Engine - Installation

Engine









All vehicles

1. 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 bolt and the stud bolt.
- Tighten to 27 Nm (20 lb-ft).





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 (106 lb-in).

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





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





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





13. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
- Tighten the 3 nuts to 63 Nm (46 lb-ft).

- Tighten the bolt to 80 Nm (59 lb-ft).





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





All-Wheel Drive (AWD) vehicles

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





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





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 lb-ft).

- Tighten the 2 catalytic converter-to-bracket bolts to 20 Nm (177 lb-in).





19. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.





All vehicles

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





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





22. Install the 2 middle subframe nuts.
- Tighten to 133 Nm (98 lb-ft).





23. Install the 2 front subframe nuts.
- Tighten to 133 Nm (98 lb-ft).





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





25. Install the 2 rear subframe bracket nuts.
- Tighten to 133 Nm (98 lb-ft).





26. Tighten the 4 subframe support bracket bolts.
- Tighten to 90 Nm (66 lb-ft).





27. Position the lower bumper on the subframe and install the 3 LH nuts.
- Tighten to 9 Nm (80 lb-in).





28. Install the 3 RH lower bumper-to-subframe nuts.
- Tighten to 9 Nm (80 lb-in).





29. NOTE: RH shown, LH similar.

Install the tie-rod ends and nuts.

- Tighten to 48 Nm (35 lb-ft).

- Install new cotter pins.





30. NOTICE: 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 23 Nm (17 lb-ft).





31. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube.
- Tighten to 48 Nm (35 lb-ft).





32. Install the engine roll restrictor-to-subframe through bolt.
- Tighten to 103 Nm (76 lb-ft).





33. Install the roll restrictor heat shield and the 2 nuts.
- Tighten to 9 Nm (80 lb-in).





AWD vehicles

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





All vehicles

35. Install the power steering cooler bracket bolt to the RH side of the subframe.
- Tighten to 9 Nm (80 lb-in).





36. Connect the power steering cooler hose.





37. 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.





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





39. Install the inspection cover and the 2 fasteners.





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





41. Connect the 2 transmission fluid cooler tubes.





42. Install the 2 secondary latches onto the transmission fluid cooler tubes.





43. Install the LH inner splash shield.

44. Install the radiator splash shield, the 3 pin-type retainers and the 7 screws.





45. Using a new gasket, install the Y-pipe and exhaust flexible pipe assembly and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).





46. Install the 2 exhaust hangers and tighten the exhaust clamp.
- Tighten to 40 Nm (30 lb-ft).





47. Install the ground wire, the radio interference capacitor wire and the nut to the engine front cover stud.
- Tighten to 10 Nm (89 lb-in).





48. Install the ground wire and bolt to the engine front cover.
- Tighten to 10 Nm (89 lb-in).





49. Attach the wiring harness retainer to the RH valve cover stud bolt.





50. Install the oil level indicator.





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





52. Connect the fuel hose routing clip to the transaxle stud.





53. Connect the fuel supply tube.





54. Connect the hose to the power steering reservoir.





55. Connect the A/C suction tube fitting.
- Install the safety clip onto the A/C fitting.





56. Using a new O-ring seal, connect the A/C tube fitting and install the nut.
- Tighten to 8 Nm (71 lb-in).





57. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.





58. Connect the transaxle control electrical connector.





59. Attach the control cable to the bracket.
- Connect the transaxle control cable to the control lever.





60. Attach the wiring harness retainer to the transaxle control cable bracket.





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





62. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve.





63. Connect the vacuum hose to the upper intake manifold.





64. Install the ground wire and the bolt.
- Tighten to 10 Nm (89 lb-in).

- Attach the 2 wiring harness retainers to the cowl.





65. Connect the power feed to the battery terminal and install the nut.
- Tighten to 8 Nm (71 lb-in).





66. Connect the battery harness electrical connector.





67. Install the battery tray.

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

69. Install the degas bottle.

70. Install the LH halfshaft and intermediate shaft.

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

72. Fill the engine with clean engine oil.

73. Fill and bleed the cooling system.

74. Fill the power steering system.

75. Recharge the air conditioning system.