Part 2

Engine Replacement

Tools Required
* J 38185 Hose Clamp Pliers
* J 37096 Flywheel Holding Tool
* J 45059 Angle Meter

Installation Procedure - Part 2




51. 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).




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

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




56. Connect the engine harness electrical connector to the rear knock sensor jumper harness.
57. Install the engine harness clip (4) to the steering gear bracket.
58. Install the engine harness clip (1) to the engine bracket.
59. Connect the engine harness electrical connector (3) to the VSS.
60. Connect the engine harness electrical connector (2) to the oil pressure sensor.




61. Install the exhaust manifold to catalytic converter nuts.

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




62. Install the rear engine mount to frame nut.

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




63. Install the front engine mount to frame nut.

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




64. 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).




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

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




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

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

68. Install the starter motor. Refer to Starter Motor Replacement (RPO L26/3.8L) (Service and Repair).




69. Position the rear transaxle converter cover (4).
70. Install the rear transaxle converter cover bolts (3).

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

71. Position the front transaxle converter cover (2).
72. Install the front transaxle converter cover bolt (1).

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




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

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




74. Install the transaxle brace to transaxle bolts.

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




75. Lower the vehicle.
76. Remove the oil fill tube from the valve rocker cover.
77. Insert the tab on the rear of the intake manifold cover through the engine bracket.
78. Align the hole in the intake manifold cover with the oil fill tube hole in the valve rocker cover.
79. 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.
80. Install the hood. Refer to Hood Replacement (Service and Repair).
81. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
82. Fill the crankcase with oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
83. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair).
84. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Programming and Relearning).
85. Start the vehicle and inspect for leaks.