Installation Procedure

Engine Replacement

Installation Procedure




1. Remove the engine from the engine stand.
2. Install the flywheel.
3. Install and mate the engine to the transaxle/frame.

Notice: Refer to Fastener Notice.

4. Install the transaxle to engine bolt/stud.

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




5. Install the transaxle to engine bolts/stud.

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

6. Remove the support from the transaxle.




7. Remove the engine hoist from the engine.
8. Install the exhaust crossover pipe.
9. Install the transaxle brace, if equipped with RPO M76.
10. Install the transaxle brace bolts.

Tighten the bolts to 43 N.m (32 lb ft).




11. Install the transaxle brace, if equipped with RPO M15.
12. Install the transaxle brace bolts.

Tighten the bolts to 43 N.m (32 lb ft).




13. Install the engine mount lower nuts.

Tighten the nuts to 47 N.m (35 lb ft).

14. Install the torque converter bolts.




15. Install the transaxle covers.
16. Install the transaxle cover bolts.

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




17. Install the starter motor.
18. Lower the vehicle in order to join the powertrain/frame assembly to the vehicle.
19. Install the frame bolts.




20. Remove the J 39580 from below the vehicle.
21. Raise and suitably support the vehicle.
22. Install the front part of the inner fender liner.
23. Install the intermediate shaft pinch bolt to the steering gear.
24. Connect the drive axles to the transaxle.
25. Position the A/C compressor and install the A/C compressor bolts.

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

26. Connect the transaxle oil cooler line quick connect fittings at the transaxle.
27. Install the transaxle oil cooler line bracket bolt.

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




28. Install the lower ball joints to the knuckles.
29. Install the tie rod ends to the steering knuckles.
30. Install the stabilizer shaft links to the lower control arms.
31. Install the engine splash shields.
32. Install the lower radiator air baffle assembly.
33. Install the front tires and wheels.
34. Install the catalytic converter.
35. Lower the vehicle.
36. Install the engine mount struts.
37. Gather all branches of the engine harness and position the harness onto the engine.
38. Connect the engine harness electrical connectors (2, 4) to the instrument panel electrical connectors (3, 5).
39. Install the drive belt.




40. Raise and support the vehicle.
41. Connect the following electrical connectors:

* The knock sensor (1)
* The CKP sensor (2)




42. Connect the engine harness electrical connector (1) to the HO2S.
43. Install the CPA retainer (2).
44. Install the engine harness clips to the heat shield and underbody.




45. Connect the engine harness electrical connector to the left wheel speed sensor.
46. Install the engine harness clips to the lower control arm.




47. Connect the engine harness electrical connector to the right wheel speed sensor.
48. Install the engine harness clips to the lower control arm.




49. Connect the engine harness electrical connector (1) to the A/C compressor.




50. Connect the engine harness electrical connector to the A/C pressure sensor (1).




51. Position the engine harness and the negative battery cable.
52. Install the engine harness bolt.

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

53. Install the engine harness ground wires (1, 5) to the transaxle studs.
54. Install the negative battery cable lead (4) to the stud.
55. Install the engine harness nut (2, 3).

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




56. Install the engine harness clip (1) to the oil pan.




57. Install the engine harness lead (2) to the starter.
58. Install the starter solenoid "S" terminal nut (3).

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

59. Install the engine harness clip (1) to the oil level indicator tube.




60. Connect the following engine harness electrical connectors:

* The oil pressure switch (1)
* The knock sensor (2)




61. Lower the vehicle.
62. Connect the engine harness electrical connector (1) to the transaxle.
63. Install the engine harness clip (2) to the transaxle stud.




64. Connect the VSS electrical connector (2).
65. Install the engine harness clip (1) to the transaxle brace.




66. Connect the engine harness electrical connector to the HO2S.
67. Install the CPA retainer.
68. Install the HO2S electrical connector clip to the ignition coil bracket.




69. Connect the engine harness electrical connector to the generator.




70. Install the engine harness clip (1) to the bracket attached to the engine mount strut.




71. Connect the engine harness electrical connector (1) to the ignition coil.




72. Install the engine harness clip (1) to the ignition coil bracket.




73. Connect the engine harness electrical connector (2) to the fuel injector electrical connector (1).
74. Install the engine harness electrical connector clip to the belt shield.




75. Install the engine harness clips to the intake manifold.




76. Connect the following electrical connectors:

* The EGR valve
* The EVAP canister purge solenoid

77. Install the engine harness clip (1) to the PCV foul air tube clip.




78. Connect the engine harness to the TAC.




79. Install the selector cable to the bracket.
80. Connect the automatic transaxle range selector cable to the selector lever.




81. Install the brake booster vacuum hose to the intake manifold.
82. Connect the fuel and EVAP line quick connect fittings at the engine.




83. Connect the heater inlet and outlet hoses to the engine.




84. Install the radiator outlet hose to the engine.
85. Position the radiator inlet hose clamp at the engine.




86. Install the radiator inlet hose to the engine.
87. Position the radiator inlet hose clamp at the engine.
88. Fill the cooling system.
89. Install the air cleaner assembly.
90. Fill the engine with oil.
91. Install the intake manifold cover.
92. Connect the negative battery cable.
93. Perform the CKP system variation learn procedure.
94. Start the vehicle and allow the engine to run.
95. Inspect for leaks.
96. Road test the vehicle.