Removal and installation the engine (Chevrolet Captiva 1)

Contents: Removal procedure ↧ Installation procedure ↧

Necessary equipment

EN-48243 Engine assembly removal/installation rack

EN-48244 Rack bracket for engine assembly removal/installation

Removal procedure

1. Discharge the air conditioning (A/C) system, if equipped.

2. Drain the power steering fluid, if provided by the design.

3. Disconnect the negative battery cable.

4. Remove the decorative cover. See "Decorative cover" in this section.

5. Remove the air intake hoses and ducts. See "Air injection system" in this section.

6. Drain the engine coolant. See Section 1D1, Engine Cooling - 2.0 Diesel.

6. Drain the engine coolant. See Section 1D1, Engine Cooling - 2.0 Diesel.

7. Disconnect the fuel supply line connector (a).

8. Disconnect the coolant hose from the expansion tank (b, c).

9. Disconnect the fuel return hose from the connection block (d).

9. Disconnect the fuel return hose from the connection block (d).

10. Disconnect the engine wiring harness.

a) Disconnect the fuel heater wire connector.
b) Disconnect the mass air flow (MAF) sensor connector.
c) Disconnect the exhaust gas temperature sensor wire connector.
d) Disconnect the diesel particulate filter (DPF) pressure sensor connector.
e) Disconnect the engine oil pressure sensor connector.
f) Disconnect the common rail pressure sensor connector.
g) Disconnect the coolant temperature sensor connector.
h) Disconnect the EGR vacuum solenoid valve connector.
i) Disconnect the fuel injector connector.
j) Disconnect the camshaft position (CMP) sensor connector.
k) Disconnect the turbocharger drive connector.
l) Disconnect the glow plug wire connector.
m) Disconnect the boost pressure sensor (T-MAP) connector.
n) Disconnect the common rail fuel regulator connector.
o) Disconnect the ETC housing connector.
p) Disconnect the fuel injection pump connector.
q) Disconnect the cooling fan connectors.
r) Disconnect the air conditioning compressor connector.
s) Disconnect the starter solenoid wire connector.
t) Disconnect the air conditioner pressure sensor connector.
u) Disconnect the range selector connector of the main gear box assembly if it is an automated main gear box assembly.
v) Disconnect the transaxle wiring harness electrical connector if it is an automated transaxle.
w) Disconnect the input shaft speed sensor electrical connector if it is an automatic transmission with a final drive assembly.
x) Disconnect the secondary shaft speed sensor electrical connector if it is an automatic transmission with a final drive assembly.
y) Disconnect the speed sensor connector if it is a manual transmission with final drive assembly.
z) Disconnect the crankshaft position sensor.
(B) Disconnect the generator connector.

Remove the engine contact block clamp bolt from the intake manifold.
Remove the glow plug module.
Remove the glow plug fuse box.
Loosen the nut of the B+ generator connector.
Loosen the starter solenoid valve connector nut.
Loosen the engine ground bolt.

11. Remove the expansion tank. See Section 1D1, Engine Cooling - 2.0 Diesel.

12. Remove the power steering pump pipes from the power steering pump. Follow section 6B, Power Steering Pump.

13. Remove the right/left drive axle shaft. See section 3A, "Front Drive Axle".

14. Loosen the lower intermediate shaft clamp bolt. See Section 6C, Power Steering.

14. Loosen the lower intermediate shaft clamp bolt. See Section 6C, Power Steering.

15. Remove the shift control cable from the automated transaxle assembly. See Section 5A, AISIN 55-51LE automatic transmission with main gear assembly, if it is an automated transmission with main gear assembly.

16. Remove the selector cable from the transaxle assembly. See Section 5B, Five-Speed Manual Transaxle with Final Drive Assembly, if it is a manual transaxle with final drive assembly.

17. Remove the oil cooler hoses of the main transmission assembly from the automated main transmission assembly. Section 5A, AISIN 55-51LE automatic transmission with main gear assembly, if it is an automated transmission with main gear assembly.

18. Remove the clutch cylinder pipe from the transaxle assembly. See Section 5B, Five-Speed Manual Transaxle with Final Drive Assembly, if it is a manual transaxle with final drive assembly.

19. Remove the exhaust pipe between the pre-catalytic converter and the diesel particulate filter (DPF) pipe. See Section 1G1, Exhaust System - 2.0 Diesel.

20. Remove the air conditioner compressor tube from the compressor. Follow section 7B, Heating, Ventilation, and Air Conditioning Systems Control.

21. Remove the power steering cooling return pipe. See section 6A, Power Steering System.

22. Remove the driveshaft assembly from the transfer case, if equipped. See Section 3B, "Rear Drive Axle".

22. Remove the driveshaft assembly from the transfer case, if equipped. See Section 3B, «Rear Drive…

23. Remove the support bracket bracket.

24. Loosen the support tie bolts.

Caution: Make sure that all components of the EN-48243 Engine Assembly Removal/Installation Rack are aligned exactly with the EN-48244 Bracket as shown in the figure.

1~4: Support bracket
a: Diesel engine oil pan bracket
b: FAM II 2.4D Engine Oil Pan Bracket
c & d: HFV6 3.2L Engine Oil Pan Bracket
e: Manual gearbox bracket with final drive assembly
f: Automatic transmission bracket with final drive assembly
g: Transfer case bracket (M/T and A/T)
h: Transmission mount bracket with final drive assembly (M/T& A/T)

h: Transmission mount bracket with final drive assembly (M/T& A/T)

Caution: Lower the vehicle sufficiently to relieve the load on the engine mount and the transmission assembly, otherwise suspension damage and rack/rack bracket failure may occur.

25. Lower the vehicle and place the engine assembly on the EN-48243 Engine Assembly Rack with EN-48244 Rack Bracket until it rests.

26. Remove the engine mount bolt from the engine mount bracket.

27. Remove the transmission mount bolt with the final drive assembly from the transmission.

28. Tighten the engine assembly using a lifting device, etc.

29. Remove the front suspension of the gearbox with the final drive assembly.

30. Remove the rear suspension of the gearbox with the final drive assembly.

31. Remove the engine and gearbox with the final drive assembly.

Installation procedure

1. Install the gearbox with the final drive assembly onto the engine assembly.

Tighten

Tighten the gearbox assembly tie bolts to 75 Nm (55.3 ft·lbs).

Tighten the oil pan flange mounting bolts to the gearbox assembly to 50 N·m (36.9 ft·lbs).

2. Install the support on the EN-48243 Engine Assembly Removal/Installation Rack with the EN-48244 Rack Bracket, and then assemble the engine and gearbox assembly on the support.

Caution: Ensure that all components of the EN-48243 Engine Assembly Removal/Installation Rack are aligned precisely with the EN-48244 Rack Bracket.

Caution: Ensure that all components of the EN-48243 Engine Assembly Removal/Installation Rack are…

3. Lower the vehicle and place the engine and gearbox assembly with the final drive connected to the support on the EN-48243 Engine Assembly Rack with EN-48244 Rack Bracket in the vehicle.

4. Install the rear suspension of the gearbox with the final drive assembly.

Tighten

Tighten the rear suspension bolt of the gearbox with the final drive assembly to 90 N·m (66.4 ft·lbs).

Tighten the rear suspension bolt of the gearbox with the final drive assembly to 90 N·m (66.4 …

5. Install the front suspension of the gearbox with the final drive assembly.

Tighten

Tighten the front suspension bolt of the gearbox with the final drive assembly to 90 N·m (66.4 ft·lbs).

Tighten the front suspension bolt of the gearbox with the final drive assembly to 90 N·m (66.4 …

6. Install the gearbox suspension with the final drive assembly.

Tighten

Tighten the transaxle mount retaining bolts (2) to 37 N·m (27 lb-ft).

Tighten the transmission mount bracket retaining bolts (1) to 50 N·m (37 lb-ft).

Tighten the transmission mount bracket retaining bolts (1) to 50 N·m (37 lb-ft).

7. Tighten the engine mount bolt.

Tighten

Tighten the engine mount bracket lock bolts to 50 Nm (37 ft·lbs).

8. Remove the EN-48243 engine assembly removal/installation rack with the EN-48244 rack bracket from the vehicle.

9. Tighten the mounting bolts that connect the support to the body. See section 2C, "Front Suspension".

Tighten

Tighten the frame mounting bolts to 155 Nm (114,3 lb-ft).

10. Install the support bracket retaining bolts. See section 2C, "Front Suspension".

Tighten

Tighten the frame bracket bolts to 50 Nm (36,9 lb-ft).

Tighten the frame bracket bolts to 50 Nm (36,9 lb-ft).

11. Connect the engine wiring harness.

a) Connect the fuel heater connector.
b) Connect the mass air flow (MAF) sensor connector.
c) Connect the exhaust gas temperature sensor wire connector.
d) Connect the diesel particulate filter (DPF) pressure sensor connector.
e) Connect the engine oil pressure sensor connector.
f) Connect the common rail pressure sensor connector.
g) Connect the coolant temperature sensor connector.
h) Connect the EGR vacuum solenoid valve connector.
i) Connect the fuel injector connector.
j) Connect the camshaft position (CMP) sensor connector.
k) Connect the turbocharger drive connector.
l) Connect the glow plug wire connector.
m) Connect the boost pressure sensor (T-MAP) connector.
n) Connect the common rail fuel regulator connector.
o) Connect the ETC housing connector.
p) Connect the fuel injection pump connector.
q) Connect the cooling system fan connectors.
r) Connect the air conditioning compressor connector.
s) Connect the starter solenoid wire connector.
t) Connect the air conditioner pressure sensor connector.
u) Connect the range selector connector of the main gear box assembly if it is an automated main gear box assembly.
v) Connect the electrical connector of the transmission assembly wiring harness if it is an automated transmission assembly.
w) Connect the input shaft speed sensor electrical connector if it is an automatic transmission with a final drive assembly.
x) Connect the secondary shaft speed sensor electrical connector if it is an automatic transmission with a final drive assembly.
y) Connect the speed sensor connector if it is a manual transmission with final drive assembly.
z) Connect the crankshaft position sensor.
(B) Connect the generator connector.

Tighten the engine connector clamp bolt onto the intake manifold.
Tighten the glow plug module nut.
Tighten the glow plug fuse box bolt.
Tighten the nut of the B+ generator connector.
Tighten the starter solenoid valve connector nut.
Tighten the engine ground bolt.

Tighten

Tighten the engine wiring harness connector clamp bolt to 15 Nm (11.1 ft·lbs).

Tighten the glow plug module lock nut to 14 Nm (10.3 ft·lbs).

Tighten the glow plug fuse box bolts to 10 Nm (88.5 lbs.in).

Tighten the generator B+ connector nut to 25 Nm (18.4 ft·lbs).

Tighten the starter solenoid connector nut to 15 N·m (11.1 ft·lbs).

Tighten the engine block ground bolt to 25 Nm (18.4 ft·lbs).

The article was checked: Vladimir Romannikov

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Captiva 1: Engine repair

Rear suspension unit of the gearbox with the main gear assembly
Front suspension unit of the gearbox with the main gear assembly
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Engine support plate
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