Installation Procedure

Engine Replacement

Installation Procedure




1. Using a engine hoist, remove the engine from the engine stand.
2. Install the following components:
^ The engine mount bracket
^ The engine block heater
^ The generator
3. If equipped with a manual transaxle, install the clutch pressure plate and disc.
4. Install the engine to the transaxle.

Notice: Refer to Fastener Notice.

5. If equipped with a automatic transaxle, install the transaxle to engine bolts/stud.

Tighten the bolts/stud to 75 N.m (55 lb ft).




6. If equipped with a manual transaxle, install the transaxle to engine bolts/stud.

Tighten the bolts/stud to 75 N.m (55 lb ft).




7. Install the transaxle brace and bolts.

Tighten the bolts to 50 N.m (37 lb ft).




8. If equipped with a automatic transaxle, install the torque converter bolts.

Tighten the bolts to 62 N.m (46 lb ft).




9. If equipped with a automatic transaxle, install the torque converter housing access plug.




10. Install the starter and bolts.

Tighten the bolts to 40 N.m (30 lb ft).




11. Remove the engine lift hoist from the engine lift hooks.
12. Slide the lift table under the vehicle.
13. Slowly lower the vehicle until it aligns with the alignment marks made during the removal.
14. Tighten/install the frame bolts.

Tighten the bolts to 100 N.m (74 lb ft) plus and additional 180 degrees.

15. Raise the vehicle until the lift table can be removed from under the vehicle.
16. Remove the lift table.




17. Install the transaxle fluid cooler lines to the transaxle.
18. Install the transaxle fluid cooler bracket nut.

Tighten the nut to 7 N.m (62 lb in).




19. Connect the lower control arms to the steering knuckles.
20. Connect the intermediate shaft to the steering gear.
21. Connect the outer tie rod ends to the steering knuckles.
22. Connect the stabilizer links to the stabilizer bar.
23. Lower the vehicle.
24. Install the transaxle mount to transaxle bolts.

Tighten the bolts to 45 N.m (33 lb ft).




25. Install the engine mount.
26. Remove the blocks of wood from between the powertrain and the frame.
27. Install the catalytic converter.
28. Lower the vehicle.

Important: Ensure that the black cable is installed in the top notch of the transaxle bracket and the white cable in installed in the bottom notch of the transaxle bracket.

29. If equipped with a manual transaxle, install the range selector and shift lever cables to the transaxle bracket.
30. Connect the range selector and shift lever cables to the transaxle levers.




31. If equipped with a automatic transaxle, install the range selector lever cable to the transaxle bracket.
32. Connect the range selector lever cable to the transaxle lever.




33. Gather all engine harness branches and position the harness over the engine.
34. If equipped with a manual transaxle perform the following steps, install the HO2S clips to the engine brackets.
35. Connect the engine harness electrical connectors (1, 5) to the HO2S.
36. Install the HO2S CPA retainers (2, 4).
37. Connect the engine harness electrical connector (7) to the back up lamp switch.
38. Connect the engine harness electrical connector (1) to the VSS.




39. If equipped with a automatic transaxle perform the following steps, connect the engine harness electrical connector (1) to the park neutral position switch.
40. Install the engine harness clips to the thermostat housing and engine brackets.
41. Connect the engine harness electrical connectors (2, 4) to the HO2S.
42. Install the HO2S CPA retainers.
43. Connect the ECT sensor electrical connector (1).




44. If equipped with a automatic transaxle, connect the engine harness to the transaxle.




45. Install the engine harness lead terminal (1) to the generator.
46. Install the generator nut (2).

Tighten the nut to 20 N.m (27 lb ft).

47. Position the engine harness boot (3).
48. Raise the vehicle.




49. Install the engine harness lead terminal (1) to the starter solenoid.
50. Install the engine harness to starter solenoid "S" terminal nut (2).

Tighten the nut to 3 N.m (27 lb in).

51. Install the positive battery cable terminal (3) to the starter.
52. Install the positive/negative battery cable lead nut (4) to the starter solenoid.

Tighten the nut to 17 N.m (13 lb ft).




53. Install the engine harness clip (3) to the speed sensor.
54. Connect the engine harness electrical connector (2) to the VSS.
55. Install the engine harness clip (1) to the stud.
56. Install the engine harness clip nut (3) to the engine stud.

Tighten the nut to 50 N.m (37 lb ft).




57. Lower the vehicle.
58. Reposition and install the A/C compressor.

Tighten the bolts to 50 N.m (37 lb ft).

59. Connect the engine harness electrical connector (2) to the A/C compressor.
60. Connect the engine harness electrical connector (1) to the A/C pressure switch.




61. Position the engine harness ground terminal to the engine block.
62. Install the engine harness ground bolt.

Tighten the bolt to 25 N.m (18 lb ft).




63. Connect the EVAP purge solenoid electrical connector (2).
64. Install the engine harness clip (1) to the EVAP purge solenoid bracket.




65. Connect the following electrical connectors:
^ Knock sensor (5)
^ CKP sensor (6)
^ Oil pressure sensor (4)




66. Position the engine harness ground terminals (5).
67. Install the stud (1).

Tighten the stud to 25 N.m (18 lb ft).

68. Install the negative battery cable ground terminal (1) to the stud.
69. Install the engine harness ground terminal (3) to the stud.
70. Install the negative battery cable ground nut (4).

Tighten the nut to 10 N.m (89 lb in).




71. Install the engine harness clip (1) to the camshaft cover.




72. Connect the intake (3) and exhaust (2) camshaft position actuator electrical connectors.
73. Connect the ignition coils electrical connectors (1).




74. Connect the engine harness clips (1, 3, 4) to the intake manifold.
75. Connect the engine harness clip (2) to the oil level indicator tube.




76. Connect the following electrical connectors:
^ TAC (1)
^ MAP sensor
^ Fuel injector harness (2)
^ Generator (3)




77. Install the brake booster vacuum hose (2) to the intake manifold.
78. Position the brake booster vacuum hose clamp at the intake manifold.




79. Install the heater inlet and outlet hoses (1, 2) to the thermostat housing.
80. Position the heater inlet and outlet hose clamps at the thermostat housing.




81. If the vehicle is not equipped with a engine oil cooler perform the following steps, otherwise proceed to step 86.
82. Install the surge tank outlet hose to the surge tank.
83. Position the surge tank outlet hose clamp at the surge tank.




84. Install the radiator outlet hose to the thermostat cover.
85. Position the radiator outlet hose clamp (1) at the thermostat cover. Proceed to step 90.




86. If the vehicle is equipped with a engine oil cooler perform the following steps, install the radiator outlet hose to the oil cooler.
87. Install the radiator outlet hose to the water outlet.
88. Position the radiator outlet hose clamp (2) at the oil cooler.
89. Position the radiator outlet hose clamp (1) at the water outlet.




90. Install the radiator inlet hose to the engine.
91. Position the radiator inlet hose clamp at the engine.




92. Connect the cooling fan electrical connector.




93. Install the engine drive belt.
94. Unsecure the cooling module from the upper body structure.
95. Fill the cooling system.
96. Check and fill the transaxle fluid as needed.




97. Connect the EVAP line quick connect fitting (3) to the EVAP purge solenoid.
98. Connect the fuel feed line quick connect fitting (4) to the fuel rail.
99. Install the fuel line clips (1, 2) to the engine brackets.
100. Fill the engine with oil.
101. Connect the negative battery cable.
102. Close the hood.
103. Road test the vehicle.