (LDK, LHU) Removal»(ref-653636-S09079441362014090100000) .
2. Remove the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .
3. Rotate the crankshaft balancer mark (1) to the oil pump housing mark (2).
4. Remove the camshaft position actuator - exhaust. Refer to «CAMSHAFT POSITION EXHAUST ACTUATOR REPLACEMENT»(ref-653636-S10827684012014090100000) .
5. If the adjustment is NOT correct, release the timing chain from camshaft position actuator - intake (1) and rotate anti clock wise the intake camshaft up to the fixing from the EN-49212-2 camshaft fixer (2).

Scheme 490

1. Install the timing chain to the camshaft position actuator - intake.
2. Install the camshaft position actuator - exhaust. Refer to «CAMSHAFT POSITION EXHAUST ACTUATOR REPLACEMENT»(ref-653636-S10827684012014090100000) . Count the number of the end to end connectors of the camshaft timing chain between the mark on the intake camshaft drive pulley and the mark on the exhaust camshaft drive pulley. The timing chain must have 29 end to end connectors to guarantee a correct adjustment. During assembly it is necessary to tension the timing chain. Turn the camshaft in clockwise direction to install the exhaust camshaft drive pulley. Install the exhaust camshaft drive pulley and fixes with that fastener in the camshaft.
3. Fix the exhaust camshaft with the EN-49212-1 camshaft fixer. Check setup over again.
4. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Tighten the camshaft position actuator - intake to 30 Nm (22 lb ft) 100 degrees
5. Tighten the camshaft position actuator - exhaust to 30 Nm (22 lb ft) 100 degrees .
6. Remove EN-49212 camshaft fixer.
7. Install the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .
8. Install the timing chain tensioner. Refer to «Timing Chain and Tensioner (LDK, LHU) Removal»(ref-653636-S09079441362014090100000) .
9. Turn the crankshaft two round and examine the track tension and the attitudes again.

EN-45027 Tensioner Tool

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 491

1. Remove the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .
2. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-653646-S02731215182014090100000) .
3. Remove the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-653636-S22135760502014090100000) .
4. Release the turbocharger coolant feed pipe. Refer to «TURBOCHARGER COOLANT FEED PIPE REPLACEMENT (LHU/A20NFT)»(ref-653648-S24832238872014090100000)
5. Remove the timing chain tensioner (1) from cylinder head.

Scheme 492

Scheme 493

Scheme 494

1. Remove the snap ring with a snap ring pincer from tensioner body.
2. Pull out the ratchet cylinder from the tensioner body.
3. Install the EN-45027-2 tensioner tool into a visa and rotary the ratchet cylinder with EN-45027-1 tensioner tool in the clockwise direction to end position.
4. Install the ratchet cylinder and the snap ring with a snap ring pincer to tensioner body.
5. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the timing chain tensioner and tighten to 75 Nm (55 lb ft) . Use a new gasket.
6. Push the adjustable timing chain guide from the timing chain tensioner with a ratchet drill extension down and check the chain tension.
7. Install the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-653636-S22135760502014090100000) .
8. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-653646-S02731215182014090100000) .
9. Install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .

EN-49212 Camshaft Fixer

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

1. EN-840 Valve Stem Oil Seal Remover
2. EN-6086 Spring and Wedge Replacer
3. EN-6152 Valve Stem Oil Seal Installer
4. EN-6171 Valve Spring Key Solvent

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

1. EN-38188 Cylinder Head Broken Bolt Extractor Kit
2. EN-45059 Angle Meter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 495

Scheme 496

Scheme 497

1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
2. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
3. Remove the camshaft position actuator solenoid valve - intake. Refer to «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (EXHAUST)»(ref-653646-S20847205462014090100000) or «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (INTAKE)»(ref-653646-S23577426242014090100000) .
4. Remove the camshaft position actuator solenoid valve - exhaust. Refer to «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (EXHAUST)»(ref-653646-S20847205462014090100000) or «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (INTAKE)»(ref-653646-S23577426242014090100000) .
5. Remove the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-653636-S14832792362014090100000) .
6. Remove the exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT (LHU/A20NFT)»(ref-653647-S17534849202014090100000) .
7. Remove the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .
8. Remove the hydraulic valve lash adjuster - exhaust. Refer to «HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT - EXHAUST»(ref-653636-S11333592792014090100000) .
9. Remove the hydraulic valve lash adjuster - intake. Refer to «HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT - INTAKE»(ref-653636-S21510177342014090100000) .
10. Remove the cylinder head to the block fastener in sequence.
11. Remove the cylinder head (1) and the cylinder head gasket (2) from the block.
12. Clean all of the gasket surfaces. Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surfaces. NOTE: Do not use any other method or technique to clean these gasket surfaces. Use a new blade for each cylinder head and cylinder block. NOTE: Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket. Hold the razor blade (1) as parallel to the gasket surfaces (2) as possible.
13. NOTE: Do not use a tap to clean the cylinder head fastener holes. Clean the fastener holes with a nylon bristle brush.
14. WARNING: Wear safety glasses when using compressed air in order to prevent eye injury. When cleaning the cylinder head bolt holes, use a suitable solvent in spray form. Use a compressed-air cleaning pistol with an extra long nozzle to reach the bottom of the holes.
15. Remove any broken long cylinder head fastener using the EN-38188 cylinder head broken bolt extractor kit.

Scheme 498

Scheme 499

Scheme 500

Scheme 501

1. NOTE: Do not use any sealing material. Install the cylinder head gasket (1) to the cylinder block (2). On right ones sit pay attention from the cylinder head lock pin (3).
2. Ensure the number 1 cylinder is at top dead center (TDC). Setting up the crankshaft balancer mark (1) to the oil pump housing mark (2).
3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: Always use NEW cylinder head fastener. Install the cylinder head.
4. Install NEW cylinder head fastener. Tighten the fasteners in sequence to 30 Nm (22 lb ft) . Tighten the fastener in additional 155 degrees in sequence using the EN-45059 angle meter.
5. Install the front cylinder head fastener (1) and tighten to 35 Nm (26 lb ft) .
6. Install the hydraulic valve lash adjuster - intake. Refer to «HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT - INTAKE»(ref-653636-S21510177342014090100000) .
7. Install the hydraulic valve lash adjuster - exhaust. Refer to «HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT - EXHAUST»(ref-653636-S11333592792014090100000) .
8. Install the timing chain guide - upper. Refer to «TIMING CHAIN GUIDE REPLACEMENT - UPPER»(ref-653636-S10323540042014090100000) .
9. Install the exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT (LHU/A20NFT)»(ref-653647-S17534849202014090100000) .
10. Install the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-653636-S14832792362014090100000) .
11. Install the camshaft position actuator solenoid valve - exhaust. Refer to «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (EXHAUST)»(ref-653646-S20847205462014090100000) or «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (INTAKE)»(ref-653646-S23577426242014090100000) .
12. Install the camshaft position actuator solenoid valve - intake. Refer to «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (EXHAUST)»(ref-653646-S20847205462014090100000) or «CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT (INTAKE)»(ref-653646-S23577426242014090100000) .
13. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
14. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .

Scheme 502

Scheme 503

1. EN-43953 Piston Pin Clip Remover/Installer
2. EN-43966-1 Connecting Rod Guides
3. EN-45059 Piston Pin Clip Remover/Installer Adapter
4. EN-46745 Piston Clip Retainer Remover/Installer
5. EN-46745-4 Piston Clip Retainer Remover/Installer Adapter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 504

Scheme 505

1. Remove the cylinder head. Refer to «CYLINDER HEAD REPLACEMENT»(ref-653636-S28995126012014090100000) .
2. Remove the oil pan. Refer to «OIL PAN REPLACEMENT»(ref-653636-S24612324122014090100000) .
3. Rotate the crankshaft to a position where the connecting rod fasteners are the most accessible.
4. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure the caps and connecting rods are reassembled properly.
5. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
6. Remove the connecting rod fasteners.
7. Remove the connecting rod cap (1).
8. Install EN-43966-1 guides (1) on the connecting rod fasteners before removing the piston and connecting rod assembly.
9. Remove the piston and connecting rod assembly (2).

Scheme 506

Scheme 507

Scheme 508

1. WARNING: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury. Disassemble the piston rings (1). Use a suitable tool to expand the rings. The piston rings must not be reused.
2. NOTE: 2 piston pin retainers hold the piston pins in place. No special tools are required to remove the piston pins. Ensure that the piston pin is not damaged. Do not reuse the retainers. Remove the piston pin retainers using the EN-46745 remover (1) and the EN-46745-4 adapter.
3. Remove the piston pin (1) and connecting rod (3) from the piston (2).

Scheme 509

1. WARNING: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. Clean the connecting rods (1) in solvent and dry with compressed air.
2. Inspect the connecting rods for the following conditions: Signs of being twisted, bent, nicked, or cracked Scratches or abrasion on the rod bearing seating surface
3. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with fine emery cloth. DO NOT scrape the rod or rod cap.
4. If the beam of the rod is scratched or has other damage replace the connecting rod.
5. Measure the piston pin to connecting rod bore using the following procedure: Using an outside micrometer, take two measurements of the piston pin in the area of the connecting rod contact. Using an inside micrometer, measure the connecting rod piston pin bore. Subtract the piston pin diameter from the piston pin bore diameter. The clearance should not be more than 0.021 mm (0.0008 in) .
6. If there is excessive clearance, replace the piston pin.
7. If there is still excessive clearance, replace the connecting rod.

Scheme 510

Scheme 511

Scheme 512

Scheme 513

1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
2. Clean the piston ring grooves with a groove cleaner. Ensure the oil ring holes and slots are clean.
3. Inspect the pistons for the following conditions: Cracked ring lands, skirts, or pin bosses Ring grooves for nicks, burrs that may cause binding Warped or worn ring lands Eroded areas at the top of the piston (1) Scuffed or damaged skirts (2) Worn piston pin bores (3)
4. Replace pistons that show any signs or damage or excessive wear.
5. Measure the piston pin bore to piston pin clearances using the following procedure: Piston pin bores and pins must be free of varnish or scuffing. Use an outside micrometer to measure the piston pin in the piston contact areas. Using an inside micrometer, measure the piston pin bore. Subtract the measurement of the piston pin bore from the piston pin. The clearance should be within 0.002 mm - 0.012 mm (0.00007 in - 0.00047 in) . If the clearance is excessive, determine which component is out of specification.
6. Measure the piston ring end gap using the following procedure: Place the piston ring in the area of the bore where the piston ring will travel, approximately 25 mm or 1 inch down from the deck surface. Ensure the ring is square with the cylinder bore by positioning the ring with the piston head Measure the end gap of the piston ring with feeler gauges (1). Compare the measurements with those provided below. The top compression ring end gap should be 0.20 mm - 0.35 mm (0.0078 in - 0.0138 in) . The second compression ring end gap should be 0.35 mm - 0.55 mm (0.0137 in - 0.0216 in) . The oil ring end gap should be 0.25 mm - 0.76 mm (0.0098 in - 0.029 in) . If the clearance exceeds the provided specifications, the piston rings must be replaced. Repeat the procedure for all the piston rings.
7. Measure the piston ring side clearance using the following procedure: Roll the piston ring (2) entirely around the piston ring groove. If any binding is caused by a distorted piston ring, replace the ring. With the piston ring on the piston, use feeler gauges (1) to measure clearance at multiple locations. The clearance between the surface of the top piston ring and the ring land should be no greater than 0.055 mm (0.0022 in) . If the clearance is greater than specifications, replace the piston ring. If the new ring does not reduce the top ring side clearance to 0.055 mm (0.0022 in) or less, install a new piston.
8. The top compression ring may be installed with either side up. There is a locating dimple on the second compression ring near the end for identification of the top side. Install the second compression ring with the dimple facing up.
9. The clearance between the surface of the second piston ring and the ring land should be no greater than 0.032 mm (0.0012 in) .
10. If the new ring does not reduce the clearance to 0.032 mm (0.0012 in) 0.032 mm (0.0012 in) or less, install a new piston.
11. Measure piston width using the following procedure: Using an outside micrometer (2), measure the width of the piston (1) 12.5 mm (0.4925 in) above the bottom of the piston skirt at the thrust surface perpendicular to the centerline of the piston pin. Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter. The proper clearance specification for the piston is 0.010 mm - 0.041 mm (0.0006 in - 0.0016 in) .
12. If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within specification, replace the piston.

Scheme 514

Scheme 515

Scheme 516

1. Inspect the engine block cylinder bore. Refer to «ENGINE BLOCK CLEANING AND INSPECTION»(ref-653636-S06137258852014090100000) .
2. Using a bore gauge (1), measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.
3. Measure the bore gauge (1) with a micrometer and record the reading.
4. With a micrometer (2) or caliper at a right angle to the piston, measure the piston (1) 14 mm (0.570 in) from the bottom of the skirt.
5. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.
6. For proper piston-to-bore clearance. Refer to «ENGINE MECHANICAL SPECIFICATIONS (LDK, LHU)»(ref-653636-S28533554622014090100000) .
7. If the proper clearance cannot be obtained, select another piston and measure for the clearances.
8. If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.
9. When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a permanent marker for installation to the proper cylinder. Refer to «SEPARATING PARTS»(ref-653636-S34345841302014090100000) .

Scheme 517

Scheme 518

Scheme 519

1. NOTE: Install the piston onto the connecting rod with the arrow oriented toward the front of the engine. Assemble the connecting rod (2) and the piston (1).
2. WARNING: Install the piston pin retainers correctly in the retaining groove during assembly in order to avoid engine damage. Use the following procedure to assemble the piston pin and the retainer: Coat the piston pin with oil. Using the EN-46745 installer (1) and the EN-46745-4 adapter, install one side of one piston pin retainer into the retaining groove. Rotate the retainer until it is fully seated in the groove. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. Using the EN-46745 installer and the EN-46745-4 adapter, install the second piston pin retainer. Ensure that the piston moves freely.
3. WARNING: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary. Install the following components of the oil control ring assembly - bottom ring: The expander (5). The lower oil control ring (4). The upper control ring (3).
4. Install the lower compression ring - second ring (2). Place the manufacturer's mark facing up.
5. Install the upper compression ring - top ring (1).

Scheme 520

Scheme 521

1. Install the NEW connecting rod bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the EN-43966-1 guides (1) into the connecting rod fastener holes. This protects the crankshaft journal during piston and connecting rod installation.
3. Install the EN-43953 compressor, the piston (2), and the connecting rod to the correct bore. Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the EN-43953 compressor against the engine block until all the rings have entered the cylinder bore. Remove the connecting rod guides from the connecting rod fastener holes.
4. Install the connecting rod cap (1).
5. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . NOTE: Always use NEW fasteners. Install NEW connecting rod fasteners with EN-45059 angle meter and tighten the fasteners to 25 Nm (18 lb ft) plus 100 degrees .
6. Install the remaining connecting rods and piston assemblies. The correct clearance is 0.07 mm - 0.37 mm (0.0027 in - 0.0145 in) .
7. Install the oil pan. Refer to «OIL PAN REPLACEMENT»(ref-653636-S24612324122014090100000) .
8. Install the cylinder head. Refer to «CYLINDER HEAD REPLACEMENT»(ref-653636-S28995126012014090100000) .

EN-42027 Installation Tool

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 522

1. Remove the engine flywheel. Refer to «ENGINE FLYWHEEL REPLACEMENT (AUTOMATIC TRANSMISSION)»(ref-653637-S17013892062014090100000) .
2. Pry out the crankshaft rear oil seal (1) using a flat-bladed tool.

Scheme 523

1. Use the EN-42027 installer and install a NEW crankshaft real oil seal (1).
2. Install the engine flywheel. Refer to «ENGINE FLYWHEEL REPLACEMENT (AUTOMATIC TRANSMISSION)»(ref-653637-S17013892062014090100000) .

Scheme 524

1. CH-49289 Blue Tool
2. CH-49290 Orange Tool

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 525

Scheme 526

Scheme 527

Scheme 528

Scheme 529

Scheme 530

Scheme 531

Scheme 532

1. Switch the ignition OFF.
2. Remove the intermediate steering shaft fastener. Refer to «INTERMEDIATE STEERING SHAFT REPLACEMENT»(ref-653651-S23650273792014090100000) .
3. Remove the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .
4. Evacuate the air conditioning system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(ref-653641-S41617780202014090100000) .
5. Remove the engine control module. Refer to «ENGINE CONTROL MODULE REPLACEMENT»(ref-653646-S24632956992014090100000) .
6. Remove the battery tray. Refer to «BATTERY TRAY REPLACEMENT»(ref-653644-S29783833042014090100000) .
7. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-653646-S02731215182014090100000) .
8. Remove the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT»(ref-653646-S05162821882014090100000) .
9. Remove the charge air cooler air hose. Refer to «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
10. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
11. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
12. Disconnect the engine wiring harness connectors (1, 2, 3).
13. Remove the engine wiring harness ground connectors (1) from the front end upper tie bar support.
14. Remove the engine wiring harness (1) from the front compartment fuse block housing (2).
15. Position and secure the wiring harness to the engine.
16. Remove the radiator surge tank hoses from the radiator surge tank. Refer to «RADIATOR SURGE TANK ENGINE HOSE REPLACEMENT»(ref-653648-S20287606462014090100000) .
17. Position and secure the surge tank hoses to the engine.
18. Remove the engine coolant air bleed hose. Refer to «ENGINE COOLANT AIR BLEED HOSE REPLACEMENT (LHU/A20NFT)»(ref-653648-S16753168192014090100000) .
19. Remove the manual transmission shift lever cable from the transmission. Refer to «MANUAL TRANSMISSION SHIFT LEVER CABLE REPLACEMENT»(ref-653652-S06499178502014090100000) .
20. Position and secure the manual transmission shift lever cable to the vehicle.
21. Remove the power brake booster pipe (1) from the power brake booster (2).
22. Remove the heater inlet hose and the heater outlet hose from the heater core. Refer to «HEATER INLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S30905892142014090100000) and «HEATER OUTLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S28088941252014090100000) .
23. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(ref-653646-S34811225142014090100000) .
24. Remove the fuel feed front pipe. Refer to «FUEL FEED PIPE REPLACEMENT (METAL)»(ref-653646-S40817608792014090100000) or «FUEL FEED PIPE REPLACEMENT (PLASTIC)»(ref-653646-S28505209902014090100000) .
25. Disconnect the evaporative pipe quick connector (1).
26. Remove the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S37743770902014090100000) and «AIR CONDITIONING EVAPORATOR HOSE ASSEMBLY REPLACEMENT (LHU/A20NFT)»(ref-653641-S26563699492014090100000) .
27. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
28. Remove the front wheels. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-653653-S27551504532014090100000) .
29. Remove the both front wheel drive shaft fasteners. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (GNB)»(ref-653654-S15710981132014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (PETROL)»(ref-653654-S38268700022014090100000) and «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNA)»(ref-653654-S06472564012014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNB)»(ref-653654-S32350945172014090100000) .
30. Remove the stabilizer shaft link fasteners. Refer to «STABILIZER SHAFT LINK REPLACEMENT (GNA)»(ref-653655-S37628602432014090100000) or «STABILIZER SHAFT LINK REPLACEMENT (GNB)»(ref-653655-S00914894792014090100000) .
31. Remove the steering linkage outer tie rod fasteners. Refer to «STEERING LINKAGE OUTER TIE ROD REPLACEMENT»(ref-653656-S01829444632014090100000) .
32. Remove both steering knuckles from both front lower control arms. Refer to «STEERING KNUCKLE REPLACEMENT (GNA)»(ref-653655-S36246679232014090100000) or «STEERING KNUCKLE REPLACEMENT (GNB)»(ref-653655-S12407693862014090100000) .
33. Remove both front wheel drive shafts from both front wheel bearings and hubs. Refer to «FRONT WHEEL BEARING AND HUB REPLACEMENT (GNA)»(ref-653655-S15172358972014090100000) or «FRONT WHEEL BEARING AND HUB REPLACEMENT (GNB)»(ref-653655-S11653518792014090100000) .
34. Disconnect both front wheel speed sensor electrical connectors. Position and secure both wiring harnesses to the vehicle. Refer to «FRONT WHEEL SPEED SENSOR REPLACEMENT (GNA)»(ref-653657-S37392728442014090100000) or «FRONT WHEEL SPEED SENSOR REPLACEMENT (GNB)»(ref-653657-S36107713202014090100000) .
35. Disconnect the power steering wiring harness connector (2).
36. Disconnect the engine coolant fan motor wiring harness connectors (1).
37. Remove the relay box (1).
38. Position and secure the relay box to the engine.
39. Remove exhaust front pipe. Refer to «EXHAUST FRONT PIPE REPLACEMENT»(ref-653636-S04493525822014090100000) .
40. Remove both drivetrain and front suspension frame transmission protectors.
41. If available remove the engine shield from the front suspension frame.
42. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
43. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
44. Install the CH-49290 tool. Refer to «ENGINE SUPPORT FIXTURE (REAR SIDE)»(ref-653636-S29550459492014090100000) or «ENGINE SUPPORT FIXTURE (FRONT SIDE)»(ref-653636-S06622593022014090100000) or «ENGINE SUPPORT FIXTURE (MOUNTING ENGINE/TRANSMISSION)»(ref-653636-S29318210432014090100000) or «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-653636-S14355090192014090100000) or «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-653636-S20856005512014090100000) .
45. Remove the powertrain lift/support table.
46. Lower the vehicle.
47. Remove the engine mount bracket from the engine mount support. Refer to «ENGINE MOUNT BRACKET REPLACEMENT»(ref-653636-S08442415952014090100000) .
48. Remove the transmission mount fasteners. Refer to «TRANSMISSION MOUNT REPLACEMENT - LEFT SIDE»(ref-653642-S35542924182014090100000) .
49. Raise the vehicle.
50. Install the CH-49289 tool. Refer to «ENGINE SUPPORT FIXTURE (REAR SIDE)»(ref-653636-S29550459492014090100000) or «ENGINE SUPPORT FIXTURE (FRONT SIDE)»(ref-653636-S06622593022014090100000) or «ENGINE SUPPORT FIXTURE (MOUNTING ENGINE/TRANSMISSION)»(ref-653636-S29318210432014090100000) or «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-653636-S14355090192014090100000) or «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-653636-S20856005512014090100000) .
51. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
52. NOTE: Positioning pins (2, 3) of CH-49289 adapter MUST stick into holes of drivetrain frame. 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»(ref-653653-S33453738802014090100000) is required after installation of drive train frame.
53. Remove the front suspension frame fasteners. Refer to «SUBFRAME, REPLACE (GNA)»(ref-653655-S03322022742014090100000) or «SUBFRAME, REPLACE (GNB)»(ref-653655-S26125939882014090100000) .
54. NOTE: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process. With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.
55. Remove the power steering fluid cooler from engine cooling module. Refer to «POWER STEERING FLUID COOLER REPLACEMENT»(ref-653656-S08956749912014090100000) .
56. Remove the power steering pressure pipe/hose from the power steering pump. Refer to «POWER STEERING PRESSURE PIPE/HOSE REPLACEMENT (L4)»(ref-653656-S18179780932014090100000) .
57. Remove the power steering return hose from the power steering gear. Refer to «POWER STEERING RETURN HOSE REPLACEMENT (L4)»(ref-653656-S11295091802014090100000) .
58. Remove the charge air cooler inlet air hose and the charge air cooler outlet hose from the charge air cooler. Refer to «CHARGE AIR COOLER RADIATOR REPLACEMENT (LHU/A20NFT)»(ref-653648-S21062065032014090100000) .
59. Remove the radiator inlet hose and the radiator outlet hose from the radiator.
60. Remove the engine cooling module wiring harness from the drivetrain and front suspension frame.
61. Remove the engine wiring harness from the radiator.
62. Remove the engine cooling module from the drivetrain and front suspension frame.
63. Remove both front wheel drive shafts from the transmission. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (GNB)»(ref-653654-S15710981132014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (PETROL)»(ref-653654-S38268700022014090100000) and «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNA)»(ref-653654-S06472564012014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNB)»(ref-653654-S32350945172014090100000) .
64. Remove the transmission rear mount fasteners from the drivetrain and front suspension frame. Refer to «TRANSMISSION REAR MOUNT REPLACEMENT»(ref-653642-S03337450852014090100000) .
65. Remove the transmission front mount fasteners from the drivetrain and front suspension frame. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-653642-S18065893682014090100000) .
66. Remove the engine and the transmission from the drivetrain and front suspension frame.
67. Remove the transmission rear mount bracket and the transfer case. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(ref-653658-S42445263252014090100000) .
68. Remove the engine oil cooler outlet hose.
69. Remove the starter motor Refer to «STARTER REPLACEMENT (LHU/A20NFT)»(ref-653644-S07228639072014090100000)
70. Remove the radiator surge tank engine hose. Refer to «RADIATOR SURGE TANK ENGINE HOSE REPLACEMENT»(ref-653648-S20287606462014090100000) .
71. Install two transmission lift brackets to the transmission housing.
72. Position a second floor crane to the transmission lift brackets and raise the floor crane to partially support the transmission.
73. Remove the transmission from the engine. Refer to «TRANSMISSION REPLACEMENT (AWD, LHU/A20NFT)»(ref-653642-S21753120722014090100000) or «TRANSMISSION REPLACEMENT (FWD, LHU/A20NFT)»(ref-653642-S24656434632014090100000) .
74. Remove the transmission front mount. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-653642-S18065893682014090100000) .

Scheme 533

Scheme 534

Scheme 535

Scheme 536

Scheme 537

Scheme 538

Scheme 539

1. Install the transmission front mount. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-653642-S18065893682014090100000) .
2. Remove the transmission from the engine. Refer to «TRANSMISSION REPLACEMENT (AWD, LHU/A20NFT)»(ref-653642-S21753120722014090100000) or «TRANSMISSION REPLACEMENT (FWD, LHU/A20NFT)»(ref-653642-S24656434632014090100000) .
3. Position a second floor crane to the transmission lift brackets and raise the floor crane to partially support the transmission.
4. Install two transmission lift brackets to the transmission housing.
5. Install the radiator surge tank engine hose. Refer to «RADIATOR SURGE TANK ENGINE HOSE REPLACEMENT»(ref-653648-S20287606462014090100000) .
6. Install the starter. Refer to «STARTER REPLACEMENT (LHU/A20NFT)»(ref-653644-S07228639072014090100000) .
7. Install the engine oil cooler outlet hose.
8. Install the transmission rear mount bracket and the transfer case. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(ref-653658-S42445263252014090100000) .
9. Install the engine and the transmission from the drivetrain and front suspension frame.
10. Install the transmission front mount fasteners from the drivetrain and front suspension frame. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-653642-S18065893682014090100000) .
11. Install the transmission rear mount fasteners from the drivetrain and front suspension frame. Refer to «TRANSMISSION REAR MOUNT REPLACEMENT»(ref-653642-S03337450852014090100000) .
12. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
13. Install both front wheel drive shafts from the transmission. Refer to «TRANSMISSION REPLACEMENT (AWD, LHU/A20NFT)»(ref-653642-S21753120722014090100000) or «TRANSMISSION REPLACEMENT (FWD, LHU/A20NFT)»(ref-653642-S24656434632014090100000) .
14. Install the engine cooling module from the drivetrain and front suspension frame.
15. Install the engine wiring harness from the radiator.
16. Install the engine cooling module wiring harness from the drivetrain and front suspension frame.
17. Install the radiator inlet hose and the radiator outlet hose from the radiator.
18. Install the charge air cooler inlet air hose and the charge air cooler outlet hose from the charge air cooler. Refer to «CHARGE AIR COOLER RADIATOR REPLACEMENT (LHU/A20NFT)»(ref-653648-S21062065032014090100000) .
19. Install the power steering return hose to the power steering pump. Refer to «POWER STEERING RETURN HOSE REPLACEMENT (L4)»(ref-653656-S11295091802014090100000) .
20. Install the power steering pressure pipe/hose to the power steering pump. Refer to «POWER STEERING PRESSURE PIPE/HOSE REPLACEMENT (L4)»(ref-653656-S18179780932014090100000) .
21. Install the power steering fluid cooler from engine cooling module. Refer to «POWER STEERING FLUID COOLER REPLACEMENT»(ref-653656-S08956749912014090100000) .
22. With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.
23. Install the front suspension frame fasteners. Refer to «SUBFRAME, REPLACE (GNA)»(ref-653655-S03322022742014090100000) or «SUBFRAME, REPLACE (GNB)»(ref-653655-S26125939882014090100000) .
24. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
25. Remove the CH-49289 tool. Refer to «ENGINE SUPPORT FIXTURE (REAR SIDE)»(ref-653636-S29550459492014090100000) or «ENGINE SUPPORT FIXTURE (FRONT SIDE)»(ref-653636-S06622593022014090100000) or «ENGINE SUPPORT FIXTURE (MOUNTING ENGINE/TRANSMISSION)»(ref-653636-S29318210432014090100000) or «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-653636-S14355090192014090100000) or «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-653636-S20856005512014090100000) .
26. Raise the vehicle.
27. Install the transmission mount fasteners. Refer to «TRANSMISSION MOUNT REPLACEMENT - LEFT SIDE»(ref-653642-S35542924182014090100000) .
28. Install the engine mount bracket to the engine mount support. Refer to «ENGINE MOUNT BRACKET REPLACEMENT»(ref-653636-S08442415952014090100000) .
29. Lower the vehicle.
30. Install the powertrain lift/support table.
31. Remove the CH-49290 tool. Refer to «ENGINE SUPPORT FIXTURE (REAR SIDE)»(ref-653636-S29550459492014090100000) or «ENGINE SUPPORT FIXTURE (FRONT SIDE)»(ref-653636-S06622593022014090100000) or «ENGINE SUPPORT FIXTURE (MOUNTING ENGINE/TRANSMISSION)»(ref-653636-S29318210432014090100000) or «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-653636-S14355090192014090100000) or «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-653636-S20856005512014090100000) .
32. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
33. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
34. If available install the engine shield from the front suspension frame.
35. Install both drivetrain and front suspension frame transmission protectors.
36. Install the exhaust front pipe. Refer to «EXHAUST FRONT PIPE REPLACEMENT»(ref-653636-S04493525822014090100000) .
37. Install the relay box (1).
38. Connect the power steering wiring harness connector (2).
39. Connect the engine coolant fan motor wiring harness connectors (1).
40. Connect both front wheel speed sensor electrical connectors. Position and secure both wiring harnesses to the vehicle. Refer to «FRONT WHEEL SPEED SENSOR REPLACEMENT (GNA)»(ref-653657-S37392728442014090100000) or «FRONT WHEEL SPEED SENSOR REPLACEMENT (GNB)»(ref-653657-S36107713202014090100000) .
41. Install both front wheel drive shafts from both front wheel bearings and hubs. Refer to «FRONT WHEEL BEARING AND HUB REPLACEMENT (GNA)»(ref-653655-S15172358972014090100000) or «FRONT WHEEL BEARING AND HUB REPLACEMENT (GNB)»(ref-653655-S11653518792014090100000) .
42. Install both steering knuckles to both front lower control arms. Refer to «STEERING KNUCKLE REPLACEMENT (GNA)»(ref-653655-S36246679232014090100000) or «STEERING KNUCKLE REPLACEMENT (GNB)»(ref-653655-S12407693862014090100000) .
43. Install the steering linkage outer tie rod fasteners. Refer to «STEERING LINKAGE OUTER TIE ROD REPLACEMENT»(ref-653656-S01829444632014090100000) .
44. Install the stabilizer shaft link fasteners. Refer to «STABILIZER SHAFT LINK REPLACEMENT (GNA)»(ref-653655-S37628602432014090100000) or «STABILIZER SHAFT LINK REPLACEMENT (GNB)»(ref-653655-S00914894792014090100000) .
45. Install the front wheel drive shaft fasteners. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (GNB)»(ref-653654-S15710981132014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (PETROL)»(ref-653654-S38268700022014090100000) and «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNA)»(ref-653654-S06472564012014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNB)»(ref-653654-S32350945172014090100000) .
46. Install the front wheels. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-653653-S27551504532014090100000) .
47. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
48. Install the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S37743770902014090100000) and «AIR CONDITIONING EVAPORATOR HOSE ASSEMBLY REPLACEMENT (LHU/A20NFT)»(ref-653641-S26563699492014090100000) .
49. Connect the evaporative pipe quick connector (1).
50. Plug the fuel feed pipe and cap the fuel injection fuel rail to prevent fuel loss or contamination.
51. Install the fuel feed front pipe. Refer to «FUEL FEED PIPE REPLACEMENT (METAL)»(ref-653646-S40817608792014090100000) or «FUEL FEED PIPE REPLACEMENT (PLASTIC)»(ref-653646-S28505209902014090100000) .
52. Install the heater hose from the water outlet.
53. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(ref-653646-S34811225142014090100000) .
54. Install the heater inlet hose and the heater outlet hose from the heater core. Refer to «HEATER INLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S30905892142014090100000) and «HEATER OUTLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S28088941252014090100000) .
55. Install the power brake booster pipe (1) from the power brake booster (2).
56. Install the manual transmission shift lever cable to the transmission. Refer to «RANGE SELECTOR LEVER CABLE REPLACEMENT»(ref-653642-S36673880132014090100000) .
57. Install the engine coolant air bleed hose. Refer to «ENGINE COOLANT AIR BLEED HOSE REPLACEMENT (LHU/A20NFT)»(ref-653648-S16753168192014090100000) .
58. Install the radiator surge tank hoses from the radiator surge tank. Refer to «RADIATOR SURGE TANK ENGINE HOSE REPLACEMENT»(ref-653648-S20287606462014090100000) .
59. Install the engine wiring harness (1) to the front compartment fuse block housing (2).
60. Install the engine wiring harness ground connectors (1) from the front end upper tie bar support.
61. Connect the engine wiring harness connectors (1, 2, 3).
62. Filling the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
63. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
64. Install the charge air cooler air hose. Refer to «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
65. Install the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT»(ref-653646-S05162821882014090100000) .
66. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-653646-S02731215182014090100000) .
67. Install the battery tray. Refer to «BATTERY TRAY REPLACEMENT»(ref-653644-S29783833042014090100000) .
68. Install the engine control module. Refer to «ENGINE CONTROL MODULE REPLACEMENT»(ref-653646-S24632956992014090100000) .
69. Evacuate the air conditioning system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(ref-653641-S41617780202014090100000) .
70. Install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .
71. Install the intermediate steering shaft fastener. Refer to «INTERMEDIATE STEERING SHAFT REPLACEMENT»(ref-653651-S23650273792014090100000) .

1. CH-49289 Blue Tool
2. CH-49290 Orange Tool

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 540

Scheme 541

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

Scheme 547

1. Switch the ignition OFF.
2. Remove the intermediate steering shaft fastener. Refer to «INTERMEDIATE STEERING SHAFT REPLACEMENT»(ref-653651-S23650273792014090100000) .
3. Remove the fuel injector sight shield (engine cover).
4. Evacuate the air conditioning system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(ref-653641-S41617780202014090100000) .
5. Remove the engine control module. Refer to «ENGINE CONTROL MODULE REPLACEMENT»(ref-653646-S24632956992014090100000) .
6. Remove the battery tray. Refer to «BATTERY TRAY REPLACEMENT»(ref-653644-S29783833042014090100000) .
7. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-653646-S02731215182014090100000) .
8. Remove the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT»(ref-653646-S05162821882014090100000) .
9. Remove the charge air cooler air inlet hose and the charge air cooler air outlet hose. Refer to «CHARGE AIR COOLER INLET AIR HOSE REPLACEMENT»(ref-653636-S26871968422014090100000) and «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
10. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
11. Disconnect the engine wiring harness connectors (1, 2, 3).
12. Remove the engine wiring harness ground connectors (1) from the front end upper tie bar support.
13. Remove the engine wiring harness (1) from the front compartment fuse block housing (2).
14. Position and secure the wiring harness to the engine.
15. Remove the radiator surge tank hoses from the radiator surge tank. Refer to «RADIATOR SURGE TANK ENGINE HOSE REPLACEMENT»(ref-653648-S20287606462014090100000) .
16. Position and secure the surge tank hoses to the engine.
17. Remove the engine coolant air bleed hose. Refer to «ENGINE COOLANT AIR BLEED HOSE REPLACEMENT (LHU/A20NFT)»(ref-653648-S16753168192014090100000) .
18. Remove the manual transmission shift lever cable from the transmission. Refer to «RANGE SELECTOR LEVER CABLE REPLACEMENT»(ref-653642-S36673880132014090100000) .
19. Position and secure the manual transmission shift lever cable to the vehicle.
20. Remove the power brake booster pipe (1) from the power brake booster (2).
21. Remove the heater inlet hose and the heater outlet hose from the heater core. Refer to «HEATER INLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S30905892142014090100000) and «HEATER OUTLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S28088941252014090100000) .
22. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(ref-653646-S34811225142014090100000) .
23. Remove the fuel feed front pipe. Refer to «FUEL FEED PIPE REPLACEMENT (METAL)»(ref-653646-S40817608792014090100000) or «FUEL FEED PIPE REPLACEMENT (PLASTIC)»(ref-653646-S28505209902014090100000) .
24. Disconnect the evaporative pipe quick connector (1).
25. Remove the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S37743770902014090100000) and «AIR CONDITIONING EVAPORATOR HOSE ASSEMBLY REPLACEMENT (LHU/A20NFT)»(ref-653641-S26563699492014090100000) .
26. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
27. Remove the front wheels. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-653653-S27551504532014090100000) .
28. Remove the both front wheel drive shaft fasteners. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (GNB)»(ref-653654-S15710981132014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (PETROL)»(ref-653654-S38268700022014090100000) and «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNA)»(ref-653654-S06472564012014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNB)»(ref-653654-S32350945172014090100000) .
29. Remove the stabilizer shaft link fasteners. Refer to «STABILIZER SHAFT LINK REPLACEMENT (GNA)»(ref-653655-S37628602432014090100000) or «STABILIZER SHAFT LINK REPLACEMENT (GNB)»(ref-653655-S00914894792014090100000) .
30. Remove the steering linkage outer tie rod fasteners. Refer to «STEERING LINKAGE OUTER TIE ROD REPLACEMENT»(ref-653656-S01829444632014090100000) .
31. Remove both steering knuckles from both front lower control arms. Refer to «STEERING KNUCKLE REPLACEMENT (GNA)»(ref-653655-S36246679232014090100000) or «STEERING KNUCKLE REPLACEMENT (GNB)»(ref-653655-S12407693862014090100000) .
32. Remove both front wheel drive shafts from both front wheel bearings and hubs. Refer to «FRONT WHEEL BEARING AND HUB REPLACEMENT (GNA)»(ref-653655-S15172358972014090100000) or «FRONT WHEEL BEARING AND HUB REPLACEMENT (GNB)»(ref-653655-S11653518792014090100000) .
33. Disconnect both front wheel speed sensor electrical connectors. Position and secure both wiring harnesses to the vehicle. Refer to «FRONT WHEEL SPEED SENSOR REPLACEMENT (GNA)»(ref-653657-S37392728442014090100000) or «FRONT WHEEL SPEED SENSOR REPLACEMENT (GNB)»(ref-653657-S36107713202014090100000) .
34. Disconnect the power steering wiring harness connector (2).
35. Disconnect the engine coolant fan motor wiring harness connectors (1).
36. Remove the relay box (1).
37. Position and secure the relay box to the engine.
38. Remove the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT»(ref-653658-S22926031032014090100000) .
39. Remove exhaust front pipe. Refer to «EXHAUST FRONT PIPE REPLACEMENT»(ref-653636-S04493525822014090100000) .
40. If available both drivetrain and front suspension frame transmission protectors.
41. Remove the engine shield from the front suspension frame.
42. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
43. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
44. Install the CH-49290 tool. Refer to «ENGINE SUPPORT FIXTURE (REAR SIDE)»(ref-653636-S29550459492014090100000) or «ENGINE SUPPORT FIXTURE (FRONT SIDE)»(ref-653636-S06622593022014090100000) or «ENGINE SUPPORT FIXTURE (MOUNTING ENGINE/TRANSMISSION)»(ref-653636-S29318210432014090100000) or «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-653636-S14355090192014090100000) or «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-653636-S20856005512014090100000) .
45. Remove the powertrain lift/support table.
46. Lower the vehicle.
47. Remove the engine mount bracket from the engine mount support. Refer to «ENGINE MOUNT BRACKET REPLACEMENT»(ref-653636-S08442415952014090100000) .
48. Remove the transmission mount fasteners. Refer to «TRANSMISSION MOUNT REPLACEMENT - LEFT SIDE»(ref-653642-S35542924182014090100000) .
49. Raise the vehicle.
50. Install the CH-49289 tool. Refer to «ENGINE SUPPORT FIXTURE (REAR SIDE)»(ref-653636-S29550459492014090100000) or «ENGINE SUPPORT FIXTURE (FRONT SIDE)»(ref-653636-S06622593022014090100000) or «ENGINE SUPPORT FIXTURE (MOUNTING ENGINE/TRANSMISSION)»(ref-653636-S29318210432014090100000) or «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-653636-S14355090192014090100000) or «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-653636-S20856005512014090100000) .
51. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
52. NOTE: Positioning pins (2, 3) of CH-49289 adapter MUST stick into holes of drivetrain frame. 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»(ref-653653-S33453738802014090100000) is required after installation of drive train frame.
53. Remove the front suspension frame fasteners. Refer to «SUBFRAME, REPLACE (GNA)»(ref-653655-S03322022742014090100000) or «SUBFRAME, REPLACE (GNB)»(ref-653655-S26125939882014090100000) .
54. NOTE: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process. With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.
55. Remove the power steering pressure pipe/hose from the power steering pump. Refer to «POWER STEERING PRESSURE PIPE/HOSE REPLACEMENT (L4)»(ref-653656-S18179780932014090100000) .
56. Remove the power steering return hose from the power steering gear. Refer to «POWER STEERING RETURN HOSE REPLACEMENT (L4)»(ref-653656-S11295091802014090100000) .
57. Remove the charge air cooler inlet air hose and the charge air cooler outlet hose from the charge air cooler. Refer to «CHARGE AIR COOLER RADIATOR REPLACEMENT (LHU/A20NFT)»(ref-653648-S21062065032014090100000) .
58. Remove the radiator inlet hose. Refer to «RADIATOR INLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653648-S13862856982014090100000) .
59. Remove the radiator outlet hose. Refer to «RADIATOR OUTLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653648-S22939023432014090100000) .
60. Remove the engine cooling module wiring harness from the drivetrain and front suspension frame.
61. Remove the engine wiring harness from the radiator.
62. Remove the engine cooling module from the drivetrain and front suspension frame.
63. Remove both front wheel drive shafts from the transmission. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (GNB)»(ref-653654-S15710981132014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (PETROL)»(ref-653654-S38268700022014090100000) and «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNA)»(ref-653654-S06472564012014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNB)»(ref-653654-S32350945172014090100000) .
64. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
65. Remove the transmission rear mount fasteners from the drivetrain and front suspension frame. Refer to «TRANSMISSION REAR MOUNT REPLACEMENT»(ref-653642-S03337450852014090100000) .
66. Remove the transmission front mount fasteners from the drivetrain and front suspension frame. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-653642-S18065893682014090100000) .
67. Remove the engine and the transmission from the drivetrain and front suspension frame.
68. Remove the transmission rear mount bracket and the transfer case. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(ref-653658-S42445263252014090100000) .
69. Remove the transmission front mount. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-653642-S18065893682014090100000) .
70. Remove the starter motor Refer to «STARTER REPLACEMENT (LHU/A20NFT)»(ref-653644-S07228639072014090100000) .
71. Install two transmission lift brackets to the transmission housing.
72. Position a second floor crane to the transmission lift brackets and raise the floor crane to partially support the transmission.
73. Remove the transmission from the engine. Refer to «TRANSMISSION REPLACEMENT (AWD, LHU/A20NFT)»(ref-653642-S21753120722014090100000) or «TRANSMISSION REPLACEMENT (FWD, LHU/A20NFT)»(ref-653642-S24656434632014090100000) .

Scheme 548

Scheme 549

Scheme 550

Scheme 551

Scheme 552

Scheme 553

Scheme 554

1. Remove the transmission from the engine. Refer to «TRANSMISSION REPLACEMENT (AWD, LHU/A20NFT)»(ref-653642-S21753120722014090100000) or «TRANSMISSION REPLACEMENT (FWD, LHU/A20NFT)»(ref-653642-S24656434632014090100000) .
2. Position a second floor crane to the transmission lift brackets and raise the floor crane to partially support the transmission.
3. Install two transmission lift brackets to the transmission housing.
4. Install the starter. Refer to «STARTER REPLACEMENT (LHU/A20NFT)»(ref-653644-S07228639072014090100000) .
5. Install the transmission front mount fasteners from the drivetrain and front suspension frame. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-653642-S18065893682014090100000) .
6. Install the transmission rear mount fasteners from the drivetrain and front suspension frame. Refer to «TRANSMISSION REAR MOUNT REPLACEMENT»(ref-653642-S03337450852014090100000) .
7. Install the engine and the transmission from the drivetrain and front suspension frame.
8. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
9. Install both front wheel drive shafts from the transmission. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (GNB)»(ref-653654-S15710981132014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (PETROL)»(ref-653654-S38268700022014090100000) and «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNA)»(ref-653654-S06472564012014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNB)»(ref-653654-S32350945172014090100000) .
10. Install the engine cooling module from the drivetrain and front suspension frame.
11. Install the engine wiring harness from the radiator.
12. Install the engine cooling module wiring harness from the drivetrain and front suspension frame.
13. Install the radiator outlet hose. Refer to «RADIATOR OUTLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653648-S22939023432014090100000) .
14. Install the radiator inlet hose. Refer to «RADIATOR INLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653648-S13862856982014090100000) .
15. Install the charge air cooler inlet air hose and the charge air cooler outlet hose from the charge air cooler. Refer to «CHARGE AIR COOLER RADIATOR REPLACEMENT (LHU/A20NFT)»(ref-653648-S21062065032014090100000) .
16. Install the power steering return hose to the power steering pump. Refer to «POWER STEERING RETURN HOSE REPLACEMENT (L4)»(ref-653656-S11295091802014090100000) .
17. Install the power steering pressure pipe/hose to the power steering pump. Refer to «POWER STEERING PRESSURE PIPE/HOSE REPLACEMENT (L4)»(ref-653656-S18179780932014090100000) .
18. With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.
19. Install the front suspension frame fasteners. Refer to «DRIVETRAIN AND FRONT SUSPENSION FRAME INSULATOR REPLACEMENT»(ref-653645-S04007695152014090100000) .
20. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
21. Remove the CH-49289 tool. Refer to «ENGINE SUPPORT FIXTURE (REAR SIDE)»(ref-653636-S29550459492014090100000) or «ENGINE SUPPORT FIXTURE (FRONT SIDE)»(ref-653636-S06622593022014090100000) or «ENGINE SUPPORT FIXTURE (MOUNTING ENGINE/TRANSMISSION)»(ref-653636-S29318210432014090100000) or «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-653636-S14355090192014090100000) or «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-653636-S20856005512014090100000) .
22. Raise the vehicle.
23. Install the transmission mount fasteners. Refer to «TRANSMISSION MOUNT REPLACEMENT - LEFT SIDE»(ref-653642-S35542924182014090100000) .
24. Install the engine mount bracket to the engine mount support. Refer to «ENGINE MOUNT BRACKET REPLACEMENT»(ref-653636-S08442415952014090100000) .
25. Lower the vehicle.
26. Install the powertrain lift/support table.
27. Remove the CH-49290 tool. Refer to «ENGINE SUPPORT FIXTURE (REAR SIDE)»(ref-653636-S29550459492014090100000) or «ENGINE SUPPORT FIXTURE (FRONT SIDE)»(ref-653636-S06622593022014090100000) or «ENGINE SUPPORT FIXTURE (MOUNTING ENGINE/TRANSMISSION)»(ref-653636-S29318210432014090100000) or «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-653636-S14355090192014090100000) or «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-653636-S20856005512014090100000) .
28. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
29. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
30. Install the engine shield from the front suspension frame.
31. If available install both drivetrain and front suspension frame transmission protectors.
32. Install the exhaust front pipe. Refer to «EXHAUST FRONT PIPE REPLACEMENT»(ref-653636-S04493525822014090100000) .
33. Install the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT»(ref-653658-S22926031032014090100000) .
34. Position and secure the relay box to the engine.
35. Install the relay box (1).
36. Connect the power steering wiring harness connector (2).
37. Connect the engine coolant fan motor wiring harness connectors (1).
38. Connect both front wheel speed sensor electrical connectors. Position and secure both wiring harnesses to the vehicle. Refer to «FRONT WHEEL SPEED SENSOR REPLACEMENT (GNA)»(ref-653657-S37392728442014090100000) or «FRONT WHEEL SPEED SENSOR REPLACEMENT (GNB)»(ref-653657-S36107713202014090100000) .
39. Install both front wheel drive shafts from both front wheel bearings and hubs. Refer to «FRONT WHEEL BEARING AND HUB REPLACEMENT (GNA)»(ref-653655-S15172358972014090100000) or «FRONT WHEEL BEARING AND HUB REPLACEMENT (GNB)»(ref-653655-S11653518792014090100000) .
40. Install both steering knuckles to both front lower control arms. Refer to «STEERING KNUCKLE REPLACEMENT (GNA)»(ref-653655-S36246679232014090100000) or «STEERING KNUCKLE REPLACEMENT (GNB)»(ref-653655-S12407693862014090100000) .
41. Install the steering linkage outer tie rod fasteners. Refer to «STEERING LINKAGE OUTER TIE ROD REPLACEMENT»(ref-653656-S01829444632014090100000) .
42. Install the stabilizer shaft link fasteners. Refer to «STABILIZER SHAFT LINK REPLACEMENT (GNA)»(ref-653655-S37628602432014090100000) or «STABILIZER SHAFT LINK REPLACEMENT (GNB)»(ref-653655-S00914894792014090100000) .
43. Install the front wheel drive shaft fasteners. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (GNB)»(ref-653654-S15710981132014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE (PETROL)»(ref-653654-S38268700022014090100000) and «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNA)»(ref-653654-S06472564012014090100000) or «FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE (GNB)»(ref-653654-S32350945172014090100000) .
44. Install the front wheels. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-653653-S27551504532014090100000) .
45. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
46. Install the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S37743770902014090100000) and «AIR CONDITIONING EVAPORATOR HOSE ASSEMBLY REPLACEMENT (LHU/A20NFT)»(ref-653641-S26563699492014090100000) .
47. Connect the evaporative pipe quick connector (1).
48. Plug the fuel feed pipe and cap the fuel injection fuel rail to prevent fuel loss or contamination.
49. Install the fuel feed front pipe. Refer to «FUEL FEED PIPE REPLACEMENT (METAL)»(ref-653646-S40817608792014090100000) or «FUEL FEED PIPE REPLACEMENT (PLASTIC)»(ref-653646-S28505209902014090100000) .
50. Install the heater inlet hose and the heater outlet hose from the heater core. Refer to «HEATER INLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S30905892142014090100000) and «HEATER OUTLET HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S28088941252014090100000) .
51. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(ref-653646-S34811225142014090100000) .
52. Install the power brake booster pipe (1) from the power brake booster (2).
53. Position and secure the manual transmission shift lever cable to the vehicle.
54. Install the manual transmission shift lever cable to the transmission. Refer to «RANGE SELECTOR LEVER CABLE REPLACEMENT»(ref-653642-S36673880132014090100000) .
55. Install the engine coolant air bleed hose. Refer to «ENGINE COOLANT AIR BLEED HOSE REPLACEMENT (LHU/A20NFT)»(ref-653648-S16753168192014090100000) .
56. Install the radiator surge tank hoses from the radiator surge tank. Refer to «RADIATOR SURGE TANK ENGINE HOSE REPLACEMENT»(ref-653648-S20287606462014090100000) .
57. Install the engine wiring harness (1) to the front compartment fuse block housing (2).
58. Install the engine wiring harness ground connectors (1) from the front end upper tie bar support.
59. Connect the engine wiring harness connectors (1, 2, 3).
60. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
61. Install the charge air cooler air inlet hose and the charge air cooler air outlet hose. Refer to «CHARGE AIR COOLER INLET AIR HOSE REPLACEMENT»(ref-653636-S26871968422014090100000) and «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
62. Install the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT»(ref-653646-S05162821882014090100000) .
63. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-653646-S02731215182014090100000) .
64. Install the battery tray. Refer to «BATTERY TRAY REPLACEMENT»(ref-653644-S29783833042014090100000) .
65. Install the engine control module. Refer to «ENGINE CONTROL MODULE REPLACEMENT»(ref-653646-S24632956992014090100000) .
66. Evacuate the air conditioning system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(ref-653641-S41617780202014090100000) .
67. Install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT»(ref-653636-S25143567302014090100000) .
68. Install the intermediate steering shaft fastener. Refer to «INTERMEDIATE STEERING SHAFT REPLACEMENT»(ref-653651-S23650273792014090100000) .

Scheme 555

Scheme 556

Scheme 557

After the flywheel housing has been removed, mount the engine block to a suitable engine stand (1).

Scheme 558

1. Remove the oil cooler bolt (2).
2. NOTE: The oil cooler cannot be flushed or otherwise cleaned of contamination. Replace the oil cooler if a mechanical condition is suspected that could cause the oil cooler to be contaminated. Remove the oil cooler (1).

1. EN-28410 Gasket Remover
2. J 7872 Magnetic Base Dial Indicator
3. J 22738-B Valve Spring Tester

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 559

1. NOTE: Do not use a wire brush on any part of the valve stem. NOTE: Do not grind or condition the intake valve. If the intake valve is out of specification, replace the valve. Clean the valves of carbon, oil and varnish. Use a soft bristle wire brush to clean any carbon build-up from the valve head. Varnish can be removed by soaking in Parts Immersion Solvent. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
2. Clean the valve guides.
3. Inspect the valve stem for pitting or wear (4).
4. Inspect the valve key groove for chipping or wear (5). Replace the valve if chipped or worn.
5. Inspect the valve face for burning or cracking (1). If pieces are broken off, inspect the corresponding piston and cylinder head area for damage.
6. Inspect the valve stem for burrs and scratches. Burrs and minor scratches may be removed with an oil stone.
7. Check that the valve stem is straight (3) and that the valve head is not bent or damaged using V blocks. Bent or damaged valves must be replaced.
8. Clean the deposits from the valve face. Inspect the valve face for grooving.
9. Replace the valve if the face is grooved. Valve faces cannot be machined. If worn, or damaged, the valves must be replaced.
10. Replace the valve if the valve head O.D. and chamfer (2) is worn or out of specification. Refer to «VALVE AND SEAT GRINDING»(ref-653636-S10580900292014090100000) .
11. The valves may be lightly lapped to the valve seats.
12. Replace the valve if the valve tip (6) is worn.
13. If no apparent wear, pitting, grooving, or distortion is present, perform the «VALVE MEASUREMENT AND RECONDITIONING PROCEDURE»(ref-653636-S05101749232014090100000) to verify valve specification. Refer to «VALVE AND SEAT GRINDING»(ref-653636-S10580900292014090100000) .

Scheme 560

1. Measure the valve stem (1)-to-guide (2) clearance. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness.
2. Clamp the J 7872 indicator to the cylinder head at the camshaft cover rail.
3. Locate the dial indicator so that the movement of the valve stem from side to side, crossways to the cylinder head, will cause a direct movement of the indicator stem. The dial indicator stem must contact the side of the valve stem just above the valve guide.
4. Drop the valve head about 0.064 mm (0.0025 in) off the valve seat.
5. Use light pressure when moving the valve stem from side to side in order to obtain a clearance reading. Refer to «ENGINE MECHANICAL SPECIFICATIONS (LDK, LHU)»(ref-653636-S28533554622014090100000) for proper clearance.
6. NOTE: Valve guide wear at the bottom 10 mm (0.390 in) of the valve guide is not significant to normal operation. If the clearance for the valve is greater than specifications and a new standard diameter valve stem will not bring the clearance within specifications, replace the cylinder head.

Scheme 561

1. Clean the valve springs in solvent.
2. Refer to «SAFETY GLASSES WARNING»(ref-653635-S22428822072014090100000) . Dry the valve springs with compressed air.
3. Inspect the valve springs for broken coils or coil ends.
4. Measure the valve spring tension using the J 22738-B tester. Refer to «ENGINE MECHANICAL SPECIFICATIONS (LDK, LHU)»(ref-653636-S28533554622014090100000)
5. If a low valve spring loading is observed, the valve springs must be replaced. Do not use a shim to increase the spring loading. The use of shims can cause the valve spring to bottom out before the camshaft lobe is at peak lift.

Scheme 562

1. Inspect the camshaft follower roller (1) for the following: Flat spots Excessive scoring and pitting Ensure the roller spins freely
2. Inspect the camshaft follower valve tip area (2).
3. Inspect the camshaft follower stationary hydraulic lash adjuster (SHLA) pivot area (3).
4. Replace the camshaft follower or followers as necessary.

Scheme 563

Scheme 564

Scheme 565

Scheme 566

Scheme 567

Scheme 568

1. Remove the spark plugs (1).
2. Check the cylinder head gasket and mounting surfaces so that there will be no water leakage, corrosion or loss of compression. If the gasket is damaged, determine the cause by referring to the following possibilities: Incorrect installation Loose or warped cylinder head Missing, off location or not fully seated dowel pins Corrosion in the seal area around the coolant passages Chips or debris in the cylinder head bolt holes Bolt holes in the cylinder block not drilled or tapped deep enough
3. Inspect the cylinder head gasket surface. The cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1). Replace the cylinder head if the area between the valve seats is cracked (2). Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).
4. Clean the cylinder head bolts.
5. NOTE: Do not use a wire brush on any gasket sealing surface. Remove the sealant from the rear cap mating surface with EN-28410 remover. Care must be used to avoid gouging or scraping the sealing surfaces.
6. Clean the cylinder head bolts. Remove all varnish, soot and carbon to the bare metal.
7. Clean the valve guides.
8. Clean the threaded holes. Use a nylon bristle brush.
9. Clean the remains of the sealer from the plug holes.
10. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools.
11. Replace all suspect bolts.
12. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.
13. NOTE: Do not attempt to weld the cylinder head; replace it. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
14. Inspect the cylinder head deck surface for flatness using a straight edge (1) and feeler gauge (2). Refer to «ENGINE MECHANICAL SPECIFICATIONS (LDK, LHU)»(ref-653636-S28533554622014090100000) . If the cylinder head is out of specification, replace the cylinder head. Do not machine the cylinder head.
15. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
16. Inspect the sealing surfaces.
17. Inspect the cylinder head plugs (1).
18. Clean the sealant from the rear cover mating surface with EN-28410 remover. Care must be used to avoid gouging or scraping the sealing surfaces.
19. Inspect the intake and exhaust camshaft bearing rear caps (1, 2) for damage.
20. Inspect the rear bearing mating surfaces for damage.
21. Inspect the remaining bearing caps (3, 4) for damage.
22. Install the spark plugs (1) and tighten to 20 Nm (15 lb ft) .
23. Inspect the lifter bore for damage. Ensure the bore is clean of debris.

EN-43600 Thread Repair Kit

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 569

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert (1). During the bushing installation process, the driver tool expands the bottom external threads of the insert into the base material (2). This action mechanically locks the insert in place. Also, when installed to the proper depth, the flange of the insert will be seated against the counterbore of the repaired hole.

Note. The use of a cutting fluid is recommended when performing the drilling, counterboring, and tapping procedures. Driver oil MUST be used on the installer driver tool. The tool kits are designed for use with either a suitable tap wrench or drill motor.

Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU) for recommended cutting fluid and driver oil.

Scheme 570

Scheme 571

Scheme 572

Scheme 573

Scheme 574

Scheme 575

Scheme 576

Scheme 577

1. Drill out the threads of the damaged hole (1). M6 inserts require a minimum drill depth of 15 mm (0.59 in). M8 inserts require a minimum drill depth of 20 mm (0.79 in). M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
2. Refer to «SAFETY GLASSES AND COMPRESSED AIR WARNING»(ref-653635-S14692233142014090100000) . Using compressed air, clean out any chips.
3. Counterbore the hole to the full depth permitted by the tool (1).
4. Using compressed air, clean out any chips.
5. Using a tap wrench (2), tap the threads of the drilled hole. M6 inserts require a minimum tap depth of 15 mm (0.59 in). M8 inserts require a minimum tap depth of 20 mm (0.79 in). M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).
6. Refer to «SAFETY GLASSES AND COMPRESSED AIR WARNING»(ref-653635-S14692233142014090100000) . Refer to «CLEANING SOLVENT WARNING»(ref-653635-S18336785612014090100000) . Using compressed air, clean out any chips.
7. Spray cleaner into the hole. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
8. Using compressed air, clean any cutting oil and chips out of the hole.
9. NOTE: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert. Lubricate the threads of the installer tool (2) with the driver oil (1).
10. Install the insert (2) onto the driver tool (1).
11. Apply threadlock LOCTITE™ 277, EN-43600-109 (1) loctite, or equivalent to the insert OD threads (2).
12. Install the insert (2) into the hole. Install the insert until the flange of the insert contacts the counterbored surface. Continue to rotate the installer tool (1) through the insert. The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.
13. Inspect the insert for proper installation into the hole. A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).

1. EN-8087 Cylinder Bore Gauge
2. EN-45059 Angle Meter

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

Scheme 578

Note. If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft or connecting rod bearing bores.

Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure

1. Tighten the bedplate to specification using the EN-45059 angle meter.
2. Measure the bearing bore for taper and out-of-round using the EN-8087 gauge (1).
3. No taper or out-of-round should exist.

1. EN-44887 Oil Filter Spanner
2. EN-38122-ACrankshaft Balancer Holder
3. EN-43653 Flywheel Holder Tool
4. DT-2619-01 Slide Hammer
5. EN-37281-AInjector Remover
6. EN-48953 Camshaft Actuator Locking Tool
7. EN-43650 Balancer Shaft Bearing Remover and Installer
8. EN-38188Cylinder Head Broken Bolt Extractor Kit
9. EN-43966-1Connecting Rod Guides

For equivalent regional tools, refer to " SPECIAL TOOLS "

1. EN-7872Magnetic Base Dial Indicator
2. EN-8087Cylinder Bore Gauge
3. EN-45680-850Cylinder Sleeve Removal and Installation Kit
4. EN-46745 Piston Pin Retainer Remover/Installer
5. EN-46745-4 Piston Pin Retainer Remover/Installer Adapter
6. EN-46745 Piston Pin Clip Remover/Installer
7. EN-46745-4 Piston Pin Clip Remover/Installer Adapter
8. EN-8062Valve Spring Compressor
9. EN-36017Valve Seal Remover
10. EN-43963Valve Spring Compressor (off car)
11. EN-28410Gasket Remover
12. J 7872Magnetic Base Dial Indicator
13. J 22738-BValve Spring Tester
14. EN-9666Valve Spring Tester
15. EN-48266 Injector Seal Installer and Sizer
16. EN-43600Thread Repair Kit

For equivalent regional tools, refer to SPECIAL TOOLS

1. EN-8087Cylinder Bore Gauge
2. EN-45059 Angle Meter
3. EN-42067Rear Main Seal Installer
4. EN-43953 Piston Ring Compressor
5. EN-43966-1Connecting Rod Guides
6. EN-43650 Balance Shaft Bushing Remover/Installer
7. EN-45027Tensioner Tool
8. EN-48953 Camshaft Actuator Locking Tool
9. EN-34115Sprocket Bearing Installer
10. EN-43653 Flywheel Holder Tool
11. EN-38122-ACrankshaft Balancer Holder
12. EN-48585 Crankshaft Balancer Guide
13. EN-44887 Oil Filter Spanner
14. EN-47909 Injector Bore and Sleeve Cleaning Kit
15. EN 48896 HP Fuel Pump Installation Alignment Gauge
16. EN-45299 Engine Preluber

For equivalent regional tools, refer to SPECIAL TOOLS