Engine - Installation

Engine









All vehicles

1. Using the Heavy Duty Floor Crane and Spreader Bar, align the transaxle to the engine.





2. Install the 5 transaxle-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





3. Install the 2 engine-to-transaxle bolts.
- Tighten to 48 Nm (35 lb-ft).





4. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the lift table.





5. NOTE: Position a block of wood under the transaxle.

Install the Powertrain Lift and Universal Adapter Brackets.





6. Install the starter, the stud bolt and bolt.
- Tighten to 27 Nm (20 lb-ft).





7. Connect the wiring harness retainer to the starter motor stud bolt.





8. Attach the starter wire terminals and install the 2 nuts.

1. Tighten to 12 Nm (106 lb-in).

2. Tighten to 5 Nm (44 lb-in).





9. Install the starter motor solenoid cover.





10. Raise the engine and transaxle assembly into the vehicle.

11. Install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).





12. Install the 4 engine mount nuts.
- Tighten to 63 Nm (46 lb-ft).





13. Install the engine mount brace, nut and bolt.
- Tighten to 20 Nm (177 lb-in).





14. Install the transaxle support insulator bracket, 3 nuts and the bolt.
- Tighten to 80 Nm (59 lb-ft).





15. Install the transaxle support insulator through bolt and nut.
- Tighten to 175 Nm (129 lb-ft).





All-Wheel Drive (AWD) vehicles

16. Position the Power Transfer Unit (PTU) in place and install the 5 bolts.
- Tighten to 90 Nm (66 lb-ft).





17. Position the PTU support bracket in place and install the 5 bolts.
- Tighten to 70 Nm (52 lb-ft).





18. Using a new gasket, install the RH catalytic converter and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).





19. Connect the RH catalyst monitor electrical connector.





All vehicles

20. Install the RH halfshaft support bracket and the 4 bolts.
- Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft).

- Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (177 lb-in).





21. Install the 2 halfshaft support bracket studs.
- Tighten to 10 Nm (89 lb-in).





22. Install the 4 oil pan-to-transaxle bolts.
- Tighten to 48 Nm (35 lb-ft).





23. Install 3 new torque converter bolts.
- Tighten to 55 Nm (41 lb-ft).





24. Install the inspection cover and the 2 fasteners.





25. Connect the transaxle cooling tubes and install the 2 secondary latches.





26. If equipped, connect the oil cooler coolant hoses.





27. Using the Powertrain Lift, raise the subframe into the installed position.





28. NOTE: RH shown, LH similar.

Install the 2 front subframe bolts.

- Tighten to 150 Nm (111 lb-ft).





29. NOTE: RH shown, LH similar.

Position the subframe brackets and install the 4 bolts finger-tight.





30. NOTE: RH shown, LH similar.

Install the 2 rear subframe bolts.

- Tighten to 150 Nm (111 lb-ft).





31. NOTE: RH shown, LH similar.

Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).





32. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nuts.

NOTE: RH shown, LH similar.

Install new tie-rod end nuts.

- Tighten to 115 Nm (85 lb-ft).





33. NOTE: RH shown, LH similar.

Install new upper stabilizer bar link nuts.

- Tighten to 55 Nm (41 lb-ft).





34. Install the 2 engine roll restrictor-to-transaxle bolts.
- Tighten to 103 Nm (76 lb-ft).





35. Using a new O-ring seal, install the PSP tube onto the steering gear, rotate the clamp plate and install the bolt.
- Tighten to 25 Nm (18 lb-ft).





36. Install the PSP tube bracket-to-steering gear bolt.
- Tighten to 10 Nm (89 lb-in).





37. If equipped, attach the oil cooler hose support clip to the subframe.

38. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

Install a new engine oil filter.

- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.





AWD vehicles

39. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the new 4 bolts.
- Tighten to 70 Nm (52 lb-ft).





All vehicles

40. Using a new gasket, install the Y-pipe and install the 2 new nuts.
- Tighten to 40 Nm (30 lb-ft).

- Attach the exhaust hanger.





41. Install the Y-pipe assembly and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).





42. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems.

NOTE: Align the index marks made during removal.

Install the steering intermediate shaft onto the steering gear and install a new bolt.
- Tighten to 23 Nm (17 lb-ft).





43. Connect the transaxle control electrical connector.





44. Attach the transaxle control wire harness retainer to the cooler tube.





45. Connect the hose to the power steering reservoir.





46. Install the oil level indicator.





47. Install the ground cable and bolt.
- Tighten to 12 Nm (106 lb-in).





48. Attach the wire to the RH valve cover stud bolt.





49. Attach the wiring harness retainer to the engine mount bracket stud bolt.





50. Connect the 2 engine wiring harness electrical connectors.
- Attach the electrical connector to the LH valve cover.





51. Connect the fuel supply tube to the fuel rail.





52. Using a new O-ring seal, install the A/C tube and the bolt.
- Tighten to 15 Nm (133 lb-in).





53. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
- Tighten to 15 Nm (133 lb-in).





54. Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector.
- Tighten to 15 Nm (133 lb-in).





55. If equipped, attach the engine block heater harness to the radiator support and the power steering tube.

56. Connect the transaxle control cable to the shift cable bracket and attach the wiring harness pin-type retainer.





57. Connect the transaxle control cable to the control lever.





58. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.





59. Connect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.





60. Attach the EVAP tube pin-type retainer to the upper intake manifold.





61. Connect the ground cable to the negative battery terminal and install the nut.
- Tighten to 6 Nm (53 lb-in).





62. Connect the power feed wire to the positive battery terminal and install the nut.
- Tighten to 6 Nm (53 lb-in).





63. Connect the engine wiring harness electrical connector.





64. Install the battery tray assembly and the nut and bolt.
- Tighten to 9 Nm (80 lb-in).





65. Install the 2 lower battery tray bracket bolts.
- Tighten to 9 Nm (80 lb-in).





66. Attach the 2 pin-type wiring harness fasteners to the front of the battery tray.





67. Attach the 4 pin-type wiring harness fasteners to the side of the battery tray.





68. Install the battery.

69. Install the engine Air Cleaner (ACL) and ACL outlet pipe.

70. Install the degas bottle.

71. Connect the power steering cooler tube.





72. Install the LH halfshaft and the RH halfshaft.

73. Install the accessory drive belt and the power steering belt.

74. Fill the engine with clean engine oil.

75. Fill and bleed the cooling system.

76. Fill the power steering system.

77. Recharge the A/C system.