Buick Encore: Engine replacement

Engine replacement - Removal Procedure

1. Remove the battery and battery tray. Refer to Battery Tray Replacement .
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (R-134a) .
4. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
5. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Encore) , Front Bumper Fascia Replacement (Encore) .
6. Drain the cooling system. Refer to Cooling System Draining and Filling .

Fig. 140: Intermediate Steering Shaft And Bolt

7. Remove the lower intermediate steering shaft bolt (2) and slide the shaft away from steering column.

   Refer to Intermediate Steering Shaft Replacement (NJ1) , Intermediate Steering Shaft Replacement (N40) .

Fig. 141: Air Cleaner Assembly

8. Remove the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement .

Fig. 142: Junction Block And Cover

9. Remove the junction block cover (1).

Fig. 143: Positive Battery Cable And Nut

10. Remove the positive battery cable nut (1) from the junction block.
11. Remove the positive battery cable (2) from the junction block.

Fig. 144: Body Wiring Harness Connector And Positive Cable Nut

12. Remove the positive cable nut (1) and battery positive cable from the battery positive cable junction block.
13. Disconnect the body wiring master harness connector (2) from the battery positive cable junction block.

Fig. 145: Junction Block

14. Remove the junction block nut (1).
15. Remove the junction block bolts (2).
16. Disconnect the wiring harness from the junction block base.
17. Remove the junction block (3) from the base.
18. Disconnect the wiring harness plug from the front compartment fuse block.

Fig. 146: Wiring Harness - Top Of Engine

19. Reposition the wiring harness (1) on top of the engine.

Fig. 147: Wiring Harness And Ground Nuts

20. Remove the ground nuts (1) and reposition the wiring harness (2) aside.
21. Disconnect the power vacuum brake booster vacuum sensor electrical connector, if equipped.
22. Disconnect the heater inlet hose from the heater core. Refer to Heater Inlet Hose Replacement (LUJ, LUV) .

Fig. 148: Heater Outlet Hose

23. Disconnect the heater outlet hose (1) from the heater core. Refer to Heater Outlet Hose Replacement (LUJ, LUV) , Heater Outlet Hose Replacement (LUJ, LUV Rear) .

Fig. 149: Automatic Transmission Range Selector Lever Cable Terminal And Shift Lever Pin

24. If equipped with an automatic transmission, disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin.
25. Remove the transmission range selector lever cable (2) from the cable bracket.

Fig. 150: Selector Level Cable Components

26. If equipped with manual transmission, disconnect the shift lever and selector lever cable end (1) from the transmission shift lever and selector lever.
27. Pull the cable retainers (2) to release the shift lever and selector lever cable from the shift lever and selector lever cable bracket.
28. Disconnect the shift lever and selector lever cable from the shift lever and selector lever cable bracket.

Fig. 151: Radiator Surge Tank And Mounting Bolts

29. Remove the radiator surge tank (2) and position aside. Refer to Radiator Surge Tank Replacement (LUV, 2H0, LUJ) .
30. Disconnect the fan connector.

Fig. 152: A/C Compressor And Condenser Hose

31. Remove air conditioning compressor and condenser hose nut (1).
32. Remove air conditioning compressor and condenser hose (2) from refrigerant hose.

Fig. 153: Fuel Feed Pipe And Plastic Collars

33. Disconnect the fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .

Fig. 154: Evaporative Emission Pipe

34. Disconnect the evaporative emission pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .

Fig. 155: Wheel Drive Shaft

35. Remove the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement - Left Side , and Front Wheel Drive Shaft Replacement - Right Side .
36. Remove the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .

Fig. 156: Lower Transmission Nut And Bolts

37. If equipped with an automatic transmission, remove the lower transmission nut (1) and the lower transmission bolts (2, 3, 4).

Fig. 157: Lower Transmission Bolts

38. If equipped with manual transmission, remove the lower transmission bolt (3) and nut (4).
39. Remove the lower transmission bolts (1, 2).

Fig. 158: Front Frame Bolts

40. Remove the frame front bolts (1).
41. Position the lift table under the powertrain and support with blocks of wood

Fig. 159: Frame Suspension Retaining Bolts

42. Remove the upper frame suspension retaining bolts (1) on both sides.

Fig. 160: Right Side Engine Mount

43. Remove the right side engine mount (1). Refer to Engine Mount Replacement - Right Side.

Fig. 161: Left Transmission Mount & Components

44. Remove and DISCARD the transmission mount bolts (1) - left side. Refer to Transmission Mount Replacement - Left Side .
45. Disconnect any additional electrical connections as necessary.
46. Raise the vehicle until the powertrain is clear for removal.

Fig. 162: Torque Converter To Flywheel Bolt

47. If equipped with an automatic transmission, remove the starter. Refer to Starter Replacement (LUV) .
48. Mark the relationship of the flex plate to the torque converter for reassembly.
49. Remove and DISCARD the flex plate to torque converter bolts (1).

Fig. 163: Upper Transmission To Engine Bolts

50. If equipped with an automatic transmission, remove the upper transmission to engine bolts (1) and separate the engine and transmission.

Fig. 164: Upper Transmission-To-Engine Bolts

51. If equipped with manual transmission, remove the upper transmission to engine bolts (1). And separate the engine and transmission.
52. Disconnect any electrical connectors as needed.
53. Transfer parts as necessary.

Engine replacement - Installation Procedure

1. Install the transmission to the engine.

Fig. 165: Upper Transmission-To-Engine Bolts

CAUTION: Refer to Fastener Caution .

2. If equipped with a manual transmission, install the upper transmission to engine bolts (1) to 60 (44 lb ft).

Fig. 166: Upper Transmission To Engine Bolts

3. If equipped with automatic transmission, install the upper transmission to engine bolts (1) and tighten to 60 (44 lb ft).

Fig. 167: Torque Converter To Flywheel Bolt

4. If equipped with an automatic transmission, install the torque converter to flex plate bolts (1) and tighten to 60 (44 lb ft).
5. Install the starter. Refer to Starter Replacement (LUV) .
6.  Position the powertrain under the vehicle and slowly lower the body onto the powertrain.

Fig. 168: Left Transmission Mount & Components

CAUTION: Refer to Torque-to-Yield Fastener Caution .

7. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 (37 lb ft) plus 70 degrees.

Fig. 169: Right Side Engine Mount

8. Install the right side engine mount (1). Refer to Engine Mount Replacement - Right Side.
9. Connect all previously disconnected electrical connections.

Fig. 170: Frame And Bolts

10. Install the frame (3) rear bolts (2) and front bolts (1) and tighten a little bit.
11. Install the frame (3) rear bolts (2) and tighten to 135 (100 lb ft).
12.  Install the frame (3) front bolts (1) and tighten to 58 (43 lb ft).

Fig. 171: Frame Suspension Retaining Bolts

13. Install the upper frame suspension retaining bolts (1) on both sides and tighten to 135 (100 lb ft).
14. Remove the lift table.

Fig. 172: Lower Transmission Bolts

15. If equipped with manual transmission, install the lower transmission bolts (1) and tighten to 60 (44 lb ft).
16. Install the lower transmission bolts (2) and tighten 40 (30 lb ft).
17. Install the lower transmission bolt (3) and nut (4) and tighten to 40 (30 lb ft).

Fig. 173: Lower Transmission Nut And Bolts

18. If equipped with an automatic transmission, install the lower transmission bolts (2, 4) and tighten to 60 (44 lb ft).
19. Install the lower transmission bolts (3) and the lower transmission nut (1) and tighten to 40 (30 lb ft).
20. Install the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .

Fig. 174: Wheel Drive Shaft

21. Install the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement - Left Side , and Front Wheel Drive Shaft Replacement - Right Side .

Fig. 175: Evaporative Emission Pipe

22. Connect the evaporative emission pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
23. Connect the fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service

Fig. 176: A/C Compressor And Condenser Hose

24. Install air conditioning compressor and condenser hose to the refrigerant hose.
25. Install air conditioning compressor and condenser hose nut (1) tighten nut to 22 (16 lb ft).

Fig. 177: Radiator Surge Tank And Mounting Bolts

26. Install the radiator surge tank (2). Refer to Radiator Surge Tank Replacement (LUV, 2H0, LUJ) .
27.  Connect the fan connector.

Fig. 178: Selector Level Cable Components

28. If equipped with manual transmission, Connect the shift lever and selector lever cable end (1) to the transmission shift lever and selector lever.
29. Connect the shift lever and selector lever cable to the shift lever and selector lever cable bracket.
30. Install the cable retainers (2) to the shift lever and selector lever cable bracket

Fig. 179: Automatic Transmission Range Selector Lever Cable Terminal And Shift Lever Pin

31. If equipped with automatic transmission, install the transmission range selector lever cable (2) to the cable bracket.
32.  Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin.
33. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment .
34. Connect the heater inlet hose from the heater core. Refer to Heater Inlet Hose Replacement (LUJ, LUV) .

Fig. 180: Heater Outlet Hose

35. Connect the heater outlet hose (2) from the heater core. Refer to Heater Outlet Hose Replacement (LUJ, LUV) , Heater Outlet Hose Replacement (LUJ, LUV Rear) .

Fig. 181: Wiring Harness And Ground Nuts

36. Install the ground nuts (1) and wiring harness (2).

Fig. 182: Wiring Harness - Top Of Engine

37. Clip in the wiring harness plugs (1).

Fig. 183: Junction Block

38. Install the junction block to the base (3).
39. Install the junction block bolts (2) and tighten to 5 (44 lb in).
40. Install the junction block nut (1) and tighten to 5 (44 lb in).

Fig. 184: Body Wiring Harness Connector And Positive Cable Nut

41. Install the battery positive cable to the battery positive cable junction block and tighten nut (1) to 5 (44 lb in).
42. Connect the body wiring master harness connector (2), to the battery positive cable junction block.

Fig. 185: Positive Battery Cable And Nut

43. Position the positive battery cable (2) to the junction block.
44. Install the positive battery cable nut (1) and tighten to 7 (62 lb in).

Fig. 186: Junction Block And Cover

45. Install the junction block cover (1).

Fig. 187: Air Cleaner Assembly

46. Install the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement .

Fig. 188: Intermediate Steering Shaft And Bolt

47. Install the lower intermediate steering shaft bolt (1). Refer to Intermediate Steering Shaft Replacement (NJ1) , Intermediate Steering Shaft Replacement (N40) .
48. Install the battery and battery tray. Refer Battery Tray Replacement .
49. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
50. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Encore) , Front Bumper Fascia Replacement (Encore) .
51. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (R-134a) .
52. Fill the cooling system. Refer to Cooling System Draining and Filling .

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