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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 - AWD

Engine Removal And Installation - AWD

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 turbocharger 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 exhaust pipe. Refer to PIPE, EXHAUST, REMOVAL AND INSTALLATION .
  13. Remove the rear propeller shaft. Refer to REMOVAL AND INSTALLATION .
  14. Remove the front struts. Refer to STRUT, SUSPENSION, ASSEMBLY, REMOVAL AND INSTALLATION .
  15. Remove both front half shafts. Refer to REMOVAL AND INSTALLATIONREMOVAL AND INSTALLATION .
    GC0194502Courtesy of CHRYSLER GROUP, LLC
  16. Disconnect the steering gear wire harness connectors (1).
    GC0197350Courtesy of CHRYSLER GROUP, LLC
  17. Remove and DISCARD  the bolt (1a) and disconnect the column (1b) from the steering gear.
    GC0193380Courtesy of CHRYSLER GROUP, LLC
  18. On both sides, remove the bolts (1a) and the radiator mounting brackets (1b).
    GC0198103Courtesy of CHRYSLER GROUP, LLC
  19. Open the clip (1a) and disconnect the quick coupling (1b) from the heater core engine coolant return hose.
    GC0198008Courtesy of CHRYSLER GROUP, LLC
  20. Disconnect the quick coupling and remove the engine coolant supply hose (1) from the heater core.
    GC0194462Courtesy of CHRYSLER GROUP, LLC
  21. Disengage and disconnect the downstream oxygen sensor wire harness connector (1).
    GC0198192Courtesy of CHRYSLER GROUP, LLC
  22. Loosen the clamp (1) and disconnect the engine coolant outlet hose from the turbocharger.
  23. Remove the nut (2a) and disconnect the air conditioning lines (2b).
  24. Using suitable seal plugs close the disconnected unions to prevent moisture and impurities from entering the A/C system.
    GC0193485Courtesy of CHRYSLER GROUP, LLC
  25. Remove the bolt (1a) and disconnect the outlet piping from the A/C compressor (1b).
  26. Using suitable seal plugs close the disconnected unions to prevent moisture and impurities from entering the system.
    GC0194909Courtesy of CHRYSLER GROUP, LLC
  27. Disconnect the quick coupling and remove the engine coolant hose (1) from the temperature control solenoid valve.
    GC0193473Courtesy of CHRYSLER GROUP, LLC
  28. Disconnect the quick coupling (1) and remove the engine coolant inlet hose from the water pump.
    GC0198712Courtesy of CHRYSLER GROUP, LLC
  29. Remove the retaining nut (1a) from the compressor to condenser A/C line (1b).
    GC0193114Courtesy of CHRYSLER GROUP, LLC
  30. Open the clip (1a) and disconnect the fuel vapor tube quick coupling (1b).
    GC0195031Courtesy of CHRYSLER GROUP, LLC
  31. Open the clip (1a) and disconnect the coolant temperature sensor wire harness connector (1b).
    GC0193194Courtesy of CHRYSLER GROUP, LLC
  32. Disconnect the quick coupling and remove the engine coolant delivery hose (1) from the heat exchanger.
    GC0194046Courtesy of CHRYSLER GROUP, LLC
  33. Disconnect the quick coupling and remove the engine coolant return hose (1) from the heat exchanger.
    GC0194755Courtesy of CHRYSLER GROUP, LLC
  34. Disconnect the fuel low pressure sensor wire harness connector (1).
    GC0194624Courtesy of CHRYSLER GROUP, LLC
  35. 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
  36. Disconnect the degassing hose quick coupling (1) from the pressurized coolant bottle.
    GC0198893Courtesy of CHRYSLER GROUP, LLC
  37. With cowl panel cover removed, remove the start cable junction cover by releasing the four tabs (1).
    GC0198800Courtesy of CHRYSLER GROUP, LLC
  38. Disconnect the starter motor B+ cable (1) from the junction.
    GC0196999Courtesy of CHRYSLER GROUP, LLC
  39. On both sides, remove the lower bolts (1) securing the air duct to the radiator.
    GC0195385Courtesy of CHRYSLER GROUP, LLC
  40. Remove the bolts (1a), disconnect and reposition the automatic transmission oil delivery and return lines from the radiator (1b).
    GC0197331Courtesy of CHRYSLER GROUP, LLC
  41. Remove the bolt (1a) and disconnect the ground lead (1b).
    GC0193221Courtesy of CHRYSLER GROUP, LLC
  42. Disengage and disconnect the automatic transmission wiring harness connector (1).
    GC0198859Courtesy of CHRYSLER GROUP, LLC
  43. Place Engine Support 2032200090 (1a) on a suitable lifting table (1b).
    GC0198784Courtesy of CHRYSLER GROUP, LLC
  44. 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).
  45. 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
  46. Position a suitable hydraulic lift (1) under the rear differential and support it as shown in the illustration.
    GC0197377Courtesy of CHRYSLER GROUP, LLC
  47. Remove the transmission mounting bracket bolts (1).
    GC0197315Courtesy of CHRYSLER GROUP, LLC
  48. On both sides, remove the front screws (1a) securing the front suspension cross member (1b) to the body.
    GC0196962Courtesy of CHRYSLER GROUP, LLC
  49. On both sides, remove the middle and rear bolts (1a) securing the front suspension cross member (1b) to the body.
  50. 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 .
    GC0195990Courtesy 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 .
    GC0196825Courtesy 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 from 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 coolant temperature control 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.
    GC0196128Courtesy of CHRYSLER GROUP, LLC
  29. Connect the column (1a) to the steering gear and tighten the NEW  bolt (1b) to the proper specification Refer to TECHNICAL SPECIFICATIONS .
  30. Connect the steering gear wiring harness connector.
  31. Install both front half shafts. Refer to REMOVAL AND INSTALLATION .
  32. Install the front struts. Refer to STRUT, SUSPENSION, ASSEMBLY, REMOVAL AND INSTALLATION .
  33. Install the propeller shaft. Refer to REMOVAL AND INSTALLATION .
  34. Install the exhaust pipe. Refer to PIPE, EXHAUST, REMOVAL AND INSTALLATION .
  35. Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  36. Install the intake air tube. Refer to TUBE, INTAKE AIR, REMOVAL AND INSTALLATION .
  37. Install the cowl panel cover. Refer to COVER, COWL PANEL, REMOVAL AND INSTALLATION .
  38. Install the Powertrain control Module (PCM) and bracket assembly. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL AND INSTALLATION .
  39. Evacuate and charge A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  40. Fill the turbocharger cooling system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
  41. Fill the cooling system. Refer to DRAINING AND FILLING THE ENGINE COOLING SYSTEM .
  42. Install the air dam front crossmember. Refer to AIR DAM, FRONT, REMOVAL AND INSTALLATIONAIR DAM, FRONT CROSSMEMBER, REMOVAL AND INSTALLATION .
  43. Install the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
  44. Connect the negative battery cable.
  45. 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 .
  46. Remove the support and lower the vehicle.
  47. Perform a wheel alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
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