Installation
Engine ReplacementInstallation Procedure
1. Install the front engine mount.
2. Carefully position the engine to the supported frame and transaxle assembly, aligning the engine dowels to the transaxle cover.
Notice: Refer to Fastener Notice in Service Precautions.
3. Install the bolts attaching the engine to the transaxle.
^ Tighten the bolts to 75 Nm (55 ft. lbs.).
4. Install the 2 nuts (2) securing the front engine mount (2) to the engine frame.
^ Tighten the nuts to 50 Nm (37 ft. lbs.).
5. Install the 4 bolts securing the front transaxle brace to the engine and transaxle.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
6. Install the retaining nuts (2,3) securing the vehicle speed sensor heat shield (1) to the transaxle.
^ Tighten the nuts to 50 Nm (37 ft. lbs.).
7. Position the rear transaxle brace over the studs located at the rear of the right cylinder head.
8. Loosely install the nuts (3) securing the rear transaxle brace (1) to the cylinder head.
9. Install the bolts (2) securing the rear transaxle brace (1) to the transaxle.
^ Tighten the nuts and bolt to 50 Nm (37 ft. lbs.).
10. Position the right transaxle mount (1) to the engine/transaxle assembly.
11. Install the 3 bolts securing the right transaxle mount (1) to the engine and transaxle.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
12. Install the 2 nuts (2) securing the right transaxle mount (1) to the engine frame.
^ Tighten the nuts to 50 Nm (37 ft. lbs.).
13. Remove the engine lift chain from the engine lift brackets.
14. Remove the J 42504 from the cylinder head.
15. Install the power steering pump to the engine.
16. Position the right engine mount strut bracket to the engine.
17. Install the 3 bolts securing the right engine mount strut bracket to the cylinder head.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
18. Install the bolt securing the top of the generator to the right engine mount strut bracket.
^ Tighten the bolt to 50 Nm (37 ft. lbs.).
19. Install the power steering pressure hose (1) to the power steering pump (2).
^ Tighten the hose to 30 Nm (22 ft. lbs.).
20. Install the power steering pressure hose (1) retaining bolt to the engine.
^ Tighten the nut to 9 Nm (80 inch lbs.).
21. Connect the power steering return hose to the power steering pump reservoir.
22. Install the power steering return hose retaining bolt to the right engine mount strut bracket.
^ Tighten the bolt to 13 Nm (115 inch lbs.).
23. Install the drive belt.
24. Connect the engine wiring harness to the engine.
25. Install the nut (3) securing the coil cassette ground wire to the cylinder head.
^ Tighten the nut to 17 Nm (13 ft. lbs.).
26. Install the heater pipes.
27. Install the EGR pipes.
28. Install the bolt securing the intermediate pipe to the left engine mount strut bracket.
29. Install the nut securing the intermediate hose to the AIR valve at bank 2.
^ Tighten the nut to 9 Nm (80 inch lbs.).
30. Connect the intermediate hose to the AIR valve at bank 2.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
31. Position the engine/transaxle assembly under the vehicle.
Important: Ensure clearance is maintained between the engine/transaxle assembly and the following:
^ The A/C accumulator hose
^ The A/C compressor hose
^ The brake pipes
^ The heater hoses
^ The radiator hoses
^ The wheel speed sensor leads
^ The wiring harnesses
32. Carefully lower the vehicle over the engine/transaxle assembly, aligning the struts to the strut towers.
33. Install the six frame mounting bolts (3) retaining the frame (2) to the vehicle.
Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.
^ Tighten the bolts to 98 Nm (72 ft. lbs.).
34. Raise and support the vehicle. Refer to Vehicle Lifting.
35. Remove the J 39580 powertrain support dolly from under the engine frame.
Important: Line up the flywheel and converter, using the alignment marks made during disassembly.
36. Install the bolts securing the flywheel to the torque converter.
^ Tighten the bolts to 60 Nm (44 ft. lbs.).
37. Install the torque converter cover.
38. Install the oil pan to transaxle brace.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
39. Connect the positive battery cable to the front of the frame.
40. Install the generator wire from the back of the generator.
41. Install the engine oil cooler pipes to the engine oil filter adapter, if equipped.
42. Connect the post HO2S at the sensor pigtail.
Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control, which could result in personal injury.
43. Connect the intermediate shaft to the steering gear.
44. Install the pinch bolt.
^ Tighten the bolt to 45 Nm (33 ft. lbs.).
45. Connect the A/C discharge/suction hose (1) to the compressor (3).
^ Tighten the nut to 30 Nm (20 ft. lbs.).
46. Connect the A/C pressure sensor.
47. Install the following brake pipes to the BPMV using the location recorded during the removal procedure:
^ The master cylinder brake pipes
^ The rear brake pipes
^ The left front brake pipe
^ Tighten the brake pipes to 15 Nm (11 ft. lbs.).
48. Install the bolt (2) securing the front right brake pipe frame bracket (1) to the body frame rail.
^ Tighten the bolt to 17 Nm (11 ft. lbs.).
49. Connect the front right brake pipe to the retainer at the body frame rail.
50. Install the front left brake hose retainer to the brake hose retaining bracket.
51. Install the front left brake pipe fitting to the brake hose.
^ Tighten the brake pipe to 15 Nm (11 ft. lbs.).
52. Install the AIR pump.
53. Install the front fascia extensions.
54. Install the engine splash shield.
55. Connect the front wheel speed sensor electrical connectors.
56. Connect the front wheel speed sensor electrical leads to the strut brackets.
57. Connect the following items, if equipped:
^ The road sensing suspension electrical connector (3) to the main body harness
^ The road sensing suspension electrical leads (1) to the electronic suspension position sensor brackets
^ The road sensing suspension electrical leads (1) to the body frame rail retainer (4)
^ The electronic suspension position sensor links (2) to the lower control arms
58. Install the rear exhaust manifold pipe.
59. Install the front wheels.
60. Lower the vehicle ONLY enough to allow the studs on the struts to align with the holes in the strut towers.
61. Install the right and left side strut tower nuts.
^ Tighten the nuts to 21 Nm (15 ft. lbs.).
62. Lower the vehicle.
63. Install the engine mount struts.
Important: Ensure the lower transaxle oil cooler line is positioned horizontally while tightening.
64. Connect the lower transaxle oil cooler pipe fitting to the radiator.
^ Tighten the pipe fitting to 35 Nm (26 ft. lbs.).
Important: Ensure the upper transaxle oil cooler line is positioned vertically while tightening.
65. Connect the upper transaxle oil cooler pipe fitting to the radiator.
^ Tighten the pipe fitting to 35 Nm (26 ft. lbs.).
66. Install the accumulator tube.
67. Connect the surge tank outlet hose to the heater pipe.
68. Connect the heater hoses to the heater pipes.
69. Connect the surge tank inlet hose to the surge tank.
70. Install the cooling fans.
71. Position the J 38185 to the clamp in order to connect the radiator outlet hose (2) to the thermostat housing.
72. Position the J 37097-A to the clamp in order to connect the radiator inlet hose (1) to the engine.
73. Install the shift cable (1) to the manual shift lever (2) and the bracket.
Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cabin. You must replace a damaged cable.
74. Install a NEW accelerator control cable to the throttle body.
75. Install the cruise control cable (2) to the throttle body lever (1).
76. Slide the cruise control fully into the throttle body bracket until the cruise control snaps into place.
77. Install the nut securing the battery negative cable to the engine.
^ Tighten the nut to 25 Nm (18 ft. lbs.).
78. Connect the wiring harness electrical connectors to the following components:
^ The PCM
^ The C101 (1)
^ The engine electrical harness
79. Install the radiator support sight shield.
80. Connect the hose (4) to the evaporative emission canister purge valve (3).
81. Connect the fuel inlet and return quick-connect fittings at the fuel rail.
82. Install the air cleaner assembly.
83. Connect the vacuum brake booster hose to the vacuum connection.
84. Position the intake manifold sight shield (1) to the engine.
85. Install the 2 intake manifold sight shield nuts (2).
^ Tighten the nuts to 3 Nm (27 inch lbs.).
86. Connect the battery positive cable to the battery.
^ Tighten the battery cable bolt to 17 Nm (13 ft. lbs.).
87. Connect the battery negative cable.
88. Fill the engine with oil.
89. Fill the cooling system.
90. Bleed the hydraulic brake system.
91. Recharge the A/C refrigerant system.
92. Bleed the power steering system.
93. Measure the wheel alignment.
Engine Final Test and Inspection
Complete the following procedure after the engine is installed in the vehicle:
1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle. Refer to Vehicle Lifting.
6. Inspect for oil, coolant and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP System Variation Learn Procedure.
9. Perform a final inspection for the proper engine oil and coolant levels.
10. Road test the vehicle.