Part 1

Engine Replacement

Tools Required
* J 37097-A Hose Clamp Remover/Installer
* J 38185 Hose Clamp Pliers
* J 39580 Universal Engine Support Table
* J 41623-B Cooler Quick Connect Tool
* J 42640 Steering Column Lock Pin

Installation Procedure - Part 1




1. Install the front engine mount bracket.

Notice: Refer to Fastener Notice (Fastener Notice).

2. Install the front engine mount bracket bolts/nuts.

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

3. Install an engine lift chain to the engine lift brackets and attach an engine lifting device.
4. Remove the engine assembly from the engine stand.




5. Carefully position and install the engine to the supported frame and transaxle, aligning the engine dowel pins to the transaxle.
6. Install the upper transaxle bolts.

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




7. Install the rear transaxle bolt.

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




8. Install the front engine mount to frame nut.

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




9. Position the rear engine mount bracket to the engine and transaxle.
10. Install the rear engine mount bracket bolts and stud.

Tighten the bolts/stud to 73 N.m (54 lb ft).




11. Install the rear engine mount to frame nut.

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

12. Remove the engine lifting device and lift chain.




13. Install the transaxle brace.
14. Install the transaxle brace bolt.

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




15. Tighten the front engine mount bracket nut with the transaxle brace behind it.

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




16. Position the transaxle brace to the engine and transaxle.
17. Install the transaxle brace bolts to the engine.

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




18. Install the transaxle brace bolt/stud to the transaxle.

Tighten the bolt/stud to 50 N.m (37 lb ft).




19. Install the transaxle brace to the lift bracket studs.
20. Install the transaxle brace bolt.

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

21. Install the transaxle brace nuts.

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




22. Remove the plug from the A/C compressor suction port.
23. Remove and discard the old sealing washer from the compressor end of the suction hose.
24. Install a NEW sealing washer to the compressor end of the suction hose.
25. Install the A/C compressor suction hose the compressor.
26. Install the A/C compressor suction hose nut at the compressor.

Tighten the nut to 16 N.m (12 lb ft).

27. Secure the suction hose to the engine.




28. Remove the plug from the A/C compressor discharge port.
29. Remove and discard the old sealing washer from the compressor end of the discharge hose.
30. Install a NEW sealing washer to the compressor end of the discharge hose.
31. Install the A/C compressor discharge hose the compressor.
32. Install the A/C compressor discharge hose nut at the compressor.

Tighten the nut to 16 N.m (12 lb ft).

33. Secure the discharge hose to the engine.




34. Install the power steering inlet pipe fitting to the power steering pump.

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

35. Install the power steering inlet pipe bracket to the stud.
36. Install the power steering inlet pipe nut (1) to the rear engine mount bracket stud.

Tighten the nut to 9 N.m (80 lb in).




37. Install the power steering outlet hose to the reservoir.
38. Position the power steering outlet hose clamp at the pump reservoir.
39. Install the power steering outlet pipe bolt to the engine mount strut bracket.

Tighten the bolt to 9 N.m (80 lb in).




40. Install the engine harness to the engine.
41. Position the engine harness grounds (1, 3, and 5) to the engine block.
42. Install the engine harness ground bolts (2, 4, and 6).

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

43. Connect the engine harness electrical connector to the transaxle.




44. Connect the engine harness electrical connector (3) to the HO2S.
45. Install the CPA retainer.
46. Install the engine harness clip (1) to the engine bracket.




47. Connect the engine harness electrical connectors to the following:

* The AIR pump (1)
* The brake modulator (2)




48. Install the engine harness clip (1) to the boss on the engine block.
49. Connect the following engine harness electrical connectors:

* The oil pressure sensor (2)
* The oil level sensor (3)
* The A/C compressor (4)
* The generator (5)




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