Powertrain Assembly Installation
Powertrain Assembly Installation Procedure
1. Install clutch disc and pressure plate, if applicable. The yellow dot on the pressure plate should be aligned near the mark on the flywheel. Use service tool SA9145T to align the clutch disk for the manual transaxle input shaft alignment. When installing an automatic transaxle, the yellow dot on the torque converter must be at the 6 o'clock position when the first flexplate to torque converter bolt is tightened.
Tighten
^ Tighten flexplate-to-converter to 70 Nm (52 lb ft).
^ Tighten clutch pressure plate-to-flywheel to 25 Nm (19 lb ft).
2. Carefully lift the engine using service tool SA9lOSE and install it in the cradle aligning the transaxle with the engine using two threaded 10 mm x 6 inch long guide pins in the lower attachment holes. Remove the 4 inch x 4 inch x 6 inch wood block if used, from under transaxle.
Tighten
1. Tighten the lower transaxle bolts to 130 Nm (96 lb ft).
2. Tighten the upper transaxle bolts to 90 Nm (66 lb ft).
3. Tighten the stiffening bracket-to-engine/transaxle to 54 Nm (40 lb ft).
3. Install the front engine mount assembly.
Tighten
Tighten the front mount-to-engine block to 55 Nm (41 lb ft).
Important: Install the torque strut bracket-to-cradle nuts, but do not tighten until the upper midrail mount is installed.
4. Install the engine mount torque strut-to-cradle bracket, if removed.
Tighten
Tighten the engine strut-to-cradle bracket and engine strut-to-engine bracket to 70 Nm (52 lb ft).
Important: Installation of the wood block prior to the upper engine torque axis mount installation allows the mount to be easily installed without lifting or jacking the powertrain.
5. Place a 1 in x 1 in x 2 in long block of wood between the torque strut and frame.
6. Attach the axle shaft and starter bracket.
Tighten
^ Tighten the axle shaft intermediate bracket-to-block to 55 Nm (41 lb ft).
^ Tighten the starter support bracket-to-axle shaft bracket to 30 Nm (22 lb ft).
7. Position the powertrain and frame on the support dolly. Use two 4 in x 4 in x 36 in blocks of wood to support the frame.
8. Carefully lift the powertrain into the chassis and install the four frame attachment bolts. Use two 9/16 in x 18 in long guide pins in forward frame holes next to attachment bolts for aligning frame with chassis.
Tighten
Tighten the frame-to-body to 205 Nm (151 lb ft).
9. Attach the brake lines to frame and install steering shaft U-joint and bolt.
Tighten
Tighten the steering shaft U-joint bolt to 47 Nm (35 lb ft).
10. Install the following sensors, if applicable, and position the electrical harness around the engine and attach the following connectors from under the vehicle:
^ Starter solenoid
Tighten
Tighten the starter solenoid terminal to 5 Nm (44 lb in).
^ Generator/starter battery positive terminal.
Tighten
Tighten the generator/starter battery positive terminal to 10 Nm (89 lb in).
^ Oil pressure sending unit
Tighten
Tighten the oil pressure sending unit to 45 Nm (33 lb ft).
^ Knock Sensor
Tighten
Tighten the knock sensor to 25 Nm (19 lb ft).
^ Crankshaft position sensor
Tighten
Tighten the crankshaft position sensor 9 Nm (80 lb in).
^ Canister purge solenoid-to-block
Tighten
Tighten the canister purge solenoid-to-block to 22 Nm (16 lb ft).
^ Wiring Harness (PCM Ground)
Tighten
Tighten the wiring harness--PCM ground to 10 Nm (89 lb in).
^ Wiring Harness to transaxle case/engine block
Tighten
Tighten the wiring harness-to-transaxle case/engine block to 25 Nm (18 lb ft).
^ EVO solenoid, if equipped
^ Vehicle speed sensor
^ Attach ABS wheel sensors, if equipped.
11. Install the engine stiffening bracket.
Tighten
Tighten the engine stiffening bracket to 47 Nm (35 lb ft).
Notice: Do not bend the front exhaust pipe hanger attached to the engine stiffening bracket when servicing the front exhaust pipe and/or catalytic convertor. Bending the bracket may cause premature failure.
12. Install new exhaust front pipe/catalytic convertor gaskets and front pipe.
Tighten
Tighten the exhaust pipe to manifold to 31 Nm (23 lb ft).
Tighten the exhaust pipe bracket to stiffener bracket to 47 Nm (35 lb ft).
Tighten the exhaust pipe to support bracket to 31 Nm (23 lb ft).
Tighten the exhaust pipe to catalytic converter to 48 Nm (35 lb ft).
13. Attach heater, lower radiator, and coolant fill hoses and remove radiator safety wire/tie straps.
14. Install cylinder block drain plug and close radiator drain.
Tighten
Tighten the cylinder block drain plugs to 35 Nm (26 lb ft).
15. Install knuckle attachment bolts to strut.
Tighten
Tighten the knuckle attachment bolts-to-strut to 200 Nm (148 lb ft).
16. Install brake calipers.
Tighten
Tighten the brake caliper bolt to 110 Nm (81 lb ft).
17. Install shift cables.
18. Lower the vehicle.
Important: Use new shift cable retainers whenever removed.
19. Install clutch hydraulic slave cylinder, damper and shift cables.
20. Install automatic transaxle cooler lines.
Tighten
Tighten the A/C compressor brackets-to-head/block to 25 Nm (19 lb ft).
21. Install A/C compressor assembly.
22. Install accessory drive belt. Make sure the belt is properly aligned in the pulley grooves.
Tighten
^ Tighten the A/C compressor-to-front bracket to 54 Nm (40 lb ft).
^ Tighten the compressor-to-rear bracket to 30 Nm (22 lb ft).
Notice: To prevent engine front cover and mount damage, the three front upper mount to engine front cover nuts must be tightened down uniformly.
23. Install the two engine mounts to midrail bracket nuts first. Next, install the three engine mount to front cover nuts. Remove the wood block from under the torque strut after the upper mount assembly is installed.
Tighten
^ Tighten the engine mount-to-front cover to 50 Nm (37 lb ft).
^ Tighten the engine mount-to-frame midrail bracket nuts to 50 Nm (37 lb ft).
24. Torque the two torque strut bracket-to-frame/nuts.
Tighten
Tighten the strut bracket-to-frame nuts to 50 Nm (37 lb ft).
25. Install automatic transaxle torque converter to flexplate bolts and dust cover.
Tighten
^ Tighten the flexplate-to-converter to 70 Nm (52 lb ft).
^ Tighten the transaxle dust cover to 10 Nm (89 lb in).
26. Install the tires and splash shields.
Tighten
Tighten the wheel nuts to 140 Nm (103 lb ft).
27. Attach the following electrical and vacuum connectors where applicable:
^ The engine coolant temperature (ECT) sensor
^ The oxygen sensor
^ The idle air control valve (IAC)
^ The injector connectors
^ The ignition coil - 2 connectors
^ The throttle position (TP) sensor
^ The MAP sensor
^ The EGR valve
^ The A/C compressor, if equipped
^ The brake booster hose at intake manifold or booster
^ The ground connectors, located at transaxle attachment studs and rear side of block above starter.
28. Attach the automatic transaxle connectors:
^ Neutral safety/selector switch - 3 connectors
^ PRNDL switch - 2 connectors
^ Valve body actuator connector
^ Transaxle turbine speed sensor
^ Back-up light switch, manual transaxle
^ Temperature sensor
Caution: Whenever fuel line connectors are disconnected, lubricate steel line male ends with clean engine oil. Holding the steel line, firmly press on the female coupler until a click is heard, then pull back to confirm engagement. Make sure the fuel line connects are fully seated. Pinched, kinked, or damaged fuel lines must be replaced.
29. Install the accelerator cable and attach fuel supply and return line quick connector.
30. Install the upper radiator and deaeration hoses.
Important: Check the upper cooling module grommets for binding or misalignment. The cooling module retaining pins MUST BE centered in the grommets supported by the L brackets. If the grommets are pinched, loosen the L brackets and reposition them.
Important: Tighten the L bracket fasteners and cheek the cooling module for freedom of movement. IT IS EXTREMELY IMPORTANT THAT THE COOLING MODULE BE ABLE TO MOVE FREELY.
31. Install the air induction system, PCV valve and fresh air hoses.
32. Install the battery cables, positive cable first.
Tighten
Tighten the battery terminal bolts to 17 Nm (13 lb ft).
33. Check oil pan drain plug and fill engine with new oil.
Tighten
Tighten the oil pan drain plug to 37 Nm (27 lb ft).
34. Reset "Service Oil Soon" telltale lamp.
35. Fill with coolant. Use only a non-phosphate ethylene glycol antifreeze.
Important: Vehicle must be level when filling with coolant.
36. Prime fuel system:
36.1. Cycle the ignition ON for five seconds and then OFF for 10 seconds.
36.2. Repeat step 36.1 twice.
36.3. Crank the engine until it starts, maximum starter motor cranking time is 20 seconds.
36.4. If engine does not start, repeat steps 36.1-36.3.
37. Start engine and check for leaks.
38. Perform a three mile road test.
39. Fill the cooling system surge bottle to the FULL COLD line and check for leaks after the engine has been tested.