Part 2

Engine Replacement - continued

Installation Procedure




1. Remove the engine from the engine stand.
2. Install the flywheel.
3. Install NEW flywheel bolts until snug.
4. Install the J 37096 and ratchet to the flywheel to hold the flywheel.

Notice: Refer to Fastener Notice.

5. Tighten the flywheel bolts.

Tighten the bolts to 15 N.m (11 lb ft) plus an additional 50 degrees using J 45059.




6. Install the J 37096 to a ratchet.
7. Install the J 37096 and ratchet to the flywheel to hold the flywheel.




8. With the aid of an assistant, install the engine to the vehicle.
9. Install the upper transaxle bolts.

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

10. Remove the engine lifting device from the lift brackets.




11. Unsecure and position the A/C compressor to the engine.
12. Install the A/C compressor bolts and nut.

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




13. Install the heater inlet (4) and outlet (2) adapters to the drive belt tensioner. (heater hoses shown removed for clarity).
14. Install the heater inlet and outlet hose adapter bolts (1, 3).

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




15. Install the radiator outlet hose to the front cover.
16. Using J 38185 position the radiator outlet hose clamp at the front cover.




17. Install the radiator inlet hose to the thermostat housing.
18. Using J 38185 position the radiator inlet hose clamp at the thermostat housing.




19. Position the engine wiring harness over the engine.
20. Connect the engine harness electrical connector (3) to the MAP sensor.
21. Connect the engine harness electrical connector (1) to the ignition control module harness electrical connector (2).




22. Install the engine harness retainers (2) to the fuel rail.
23. Connect the engine harness electrical connectors (1) to the front fuel injectors.




24. Connect the engine harness electrical connector (2) to the EGR valve.
25. Connect the engine harness clips (1, 3) to the heat shield.




26. Connect the engine harness electrical connector (2) to the ECT sensor.
27. Connect the engine harness electrical connector (1) to the throttle actuator.




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




29. Connect the engine harness electrical connector to the rear HO2S.




30. Install the engine harness electrical connector retainers (2) to the fuel rail.
31. Connect the engine harness electrical connectors (1) to the rear fuel injectors.




32. Position the power steering pump and install the power steering pump bolts. (pulley shown removed for clarity).

Tighten the bolts to 34 N.m (25 lb ft).





33. Install the brake booster vacuum hose to the intake manifold.
34. Install the fan shroud.
35. Install the engine mount strut.





36. Install the water pump pulley and bolts until snug.
37. Install the drive belt.
38. Tighten the water pump pulley bolts.

Tighten the bolts to 13 N.m (115 lb in).




39. Connect the EVAP line (2) quick connect fitting to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
40. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.




41. Install the starter cable to the generator.
42. Install the generator terminal nut.

Tighten the nut to 20 N.m (15 lb ft).

43. Position the starter cable boot.
44. Install the air cleaner assembly.




45. Raise the vehicle.
46. Install the lower front transaxle bolt.

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




47. Install the lower rear transaxle bolt.

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




48. Position the oil filter adapter gasket and adapter.
49. Install the oil filter adapter bolts.

Tighten the bolts to 50 N.m (37 lb ft) plus an additional 3 degrees using J 45059.

50. Install the right wheel drive shaft.




51. Install the starter cable terminal (4) to the starter.
52. Install the starter "BAT" terminal nut (3).

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

53. Position the starter cable terminal (2) to the engine and install the starter cable ground bolt (5).

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




54. Connect the engine harness electrical connector (7) to the A/C compressor.
55. Connect the engine harness electrical connector (5) to the A/C pressure sensor.
56. Install the engine harness (3) terminal to the starter.
57. Install the starter solenoid "S" terminal nut (4).

Tighten the nut to 2.3 N.m (20.5 lb in).

58. Connect the engine harness electrical connector (2) to the oil level sensor.
59. Connect the engine harness electrical connector (1) to the front knock sensor.




60. Connect the engine harness electrical connector to the rear knock sensor jumper harness.
61. Install the engine harness clip (4) to the steering gear bracket.
62. Install the engine harness clip (1) to the engine bracket.
63. Connect the engine harness electrical connector (3) to the VSS.
64. Connect the engine harness electrical connector (2) to the oil pressure sensor.




65. Install the exhaust manifold to catalytic converter nuts.

Tighten the nut to 30 N.m (22 lb ft).




66. Install the rear engine mount to frame nut.

Tighten the nut to 80 N.m (59 lb ft).




67. Install the front engine mount to frame nut.

Tighten the nut to 80 N.m (59 lb ft).




68. Position the transaxle brace to the engine and install the bolts to the engine and oil pan.

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




69. Install the transaxle brace to transaxle bolts (1).

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




70. Position the transaxle brace and install the brace to oil pan bolts.

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




71. Install the transaxle brace to transaxle bolts.

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




72. Align the mark on the torque converter to the mark on the flywheel.
73. Install the torque converter bolts. (engine shown removed for clarity).

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

74. Install the starter motor.




75. Position the rear transaxle converter cover (4).
76. Install the rear transaxle converter cover bolts (3).

Tighten the bolts to 7.5 N.m (66 lb in).

77. Position the front transaxle converter cover (2).
78. Install the front transaxle converter cover bolt (1).

Tighten the bolt to 7.5 N.m (66 lb in).




79. Lower the vehicle.
80. Remove the oil fill tube from the valve rocker cover.
81. Insert the tab on the rear of the intake manifold cover through the engine bracket.
82. Align the hole in the intake manifold cover with the oil fill tube hole in the valve rocker cover.
83. Insert the oil fill tube into the valve rocker cover and twist clockwise in order to lock the detent on the tube into the notch in the cover.
84. Install the hood.
85. Connect the negative battery cable.
86. Fill the crankcase with oil. Refer to Engine Oil and Oil Filter Replacement.
87. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac-N-Fill).
88. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
89. Start the vehicle and inspect for leaks.