Engine Replacement (AWD)

/ 9-5 (9650) / 2010 / 2. Engine / Basic engine, 4-cylinder petrol / Adjustment/replacement / Engine Replacement (AWD)

Special Tools

•	CH-49289 Blue Tool

•	CH-49290 Orange Tool

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

Removal Procedure

1.	Turn the ignition OFF.

2.	Remove the intermediate steering shaft fastener. Refer to Intermediate Steering Shaft Replacement .

3.	Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

4.	Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging .

5.	Remove the engine control module. Refer to Engine Control Module Replacement .

6.	Remove the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LDK/A20NHT) .

7.	Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

8.	Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

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 and Charge Air Cooler Outlet Air Hose Replacement .

10.	Drain the cooling system. Refer to Cooling System Draining and Filling (LDK/A20NHT) and Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LAU/A28NER) .

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 (LDK/A20NHT) .

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 (LDK/A20NHT) Engine Coolant Air Bleed Hose Replacement (Diesel) .

18.	Remove the manual transmission shift lever cable from the transmission. Refer to Range Selector Lever Cable Replacement .

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 (Diesel) Heater Inlet Hose Replacement (LDK/A20NHT) Heater Inlet Hose Replacement (LAU/A28NER) and Heater Outlet Hose Replacement (Diesel) Heater Outlet Hose Replacement (LDK/A20NHT) Heater Outlet Hose Replacement (LAU/A28NER) .

22.	Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

23.	Remove the fuel feed front pipe. Refer to Fuel Feed Pipe Replacement (Metal) Fuel Feed Pipe Replacement (Plastic) .

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 (A20NHT/LDK) Air Conditioning Compressor and Condenser Hose Replacement (LBS/A20DTH) Air Conditioning Compressor and Condenser Hose Replacement (LAU/A28NER) and Air Conditioning Evaporator Hose Assembly Replacement (LDK/A20NHT) Air Conditioning Evaporator Hose Assembly Replacement (LAU/A28NER) Air Conditioning Evaporator Hose Assembly Replacement (LBS/A20DTH) .

26.	Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

27.	Remove the front wheels. Refer to Tire and Wheel Removal and Installation .

28.	Remove the both front wheel drive shaft fasteners. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) and Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

29.	Remove the stabilizer shaft link fasteners. Refer to Stabilizer Shaft Link Replacement (GNA) Stabilizer Shaft Link Replacement (GNB) .

30.	Remove the steering linkage outer tie rod fasteners. Refer to Steering Linkage Outer Tie Rod Replacement .

31.	Remove both steering knuckles from both front lower control arms. Refer to Steering Knuckle Replacement (GNA) Steering Knuckle Replacement (GNB) .

32.	Remove both front wheel drive shafts from both front wheel bearings and hubs. Refer to Front Wheel Bearing and Hub Replacement (GNA) Front Wheel Bearing and Hub Replacement (GNB) .

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) Front Wheel Speed Sensor Replacement (GNB) .

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 .

39.	Remove exhaust front pipe. Refer to Exhaust Front Pipe Replacement .

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) Engine Support Fixture (Front Side) Engine Support Fixture (Mounting Engine/Transmission) Engine Support Fixture (Centering Adapter) Engine Support Fixture (Engine Bridge, Retainer Frame) .

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 .

48.	Remove the transmission mount fasteners. Refer to Transmission Mount Replacement - Left Side .

49.	Raise the vehicle.

50.	Install the CH-49289 tool . Refer to Engine Support Fixture (Rear Side) Engine Support Fixture (Front Side) Engine Support Fixture (Mounting Engine/Transmission) Engine Support Fixture (Centering Adapter) Engine Support Fixture (Engine Bridge, Retainer Frame) .

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.

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Move out position pins (1) and try to insert into underbody holes.

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If guide pins can NOT be inserted, the Wheel Alignment Measurement is required after installation of drive train frame.

53.	Remove the front suspension frame fasteners. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

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) Power Steering Pressure Pipe/Hose Replacement (V6) .

56.	Remove the power steering return hose from the power steering gear. Refer to Power Steering Return Hose Replacement (L4) Power Steering Return Hose Replacement (V6) .

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 (LDK/A20NHT) Charge Air Cooler Radiator Replacement (Diesel) Charge Air Cooler Radiator Replacement (LAU/A28NER) .

58.	Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Diesel) Radiator Inlet Hose Replacement (LDK/A20NHT) Radiator Inlet Hose Replacement (LAU/A28NER) .

59.	Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LDK/A20NHT) Radiator Outlet Hose Replacement (Diesel) Radiator Outlet Hose Replacement (LAU/A28NER) .

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) Front Wheel Drive Shaft Replacement - Right Side (Petrol) and Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

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 .

66.	Remove the transmission front mount fasteners from the drivetrain and front suspension frame. Refer to Transmission Front Mount Replacement .

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 .

69.	Remove the transmission front mount. Refer to Transmission Front Mount Replacement .

70.	Remove the starter motor. refer to Starter Replacement (2.0L Diesel) Starter Replacement (LDK/A20NHT) Starter Replacement (LAU/A28NER) .

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 (All Wheel Drive - LDK/A20NHT) Transmission Replacement (Front Wheel Drive - LDK/A20NHT) Transmission Replacement (FWD, LBS/A20DTH) .

Installation Procedure

1.	Remove the transmission from the engine. Refer to Transmission Replacement (All Wheel Drive - LDK/A20NHT) Transmission Replacement (Front Wheel Drive - LDK/A20NHT) Transmission Replacement (FWD, LBS/A20DTH) .

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 (2.0L Diesel) Starter Replacement (LDK/A20NHT) Starter Replacement (LAU/A28NER) .

5.	Install the transmission front mount fasteners from the drivetrain and front suspension frame. Refer to Transmission Front Mount Replacement .

6.	Install the transmission rear mount fasteners from the drivetrain and front suspension frame. Refer to Transmission Rear Mount Replacement .

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) Front Wheel Drive Shaft Replacement - Right Side (Petrol) and Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

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 (LDK/A20NHT) Radiator Outlet Hose Replacement (Diesel) Radiator Outlet Hose Replacement (LAU/A28NER) .

14.	Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Diesel) Radiator Inlet Hose Replacement (LDK/A20NHT) Radiator Inlet Hose Replacement (LAU/A28NER) .

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 (LDK/A20NHT) Charge Air Cooler Radiator Replacement (Diesel) Charge Air Cooler Radiator Replacement (LAU/A28NER) .

16.	Install the power steering return hose from the power steering gear. Refer to Power Steering Return Hose Replacement (L4) Power Steering Return Hose Replacement (V6) .

17.	Install the power steering pressure pipe/hose from the power steering pump. Refer to Power Steering Pressure Pipe/Hose Replacement (L4) Power Steering Pressure Pipe/Hose Replacement (V6) .

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 .

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) Engine Support Fixture (Front Side) Engine Support Fixture (Mounting Engine/Transmission) Engine Support Fixture (Centering Adapter) Engine Support Fixture (Engine Bridge, Retainer Frame) .

22.	Raise the vehicle.

23.	Install the transmission mount fasteners. Refer to Transmission Mount Replacement - Left Side .

24.	Install the engine mount bracket from the engine mount support. Refer to Engine Mount Bracket Replacement .

25.	Lower the vehicle.

26.	Install the powertrain lift/support table.

27.	Remove the CH-49290 tool . Refer to Engine Support Fixture (Rear Side) Engine Support Fixture (Front Side) Engine Support Fixture (Mounting Engine/Transmission) Engine Support Fixture (Centering Adapter) Engine Support Fixture (Engine Bridge, Retainer Frame) .

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 .

33.	Install the propeller shaft. Refer to Propeller Shaft Replacement .

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) Front Wheel Speed Sensor Replacement (GNB) .

39.	Install both front wheel drive shafts from both front wheel bearings and hubs. Refer to Front Wheel Bearing and Hub Replacement (GNA) Front Wheel Bearing and Hub Replacement (GNB) .

40.	Install both steering knuckles from both front lower control arms. Refer to Steering Knuckle Replacement (GNA) Steering Knuckle Replacement (GNB) .

41.	Install the steering linkage outer tie rod fasteners. Refer to Steering Linkage Outer Tie Rod Replacement .

42.	Install the stabilizer shaft link fasteners. Refer to Stabilizer Shaft Link Replacement (GNA) Stabilizer Shaft Link Replacement (GNB) .

43.	Install the both front wheel drive shaft fasteners. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) and Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

44.	Install the front wheels. Refer to Tire and Wheel Removal and Installation .

45.	Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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 (A20NHT/LDK) Air Conditioning Compressor and Condenser Hose Replacement (LBS/A20DTH) Air Conditioning Compressor and Condenser Hose Replacement (LAU/A28NER) and Air Conditioning Evaporator Hose Assembly Replacement (LDK/A20NHT) Air Conditioning Evaporator Hose Assembly Replacement (LAU/A28NER) Air Conditioning Evaporator Hose Assembly Replacement (LBS/A20DTH) .

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) Fuel Feed Pipe Replacement (Plastic) .

50.

Install the heater inlet hose and the heater outlet hose from the heater core. Refer to Heater Inlet Hose Replacement (Diesel) Heater Inlet Hose Replacement (LDK/A20NHT) Heater Inlet Hose Replacement (LAU/A28NER) and Heater Outlet Hose Replacement (Diesel) Heater Outlet Hose Replacement (LDK/A20NHT) Heater Outlet Hose Replacement (LAU/A28NER) .

51.	Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

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 from the transmission. Refer to Range Selector Lever Cable Replacement .

55.	Install the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement (LDK/A20NHT) Engine Coolant Air Bleed Hose Replacement (Diesel) .

56.	Install the radiator surge tank hoses from the radiator surge tank. Refer to Radiator Surge Tank Engine Hose Replacement (LDK/A20NHT) .

57.	Install the engine wiring harness (1) from 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 (LDK/A20NHT) and Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LAU/A28NER) .

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 and Charge Air Cooler Outlet Air Hose Replacement .

62.	Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

63.	Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

64.	Install the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LDK/A20NHT) .

65.	Install the engine control module. Refer to Engine Control Module Replacement .

66.	Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging .

67.	Install the engine sight shield. Refer to Engine Sight Shield Replacement .

68.	Install the intermediate steering shaft fastener. Refer to Intermediate Steering Shaft Replacement .

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