LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Alfa Romeo >> 2019 >> Giulia Base, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.0L - Engine (Service Information) >> Removal And Installation >> Engine Removal And Installation - RWD

Engine Removal And Installation - RWD

REMOVAL 

  1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  2. Disconnect and isolate the negative battery cable.
  3. Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
  4. Remove the air dam front crossmember. Refer to AIR DAM, FRONT, REMOVAL AND INSTALLATIONAIR DAM, FRONT CROSSMEMBER, REMOVAL AND INSTALLATION .
  5. Drain the engine cooling system. Refer to DRAINING AND FILLING THE ENGINE COOLING SYSTEM .
  6. Drain the turbocharger cooling system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
  7. Recover the A/C refrigerant. Refer to PLUMBING, STANDARD PROCEDURE .
  8. Remove the Powertrain control Module (PCM) and bracket assembly. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL AND INSTALLATION .
  9. Remove the cowl panel cover. Refer to COVER, COWL PANEL, REMOVAL AND INSTALLATION .
  10. Remove the intake air tube. Refer to TUBE, INTAKE AIR, REMOVAL AND INSTALLATION .
  11. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  12. Remove the propeller shaft. Refer to REMOVAL AND INSTALLATION .
    GC0198189Courtesy of CHRYSLER GROUP, LLC
  13. Temporarily install the transmission rear mounting (1a) and tighten the NEW  rear engine/transmission mount lower bracket bolts (1b) to the proper specification Refer to TORQUE SPECIFICATIONS  .
    GC0197951Courtesy of CHRYSLER GROUP, LLC
  14. Install the NEW  rear engine/transmission mount nuts (1) securing the transmission assembly rear mounting bracket and tighten to the proper specification Refer to TORQUE SPECIFICATIONS  .
  15. Remove the hydraulic lift.
    GC0194694Courtesy of CHRYSLER GROUP, LLC
  16. On both sides, disconnect the brake pad wear sensor wire harness connector (1).
    GC0193130Courtesy of CHRYSLER GROUP, LLC
  17. On both sides, disengage the wheel speed sensor wiring (1).
  18. On both sides, remove the bolts (2a) securing the bracket (2b) to the steering knuckle.
    GC0194966Courtesy of CHRYSLER GROUP, LLC
  19. On both sides, remove the lower bolt (1) complete with counterweight.
  20. On both sides, remove the upper bolt (2a) and the brake caliper (2b) and reposition it without disconnecting the brake fluid line.
    GC0195183Courtesy of CHRYSLER GROUP, LLC
  21. On both sides, remove and DISCARD  the upper control arm (1b) to knuckle (1c) pinch bolt (1a).
    GC0194149Courtesy of CHRYSLER GROUP, LLC
  22. On both sides, remove the nut (1a) and disconnect the stabilizer bar link (1b) from the strut assembly.
    GC0194973Courtesy of CHRYSLER GROUP, LLC
  23. On both sides, remove the bolt (1a) and disconnect the strut assembly (1b) from the rear lower control arm (1c).
    GC0193323Courtesy of CHRYSLER GROUP, LLC
  24. On both sides, remove the bolt (1a) and the wheel speed sensor (1b).
    GC0194502Courtesy of CHRYSLER GROUP, LLC
  25. Disconnect the steering gear wire harness connectors (1).
    GC0196546Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Never disconnect the electrical connections between the Electric Power Steering (EPS) module (a) and the steering box pinion (b).

    GC0193661Courtesy of CHRYSLER GROUP, LLC
  26. Remove and DISCARD  the bolt (1a) and disconnect the column (1b) from the steering gear (1c).
    GC0193380Courtesy of CHRYSLER GROUP, LLC
  27. On both sides, remove the bolts (1a) and the radiator mounting brackets (1b).
    GC0198103Courtesy of CHRYSLER GROUP, LLC
  28. Open the clip (1a) and disconnect the quick coupling (1b) from the heater core engine coolant return hose.
    GC0198008Courtesy of CHRYSLER GROUP, LLC
  29. Disconnect the quick coupling and remove the engine coolant supply hose (1) from the heater core.
    GC0194462Courtesy of CHRYSLER GROUP, LLC
  30. Disengage and disconnect the downstream oxygen sensor wire harness connector (1).
    GC0198192Courtesy of CHRYSLER GROUP, LLC
  31. Loosen the clamp (1) and disconnect the engine coolant outlet hose from the turbocharger.
  32. Remove the nut (2a) and disconnect the air conditioning lines (2b).
  33. Using suitable seal plugs close the disconnected unions to prevent moisture and impurities from entering the A/C system.
    GC0193485Courtesy of CHRYSLER GROUP, LLC
  34. Remove the bolt (1a) and disconnect the outlet piping from the A/C compressor (1b).
  35. Using suitable seal plugs close the disconnected unions to prevent moisture and impurities from entering the A/C system.
    GC0194909Courtesy of CHRYSLER GROUP, LLC
  36. Disconnect the quick coupling and remove the engine coolant hose (1) from the temperature control solenoid valve.
    GC0193473Courtesy of CHRYSLER GROUP, LLC
  37. Disconnect the quick coupling (1) and remove the engine coolant inlet hose from the water pump.
    GC0193114Courtesy of CHRYSLER GROUP, LLC
  38. Open the clip (1a) and disconnect the fuel vapor tube quick coupling (1b).
    GC0195031Courtesy of CHRYSLER GROUP, LLC
  39. Open the clip (1a) and disconnect the coolant temperature sensor wire harness connector (1b).
    GC0193194Courtesy of CHRYSLER GROUP, LLC
  40. Disconnect the quick coupling and remove the engine coolant delivery hose (1) from the heat exchanger.
    GC0194046Courtesy of CHRYSLER GROUP, LLC
  41. Disconnect the quick coupling and remove the engine coolant return hose (1) from the heat exchanger.
    GC0194755Courtesy of CHRYSLER GROUP, LLC
  42. Disconnect the fuel low pressure sensor wire harness connector (1).
    GC0194624Courtesy of CHRYSLER GROUP, LLC
  43. Open the clip (1a) and disconnect the quick coupling (1b) of the front fuel supply pipe from the pressure pump.
    GC0193980Courtesy of CHRYSLER GROUP, LLC
  44. Disconnect the degassing hose quick coupling (1) from the pressurized coolant bottle.
    GC0198893Courtesy of CHRYSLER GROUP, LLC
  45. With cowl panel cover removed, remove the start cable junction cover by releasing the four tabs (1).
    GC0198800Courtesy of CHRYSLER GROUP, LLC
  46. Disconnect the starter motor B+ cable (1) from the junction.
    GC0198314Courtesy of CHRYSLER GROUP, LLC
  47. On both sides, remove the lower bolts (1) securing the air duct to the radiator.
    GC0195385Courtesy of CHRYSLER GROUP, LLC
  48. Remove the bolts (1a), disconnect and reposition the automatic transmission oil delivery and return lines from the radiator (1b).
    GC0194090Courtesy of CHRYSLER GROUP, LLC
  49. Remove the bolt (1a) and disconnect the ground lead (1b).
    GC0193221Courtesy of CHRYSLER GROUP, LLC
  50. Disengage and disconnect the automatic transmission wiring harness connector (1).
    GC0198859Courtesy of CHRYSLER GROUP, LLC
  51. Place Engine Support 2032200090 (1a) on a suitable lifting table (1b).
    GC0198902Courtesy of CHRYSLER GROUP, LLC
  52. Position the Engine Support 2032200090 under the powertrain and support the suspension cross member with the uprights (1a) and the transmission with the uprights (1b).
  53. If the Engine Support 2032200090 is not available, place commercially available rubber spacer blocks, such as ROTFJ2427/J2440 or equivalent, on the (special tool #BX50-CHR, Table, Bishamon Lift) and position it under the powertrain and suspension crossmember assembly.
    GC0194645Courtesy of CHRYSLER GROUP, LLC
  54. Position a suitable hydraulic lift (1) under the rear differential and support it as shown in the illustration.
    GC0194522Courtesy of CHRYSLER GROUP, LLC
  55. Remove the transmission mounting bracket bolts (1).
    GC0193062Courtesy of CHRYSLER GROUP, LLC
  56. On both sides, remove the front bolts (1a) securing the front suspension cross member (1b) to the body.
    GC0198101Courtesy of CHRYSLER GROUP, LLC
  57. On both sides, remove the middle and rear bolts (1a) securing the front suspension cross member (1b) to the body.
  58. Lower the lift table away from the vehicle complete with the powertrain assembly and suspension crossmember.

INSTALLATION 

  1. Use Engine Support 2032200090 on a suitable lifting table to install the powertrain assembly and suspension crossmember in position.
  2. If the Engine Support 2032200090 is not available, use the (special tool #BX50-CHR, Table, Bishamon Lift) and commercially available rubber spacer blocks such as ROTFJ2427/J2440 or equivalent to install the powertrain assembly and suspension crossmember in position.
    GC0195999Courtesy of CHRYSLER GROUP, LLC
  3. On both sides, Install the NEW  middle bolts (1a) and rear bolts (1b) securing the front suspension cross member to the body and tighten to the proper specification Refer to TECHNICAL SPECIFICATIONS .
    GC0197502Courtesy of CHRYSLER GROUP, LLC
  4. On both sides, Install the NEW  front bolts (1a) securing the front suspension cross member (1b) to the body and tighten to the proper specification Refer to TECHNICAL SPECIFICATIONS .
    GC0197903Courtesy of CHRYSLER GROUP, LLC
  5. Install the NEW  rear engine/transmission mount lower bracket bolts and tighten to the proper specification Refer to TORQUE SPECIFICATIONS  .
  6. Remove the lift table complete with rubber spacer blocks such as ROTFJ2427/J2440 or equivalent supporting the powertrain assembly.
  7. Connect the automatic transmission wiring harness connector.
  8. Connect the ground lead and securely tighten the bolt.
  9. Install the automatic transmission oil delivery and return lines to the radiator and securely tighten the bolts.
  10. Install the front bolts securing the air duct to the radiator and securely tighten.
  11. Connect the starter motor B+ wiring harness, securely tighten the nut and install the protective cover.
  12. Connect the degassing hose quick coupling to the pressurized coolant bottle.
  13. Connect the quick coupling of the front fuel supply line to the pressure pump and close the retaining clip.
  14. Connect the fuel low pressure sensor wiring harness connector.
  15. Connect the quick coupling of the engine coolant return hose to the heat exchanger.
  16. Connect the quick coupling of the engine coolant supply hose to the heat exchanger.
  17. Connect the coolant temperature sensor wiring harness connector and close the retaining clip.
  18. Connect the fuel vapor line quick coupling and close the retaining clip.
  19. Connect the quick coupling of the engine coolant inlet hose to the water pump.
  20. Connect the quick coupling of the engine coolant hose to the temperature control solenoid valve.
    GC0197913Courtesy of CHRYSLER GROUP, LLC
  21. Remove the protective plugs from the opened refrigerant line fittings and ports.
    NOTE:

    Lubricate NEW  rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fittings. Use only the specified O-rings as they are made of a special material for the system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

  22. Install the refrigerant line (1a) to the A/C compressor and tighten the bolt (1b) to the proper specification Refer to TECHNICAL SPECIFICATIONS .
    GC0198059Courtesy of CHRYSLER GROUP, LLC
  23. Remove the protective plugs from the opened refrigerant line fittings and ports.
    NOTE:

    Lubricate NEW  rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fittings. Use only the specified O-rings as they are made of a special material for the system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

  24. Connect the A/C lines (1a) and tighten the nut (1b) to the proper specification Refer to TECHNICAL SPECIFICATIONS .
  25. Connect the downstream oxygen sensor wiring harness connector and engage it in the support bracket.
  26. Connect the engine coolant supply hose quick coupling to the heater core.
  27. Connect the engine coolant return hose quick coupling to the heater core.
  28. On both sides, Install the radiator mounting brackets and securely tighten the bolts.
    GC0194777Courtesy of CHRYSLER GROUP, LLC
  29. Connect the column (1a) to the steering gear (1b) and tighten the NEW  bolt (1c) to the proper specification Refer to TECHNICAL SPECIFICATIONS .
  30. Connect the steering gear wiring harness connector.
  31. On both sides, install the wheel speed sensor and securely tighten the bolt.
    GC0195397Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Tightening (to the prescribed torque) of the strut assembly to lower control arm mounting bolt (1c) must be done when performing a wheel alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .

  32. On both sides, connect the strut assembly (1a) to the rear lower control arm (1b) and install the NEW  bolt (1c) without tightening it.
    GC0194691Courtesy of CHRYSLER GROUP, LLC
  33. On both sides, install the stabilizer bar link (1a) to the strut assembly and tighten the NEW  nut (1b) to the proper specification Refer to FRONT, TECHNICAL SPECIFICATIONS .
    GC0195183Courtesy of CHRYSLER GROUP, LLC
  34. Install the upper control arm (1b) to the steering knuckle (1c) and tighten the NEW  pinch bolt (1a) to the proper specification Refer to FRONT, TECHNICAL SPECIFICATIONS .
    GC0193229Courtesy of CHRYSLER GROUP, LLC
  35. On both sides, install the brake caliper (1a) and tighten the upper bolt (1b) to the proper specification Refer to TORQUE SPECIFICATIONS .
  36. Install the brake caliper lower bolt (2) complete with counterweight and tighten to the proper specification Refer to TORQUE SPECIFICATIONS .
  37. On both sides, install the wheel speed sensor wiring and tighten the bolts securing the bracket to the steering knuckle.
  38. On both sides, connect the brake pad wear sensor wiring harness connector.
  39. Install the propeller shaft. Refer to REMOVAL AND INSTALLATION .
  40. Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  41. Install the intake air tube. Refer to TUBE, INTAKE AIR, REMOVAL AND INSTALLATION .
  42. Install the cowl panel cover. Refer to COVER, COWL PANEL, REMOVAL AND INSTALLATION .
  43. Install the Powertrain control Module (PCM) and bracket assembly. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL AND INSTALLATION .
  44. Evacuate and charge A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  45. Fill the turbocharger cooling system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
  46. Fill the engine cooling system. Refer to DRAINING AND FILLING THE ENGINE COOLING SYSTEM .
  47. Install the air dam front crossmember. Refer to AIR DAM, FRONT, REMOVAL AND INSTALLATIONAIR DAM, FRONT CROSSMEMBER, REMOVAL AND INSTALLATION .
  48. Install the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
  49. Connect the negative battery cable.
  50. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  51. Remove the support and lower the vehicle.
  52. Perform a wheel alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
scientia non olet · About LEMON Manuals