Engine Replacement

/ 9-5 (9650) / 2011 / 2. Engine / Basic engine, V6 / Adjustment/replacement / Engine Replacement

Special Tools

•	CH-49289 Centring Adapter

•	CH-49290 Mounting Engine/Transmission

For equivalent regional tools, refer to Special Tools .

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 (LHU/A20NFT) .

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 outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement .

10.	Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

11.	Drain the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .

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 (1).

17.	Position and secure the surge hoses to the engine.

18.	Remove the engine coolant air bleed pipe from the upper intake manifold. Refer to Upper Intake Manifold Replacement .

19.	Remove the automatic transmission range selector lever cable from the transmission. Refer to Range Selector Lever Cable Replacement .

20.	Position and secure the automatic transmission range selector lever cable to the vehicle.

21.	Remove the automatic transmission vent pipe.

22.	Remove the power brake booster pipe (1) from the power brake booster (2).

23.

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 (LAU/A28NER) Heater Inlet Hose Replacement (LLU/A16LET) Heater Inlet Hose Replacement (LHU/A20NFT) and Heater Outlet Hose Replacement (Diesel) Heater Outlet Hose Replacement (LAU/A28NER) Heater Outlet Hose Replacement (LLU/A16LET) Heater Outlet Hose Replacement (LHU/A20NFT) .

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

25.	Remove the heater hose (1) from the water outlet.

26.	Remove the fuel feed pipe from the fuel injection fuel rail. Refer to Fuel Feed Pipe Replacement .

27.	Plug the fuel feed pipe and cap the fuel injection fuel rail to prevent fuel loss or contamination.

28.	Disconnect the evaporative emission pipe quick connector (1).

29.

Remove the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LBS/A20DTH) Air Conditioning Compressor and Condenser Hose Replacement (LAU/A28NER) Air Conditioning Compressor and Condenser Hose Replacement (LLU/A16LET) Air Conditioning Compressor and Condenser Hose Replacement (LBY/A20DTR) Air Conditioning Compressor and Condenser Hose Replacement (LHU/A20NFT) and Air Conditioning Evaporator Hose Assembly Replacement (LAU/A28NER) Air Conditioning Evaporator Hose Assembly Replacement (LBS/A20DTH) Air Conditioning Evaporator Hose Assembly Replacement (LLU/A16LET) Air Conditioning Evaporator Hose Assembly Replacement (LBY/A20DTR) Air Conditioning Evaporator Hose Assembly Replacement (LHU/A20NFT) .

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

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

32.	Remove the radiator air side baffle and radiator air lower baffle.

33.	Remove the 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) .

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

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

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

37.	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) .

38.	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) .

39.	Disconnect the power steering wiring harness connector (2).

40.	Disconnect the engine coolant fan motor wiring harness connectors (1).

41.	Remove the relay box (1).

42.	Position and secure the relay box to the engine.

43.	Remove the propeller shaft. Refer to Propeller Shaft Replacement .

44.	Note Do NOT remove the exhaust system. Remove exhaust front pipe. Refer to Exhaust System Replacement (LAU/A28NER) Exhaust System Replacement (LLU/A16LET) Exhaust System Replacement (LHU/A20NFT) Exhaust System Replacement (LHU/A20NFT - AWD, LAU/A28NER - AWD) .

45.	Remove both drivetrain and front suspension frame transmission protectors.

46.	Remove the engine shield from the front suspension frame.

47.	Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.

48.	Position a suitable powertrain or engine lift table below the frame, engine and transmission.

49.	Install the CH-49290 mounting engine/transmission onto the lift table. Refer to Engine Support Fixture (Rear Left Side) Engine Support Fixture (Rear Right Side) Engine Support Fixture (Front) .

50.	Remove the powertrain lift/support table.

51.	Lower the vehicle.

52.	Remove the engine mount bracket from the engine mount support. Refer to Engine Mount Bracket Replacement - Right Side .

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

54.	Raise the vehicle.

55.	Install the CH-49289 centering adapter onto the lift table. Refer to Engine Support Fixture (Rear Left Side) Engine Support Fixture (Rear Right Side) Engine Support Fixture (Front) .

56.	Raise the lift table or lower the vehicle to support the frame, engine and transmission.

57.	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.

58.	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) .

59.	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.

60.	Remove the power steering fluid cooler from engine cooling module. Refer to Power Steering Fluid Cooler Replacement .

61.	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) .

62.	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) .

63.

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 Inlet Hose Replacement (LAU/A28NER) Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR) Charge Air Cooler Inlet Hose Replacement (LLU/A16LET) Charge Air Cooler Inlet Hose Replacement (LBS/A20DTH) and Charge Air Cooler Outlet Hose Replacement (Diesel) Charge Air Cooler Outlet Hose Replacement (LAU/A28NER) Charge Air Cooler Outlet Hose Replacement (LLU/A16LET) .

64.	Remove the radiator inlet hose and the radiator outlet hose from the radiator.

65.	Remove the transmission fluid cooler pipe from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .

66.	Remove the engine cooling module wiring harness from the drivetrain and front suspension frame.

67.	Remove the engine wiring harness from the radiator.

68.	Remove the engine cooling module from the drivetrain and front suspension frame.

69.	Remove the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Hose Replacement (Diesel) Charge Air Cooler Outlet Hose Replacement (LAU/A28NER) Charge Air Cooler Outlet Hose Replacement (LLU/A16LET) .

70.	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) .

71.	Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.

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

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

74.	Remove the engine and the transmission from the drivetrain and front suspension frame.

75.	Remove the transmission rear mount bracket and the transfer case. Refer to Transfer Case Assembly Replacement .

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

77.	Remove the catalytic converter front heat shield (1).

78.	Remove the transmission heat shield (1).

79.	Remove the secondary air injection inlet pipe. Refer to Secondary Air Injection Pipe Replacement .

80.	Remove the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

81.	Remove the secondary air injection pump. Refer to Secondary Air Injection Pump Replacement .

82.	Remove the engine oil cooler outlet hose.

83.	Remove the starter. Refer to Starter Replacement (2.0L Diesel) Starter Replacement (LAU/A28NER) Starter Replacement (LDE/A16XER, LLU/A16LET, 2H0/A18XER) Starter Replacement (LHU/A20NFT) .

84.	Remove the radiator surge tank engine hose.

85.	Remove the radiator surge tank engine pipe.

86.	Install two transmission lift brackets to the transmission housing.

87.	Position a second floor crane to the transmission lift brackets and raise the floor crane to partially support the transmission.

88.	Remove the transmission from the engine. Refer to Transmission Replacement (FWD, LBS/A20DTH) Transmission Replacement (AWD, LAU/A28NER) Transmission Replacement (AWD, LBY/A20DTR) Transmission Replacement (FWD, LHU/A20NFT) Transmission Replacement (AWD, LHU/A20NFT) .

Installation Procedure

1.	Refer to Fastener Caution . Install the transmission to the engine. Refer to Transmission Replacement (FWD, LBS/A20DTH) Transmission Replacement (AWD, LAU/A28NER) Transmission Replacement (AWD, LBY/A20DTR) Transmission Replacement (FWD, LHU/A20NFT) Transmission Replacement (AWD, LHU/A20NFT) .

2.	Remove the second floor crane from the transmission lift brackets.

3.	Remove both transmission lift brackets to the transmission housing.

4.	Install the radiator surge tank engine pipe.

5.	Install the radiator surge tank engine hose.

6.	Install the starter. Refer to Starter Replacement (2.0L Diesel) Starter Replacement (LAU/A28NER) Starter Replacement (LDE/A16XER, LLU/A16LET, 2H0/A18XER) Starter Replacement (LHU/A20NFT) .

7.	Install the engine oil cooler outlet hose.

8.	Install the secondary air injection pump. Refer to Secondary Air Injection Pump Replacement .

9.	Install the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

10.	Install the secondary air injection inlet pipe. Refer to Secondary Air Injection Pipe Replacement .

11.	Install the transmission heat shield (1). Tighten the transmission heat shield to 8 Nm (71 lb in) .

12.	Install the catalytic converter front heat shield (1). Tighten the catalytic converter front heat shield to 8 Nm (71 lb in) .

13.	Install the transmission front mount. Refer to Transmission Front Mount Replacement .

14.	Install the transfer case and the transmission rear mount bracket. Refer to Transfer Case Assembly Replacement .

15.	Install the engine and the transmission from the drivetrain and front suspension frame.

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

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

18.	Remove the floor crane from the engine.

19.	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) .

20.	Install the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Hose Replacement (Diesel) Charge Air Cooler Outlet Hose Replacement (LAU/A28NER) Charge Air Cooler Outlet Hose Replacement (LLU/A16LET) .

21.	Install the engine cooling module to the drivetrain and front suspension frame.

22.	Install the engine wiring harness from the radiator.

23.	Install the engine cooling module wiring harness from the drivetrain and front suspension frame.

24.	Install the transmission fluid cooler pipe to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .

25.	Install the radiator inlet hose and the radiator outlet hose to the radiator.

26.

Install the charge air cooler inlet air hose and the charge air cooler outlet air hose to the charge air cooler. Refer to Charge Air Cooler Inlet Hose Replacement (LAU/A28NER) Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR) Charge Air Cooler Inlet Hose Replacement (LLU/A16LET) Charge Air Cooler Inlet Hose Replacement (LBS/A20DTH) and Charge Air Cooler Outlet Hose Replacement (Diesel) Charge Air Cooler Outlet Hose Replacement (LAU/A28NER) Charge Air Cooler Outlet Hose Replacement (LLU/A16LET) .

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

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

29.	Install the power steering fluid cooler from engine cooling module. Refer to Power Steering Fluid Cooler Replacement .

30.	Note Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process. With the aid of an assistant, raise the table or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.

31.	Install 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) .

32.	Remove the powertrain lift/support table.

33.	Remove the CH-49289 centering adapter. Refer to Engine Support Fixture (Rear Left Side) Engine Support Fixture (Rear Right Side) Engine Support Fixture (Front) .

34.	Lower the vehicle.

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

36.	Install the engine mount bracket to the engine mount support. Refer to Engine Mount Bracket Replacement - Right Side .

37.	Raise the vehicle.

38.	Remove the CH-49290 mounting engine/transmission with the powertrain lift/support table. Refer to Engine Support Fixture (Rear Left Side) Engine Support Fixture (Rear Right Side) Engine Support Fixture (Front) .

39.	Install the engine shield from the front suspension frame.

40.	Install both drivetrain and front suspension frame transmission protectors.

41.	Install the exhaust front pipe. Refer to Exhaust System Replacement (LAU/A28NER) Exhaust System Replacement (LLU/A16LET) Exhaust System Replacement (LHU/A20NFT) Exhaust System Replacement (LHU/A20NFT - AWD, LAU/A28NER - AWD) .

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

43.	Remove the relay box from the engine.

44.	Install the relay box (1).

45.	Connect the engine coolant fan motor wiring harness connectors (1).

46.	Connect the power steering wiring harness connector (2).

47.	Connect both front wheel speed sensor electrical connectors. Remove both wiring harnesses from the vehicle. Refer to Front Wheel Speed Sensor Replacement (GNA) Front Wheel Speed Sensor Replacement (GNB) .

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

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

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

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

52.	Install the 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) .

53.	Install the radiator air side baffle and the radiator air lower baffle.

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

55.	Lower the vehicle.

56.

Install the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LBS/A20DTH) Air Conditioning Compressor and Condenser Hose Replacement (LAU/A28NER) Air Conditioning Compressor and Condenser Hose Replacement (LLU/A16LET) Air Conditioning Compressor and Condenser Hose Replacement (LBY/A20DTR) Air Conditioning Compressor and Condenser Hose Replacement (LHU/A20NFT) and Air Conditioning Evaporator Hose Assembly Replacement (LAU/A28NER) Air Conditioning Evaporator Hose Assembly Replacement (LBS/A20DTH) Air Conditioning Evaporator Hose Assembly Replacement (LLU/A16LET) Air Conditioning Evaporator Hose Assembly Replacement (LBY/A20DTR) Air Conditioning Evaporator Hose Assembly Replacement (LHU/A20NFT) .

57.	Connect the evaporative emission pipe quick connector (1).

58.	Install the fuel feed pipe to the fuel injection fuel rail. Refer to Fuel Feed Pipe Replacement .

59.	Install the heater hose (1) to the water outlet.

60.

Install the heater inlet hose and the heater outlet hose to the heater core. Refer to Heater Inlet Hose Replacement (Diesel) Heater Inlet Hose Replacement (LAU/A28NER) Heater Inlet Hose Replacement (LLU/A16LET) Heater Inlet Hose Replacement (LHU/A20NFT) and Heater Outlet Hose Replacement (Diesel) Heater Outlet Hose Replacement (LAU/A28NER) Heater Outlet Hose Replacement (LLU/A16LET) Heater Outlet Hose Replacement (LHU/A20NFT) .

61.	Install the power brake booster pipe (1) from the power brake booster (2).

62.	Install the automatic transmission vent pipe.

63.	Install the automatic transmission range selector lever cable to the transmission. Refer to Range Selector Lever Cable Replacement .

64.	Install the engine coolant air bleed pipe to the upper intake manifold. Refer to Upper Intake Manifold Replacement .

65.	Install the radiator surge tank hoses to the radiator surge tank (1).

66.	Install the engine wiring harness (1) to the front compartment fuse block housing (2).

67.	Install the engine wiring harness ground connectors (1) to the front end upper tie bar support.

68.	Connect the engine wiring harness connectors (1, 2, 3).

69.	Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

70.	Install the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement .

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

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

73.	Install the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

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

75.	Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging .

76.	Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

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

78.	Fill the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .

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