Orlando

Engine Replacement - Manual Gearbox

Special Tools

For equivalent regional tools, Refer to Special Tools .

1. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
2. Open the bonnet.
3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
4. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .



5. For vehicles with electrical power steering:

•	Remove the electrical power steering positive cable and nut (1) from the fuse block (4)

•	Remove the electrical power steering positive negative cable (2) and nut (3).

6. Remove the battery tray. Refer to Battery Tray Replacement .



7. Remove the front compartment fuse block cover (1).



8. Loosen the 3 front compartment fuse block bolts (1).
9. Unclip the 4 front compartment fuse block retainer clips (2) and (3) and lift the front compartment fuse block slightly up.




Note: The wiring harness plugs should remain in the lower part (4) of the front compartment fuse block.

10. Entirely loosen the 3 front compartment fuse block bolts (1) while lifting the front compartment fuse block, until it can be removed from the 3 wiring harness plugs (3), (5) and (6).



11. Remove the ECM wiring harness plug (1) from the lower part of the front compartment fuse block.
12. Disconnect the ECM wiring harness plug (2) and unclip it from the retainer clip (3).



13. Remove the 2 ground nuts (1) and put the 2 wiring harnesses (2) aside.
14. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement : LDE, LXV, LUW, 2H0 and LFH .
15. Remove the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation .
16. Remove the front tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
17. Drain the cooling system. Refer to Cooling System Draining and Filling .
18. Unclip the radiator surge tank.
19. Put the radiator surge tank aside.
20. Remove the manual gearbox gear lever and selector lever cable from the transmission. Refer to Manual Gearbox Gear Lever and Selector Lever Cable Replacement .
21. Remove the heater inlet hose from the bulkhead. Refer to Heater Inlet Hose Replacement : 2.0L Diesel LNP  → 1.8L 2H0 and LFH .
22. Remove the heater outlet hose from the bulkhead. Refer to Heater Outlet Hose Replacement : 2.0L Diesel LNP  → 1.8L 2H0 and LFH .



23. Disconnect the servo unit vacuum pipe (2) from the inlet manifold (1).
24. For vehicles with right hand drive: disconnect the servo unit vacuum pipe from the servo unit. Refer to Servo unit Vacuum Pipe Replacement : Right Hand Drive  → Left Hand Drive with Electric Pump  → Left Hand Drive .
25. Place collecting basin underneath the vehicle.
26. Disconnect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement : F40 and Right Hand Drive  → F40 and Left Hand Drive  → D16, D20, and Right Hand Drive  → D16, D20, and Left Hand Drive .
27. Disconnect the fuel tank vent pipe from the evaporative emission vent valve.
28. Close the vents with the CH-807 closure plugs.
29. Disconnect the fuel feed pipe from the multiport fuel injection fuel rail.
30. Close the vents with the EN-6015 closure plugs.
31. For vehicles with hydraulic power steering: Remove power steering fluid reservoir bolt.
32. For vehicles with hydraulic power steering: Unclip power steering fluid reservoir and support it on the engine.



33. Remove A/C compressor and condenser hose nut (1) from A/C condenser (2).



34. Remove A/C compressor and condenser hose nut (1) from refrigerant hose (2).
35. Remove the air conditioning evaporator hose assembly nut from the air conditioning condenser.
36. Unclip the Radiator outlet hose from the radiator.
37. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
38. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
39. Remove the upper stabiliser shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
40. Remove steering linkage outer track rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Track rod Replacement .
41. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement .
42. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .
43. Disconnect the wheel speed sensors on both sides.
44. Unclip the wheel speed sensor wiring harness from the frame.



45. Disconnect the 3 wiring harness (1).
46. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement : 2.0L Diesel LNP  → LDE, LLU, LXT, LXV, L2W, 2H0, LFH,LGE .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

47. Assemble the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
48. Support the CH-904 base frame on a jack.
49. Support the CH-49290 support tool on the CH-904 base frame .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

50. Install the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
51. Remove the engine mount. Refer to Engine Mount Replacement .
52. Remove the transmission mount - left side. Refer to Transmission Mount Replacement - Left Side .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

53. Assemble the CH-49289 centring frame (1) according to the details provided in the SPX installation manual.
54. Support the CH-904 base frame on a jack.
55. Support the CH-49289 centring frame on the CH-904 base frame .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

56. Install the CH-49289 centring frame (1) according to the details provided in the SPX installation manual.



57. Remove the front frame bolts (2).
58. Remove the rear frame bolts (3).
59. Remove the frame reinforcements (4).
60. Lower the frame (4) with the engine transmission unit off the vehicle.
61. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
62. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
63. For vehicles with hydraulic power steering: Remove the power steering fluid reservoir outlet hose. Refer to Power Steering Fluid Reservoir Outlet Hose Replacement .



64. Remove the radiator outlet hose clamp (3) from the water pipe (4).



65. Remove the radiator inlet hose clamp (1) from the thermostat housing (5).
66. Install suitable cable at the 3 engine lift brackets.
67. Install a suitable engine lifting device to the cable.
68. Extend the engine lifting device until the steel cable are slightly tensioned.



69. Remove the front transmission mount through bolt (1).



70. Remove the transmission bracket mount to mount through bolt (1).
71. Put the engine transmission unit down on a wooden pallet.
72. Loosen the 8 transmission bolts and remove 7 of them. Refer to Transmission Replacement .

Note: A second technician is required.

73. Remove the last transmission bolt and the transmission.
74. Install the engine to a suitable engine stand.
75. Transfer parts as needed.

1. Remove the engine from the engine stand.
2. Put the engine down on a wooden pallet.

Note: A second technician is required.

3. Install the transmission and one transmission bolt.
4. Install the 7 transmission bolts.

Caution: Refer to Fastener Caution in the Preface section.

5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Place the engine transmission unit into the front frame.



7. Install the transmission bracket mount to mount through bolt (1) and tighten to 100 N·m(74 lb ft).



8. Install the transmission mount through bolt (1) and tighten to 58 N·m (43 lb ft).
9. Remove the cable from the 3 engine lift brackets.



10. Install the radiator inlet hose (2).
11. Install the radiator inlet hose clamp (1) to the thermostat housing (5).



12. Install the radiator outlet hose (2).
13. Install the radiator outlet hose clamp (3) to the water pipe (4).
14. For vehicles with hydraulic power steering: Install the power steering fluid reservoir outlet hose. Refer to Power Steering Fluid Reservoir Outlet Hose Replacement .
15. Install the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
16. Install the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .




Note: Positioning pins (1) of CH-49289 adaptor must be extended in order to guide into underbody holes.




17. Raise the frame (1) with the engine transmission unit to the vehicle.
18. Install the frame reinforcements (4).
19. Install front frame bolts (2). Hand tighten ONLY.
20. Install reinforcement bolts (3). Hand tighten ONLY.
21. Tighten the rear frame bolts (2) and tighten to 160 N·m (118 lb ft).
22. Tighten the front frame bolts (1) and tighten to 160 N·m (118 lb ft).



23. Lower the CH-49289 centring frame (1) with the CH-904 base frame and a jack until it is removable.
24. Remove the CH-49289 centring frame from the CH-904 base frame .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

25. Disassemble the CH-49289 centring frame (1) according to the details provided in the SPX installation manual.
26. Lower the vehicle.
27. Install the engine mount. Refer to Engine Mount Replacement .
28. Install the transmission mount - left side. Refer to Transmission Mount Replacement - Left Side .
29. Raise the vehicle.



30. Lower the CH-49290 support tool (1) with the CH-904 base frame and a jack.
31. Remove the CH-49290 support tool from the CH-904 base frame .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

32. Disassemble the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
33. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement : 2.0L Diesel LNP  → LDE, LLU, LXT, LXV, L2W, 2H0, LFH,LGE .



34. Connect the 3 wiring harness (1).
35. Clip in the wheel speed sensor wiring harness to the frame.
36. Connect the wheel speed sensor on both sides.
37. Install the front wheel shafts to the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side .
38. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
39. Install the steering linkage outer track rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Track rod Replacement .
40. Install the upper stabiliser shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
41. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
42. Check the transmission fluid level. Refer to Transmission Fluid Level Inspection .
43. Lower the vehicle.
44. Clip the Radiator outlet hose into the radiator.
45. Use a NEW system seal. Refer to Air Conditioning O-Ring Seal Replacement .
46. Install the air conditioning evaporator hose assembly nut from the air conditioning condenser and tighten to 19 N·m (14 lb ft).



47. Use a NEW system seal. Refer to Air Conditioning O-Ring Seal Replacement .
48. Install the A/C compressor and the condenser hose nut (1) to the A/C condenser (2). Tighten the nut to 19 N·m (14 lb ft).




Note: Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .

49. Use a NEW system seal. Refer to Air Conditioning O-Ring Seal Replacement .
50. Install the A/C compressor and the condenser hose nut (1) to the refrigerant hose (2). Tighten the nut to 19 N·m (14 lb ft).
51. For vehicles with hydraulic power steering: Clip in the power steering fluid reservoir.
52. For vehicles with hydraulic power steering: Install power steering fluid reservoir bolt and tighten to 9 N·m (80 lb in).
53. Remove the EN-6015 closure plugs.
54. Connect the fuel feed pipe to the multiport fuel injection fuel rail.
55. Remove the CH-807 closure plugs.
56. Connect the fuel tank vent pipe to the evaporative emission vent valve.
57. Remove the heater outlet hose from the bulkhead. Refer to Heater Outlet Hose Replacement : 2.0L Diesel LNP  → 1.8L 2H0 and LFH .
58. Connect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement : F40 and Right Hand Drive  → F40 and Left Hand Drive  → D16, D20, and Right Hand Drive  → D16, D20, and Left Hand Drive .
59. Bleed the hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding .
60. Fill the reservoir with clutch/brake fluid up to the MAX level.



61. Connect the servo unit vacuum pipe (2) to the inlet manifold (1).
62. For vehicles with right hand drive: Connect the servo unit vacuum pipe to the servo unit. Refer to Servo unit Vacuum Pipe Replacement : Right Hand Drive  → Left Hand Drive with Electric Pump  → Left Hand Drive .
63. Install the heater inlet hose to the bulkhead. Refer to Heater Inlet Hose Replacement : 2.0L Diesel LNP  → 1.8L 2H0 and LFH .
64. Install the heater outlet hose to the bulkhead. Refer to Heater Outlet Hose Replacement : 2.0L Diesel LNP → 1.8L 2H0 and LFH
65. Install the manual transmission shift lever and selector lever cable to the transmission. Refer to Manual Gearbox Gear Lever and Selector Lever Cable Replacement .
66. Clip in the radiator surge tank.
67. Fill the cooling system. Refer to Cooling System Draining and Filling .
68. Install the front tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
69. Install the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation .
70. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement : LDE, LXV, LUW, 2H0 and LFH .



71. Install the 2 wiring harness (2).
72. Install the 2 ground nuts (1) and tighten to 9 N·m (80 lb in).



73. Install the ECM wiring harness plug (1) to the lower part of the front compartment fuse block.
74. Connect the ECM wiring harness plug (2) and clip it to retainer clip (3).




Note: Ensure that the 3 wiring harness plugs (3), (5) and (6) fit clearly to the front compartment fuse block.

75. Install the front compartment fuse block (2) to the lower part (4) and loosely install the bolts (1).



76. Clip in the front compartment fuse block to the 4 retainer clips (2) and (3).
77. Tighten the 3 front compartment fuse block bolts (1) to 22 N·m (16 lb in).



78. Install the front compartment fuse block cover (1).
79. Install the battery tray. Refer to Battery Tray Replacement .



80. For vehicles with electrical power steering:

•	Install the electrical power steering positive cable and nut (1) to the fuse block (4) and tighten to 9 N·m (80 lb in).

•	Remove the electrical power steering positive negative cable (2) and nut (3) and tighten to 10 N·m (89 lb in).

81. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
82. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
83. Check the oil level and fill NEW engine oil up if necessary.
84. Close the bonnet.
85. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .