Part 1

Engine

Special Tool(s):

Material:

Installation (Steps 1-42)

All vehicles
1. Align the transaxle to the engine.
2. Install the 5 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 ft. lbs).





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





4. Using the special tools, position the engine and transaxle onto the lift table.





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

Install the special tools.





6. Install the starter, the bolt and the stud bolt.
^ Tighten to 26 Nm (19 ft. lbs).





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





8. Attach the starter motor wire terminals and install the 2 nuts.
1 Tighten to 12 Nm (9 ft. lbs).
2 Tighten to 6 Nm (53 inch lbs).
- Position the starter terminal boot over the starter terminal.





9. Raise the engine and transaxle assembly into the vehicle.
10. Install the engine mount and the 3 bolts.
^ Tighten to 90 Nm (66 ft. lbs).





11. Install the 4 engine mount nuts.
^ Tighten to 63 Nm (46 ft. lbs).





12. Install the engine mount brace, the nut and the bolt.
^ Tighten to 20 Nm (15 ft. lbs).





13. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
^ Tighten the nuts to 63 Nm (46 ft. lbs).
^ Tighten the bolt to 70 Nm (52 ft. lbs).





14. Install the transaxle support insulator through bolt and nut.
^ Tighten to 175 Nm (129 ft. lbs).





All wheel drive (AWD) vehicles
15. Position the power transfer unit (PTU) in place and install the 5 bolts.
^ Tighten to 90 Nm (66 ft. lbs).





16. Position the PTU support bracket in place and install the 5 bolts.
^ Tighten to 70 Nm (52 ft. lbs).





17. NOTE: Do not tighten the 4 catalytic converter nuts at this time.

Using a new gasket, install the RH catalytic converter and 4 new nuts.





18. Install the 2 catalytic converter-to-bracket bolts.
^ Tighten the 4 catalytic converter nuts to 40 Nm (30 ft. lbs).
^ Tighten the 2 catalytic converter-to-bracket bolts to 20 Nm (15 ft. lbs).





19. Connect the RH catalyst monitor electrical connector.





20. CAUTION: A new powertrain transfer unit (PTU) seal must be installed whenever the intermediate shaft is removed.

Install a new PTU seal.

21. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.

Position the RH halfshaft/intermediate shaft assembly in the PTU and in the steering knuckle and install the 2 bolts.
^ Tighten to 23 Nm (17 ft. lbs).





Front wheel drive (FWD) vehicles

22. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new if necessary.

Position the RH halfshaft/intermediate shaft assembly in the transaxle and in the steering knuckle and install the 2 stud bolts.
^ Tighten to 55 Nm (41 ft. lbs).





23. NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.

Install the converter support bracket and the 2 bolts.





24. Install the catalytic converter bracket bolt and the nut.
1 Tighten the nut to 35 Nm (26 ft. lbs).
2 Tighten the bolt to 48 Nm (35 ft. lbs).





25. Tighten the 2 RH catalytic converter support bracket bolts to 20 Nm (15 ft. lbs).





All vehicles

26. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.

Install the LH halfshaft into the transaxle.





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





28. Using the special tool, raise the subframe into the installed position.





29. Install the 2 middle subframe nuts.
^ Tighten to 150 Nm (111 ft. lbs).





30. Install the 2 front subframe nuts.
^ Tighten to 150 Nm (111 ft. lbs).





31. Position the subframe support brackets in place and loosely install the 4 bolts.





32. Install the 2 rear subframe bracket nuts.
^ Tighten to 150 Nm (111 ft. lbs).





33. Tighten the 4 subframe support bracket bolts.
^ Tighten to 103 Nm (76 ft. lbs).





34. Position the lower bumper on the subframe and install the 3 LH nuts.
^ Tighten to 10 Nm (89 inch lbs).





35. Install the 3 RH lower bumper-to-subframe nuts.
^ Tighten to 10 Nm (89 inch lbs).





36. NOTE: RH side shown, LH side similar.

Install the ball joints in the steering knuckles and install the pinch bolts.
^ Tighten to 63 Nm (46 ft. lbs).





37. NOTE: RH side shown, LH side similar.

Position the stabilizer bar links in the lower control arms and install the nuts.
^ Tighten to 55 Nm (41 ft. lbs).





38. NOTE: RH shown, LH similar.

Install the tie-rod ends and nuts.
^ Tighten to 48 Nm (35 ft. lbs).
^ Install new cotter pins.





39. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can 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.

Install the intermediate shaft onto the steering gear and install a new bolt.
^ Tighten to 25 Nm (18 ft. lbs).





40. Using a new banjo bolt and 2 new seals, install the power steering pressure (PSP) tube.
^ Tighten to 35 Nm (26 ft. lbs).





41. Install the engine roll restrictor-to-subframe through bolt.
^ Tighten to 103 Nm (76 ft. lbs).





42. Install the roll restrictor heat shield and the 2 nuts.
^ Tighten to 11 Nm (8 ft. lbs).