Installation Procedure

Installation Procedure





1. Using a engine hoist, remove the engine from the engine stand.
2. Install the following components:
^ The engine mount bracket
^ The engine block heater
^ The generator
3. If equipped with a manual transaxle, install the clutch pressure plate and disc. Refer to Clutch Drive Plate and Clutch Driven Plate.
4. Install the engine to the transaxle.

5. Notice: Refer to Fastener Notice in Service Precautions.

If equipped with a automatic transaxle, install the transaxle to engine bolts/stud.
Tighten the bolts/stud to 75 Nm (55 ft. lbs.).





6. If equipped with a manual transaxle, install the transaxle to engine bolts/stud.
Tighten the bolts/stud to 75 Nm (55 ft. lbs.).





7. Install the transaxle brace and bolts.
Tighten the bolts to 50 Nm (37 ft. lbs.).





8. If equipped with a automatic transaxle, install the torque converter bolts.
Tighten the bolts to 62 Nm (46 ft. lbs.).





9. If equipped with a automatic transaxle, install the torque converter housing access plug.





10. Install the starter and bolts.
Tighten the bolts to 40 Nm (30 ft. lbs.).





11. Remove the engine lift hoist from the engine lift hooks.
12. Slide the lift table under the vehicle.
13. Slowly lower the vehicle until it aligns with the alignment marks made during the removal.
14. Tighten/install the frame bolts.
Tighten the bolts to 100 Nm (74 ft. lbs.) plus and additional 180 degrees.
15. Raise the vehicle until the lift table can be removed from under the vehicle.
16. Remove the lift table.





17. Connect the lower control arms to the steering knuckles.
18. Connect the intermediate shaft to the steering gear.
19. Connect the outer tie rod ends to the steering knuckles.
20. Connect the stabilizer links to the stabilizer bar.
21. Lower the vehicle.
22. Install the transaxle mount to transaxle bolts.
Tighten the bolts to 45 Nm (33 ft. lbs.).





23. Install the engine mount.
24. Install the catalytic converter.

25. Important: Ensure that the black cable is installed in the top notch of the transaxle bracket and the white cable in installed in the bottom notch of the transaxle bracket.

If equipped with a manual transaxle, install the range selector and shift lever cables to the transaxle bracket.
26. Connect the range selector and shift lever cables to the transaxle levers.





27. If equipped with a automatic transaxle, install the range selector lever cable to the transaxle bracket.
28. Connect the range selector lever cable to the transaxle lever.





29. Gather all engine harness branches and position the harness over the engine.
30. If equipped with a manual transaxle perform the following steps, install the engine harness clip (6) to the transaxle.
31. Connect the engine harness electrical connector (7) to the back up lamp switch.
32. Connect the engine harness electrical connector (4) to the HO2S.
33. Install the engine harness electrical connector clip (5) to the transaxle rear mount bracket.
34. Install the engine harness clip (2) to the transaxle.
35. Install the CPA retainer (3).
36. Connect the engine harness electrical connector (1) to the VSS.





37. If equipped with a automatic transaxle perform the following steps, connect the engine harness electrical connector (3) to the HO2S.
38. Install the CPA retainer (5).
39. Install the engine harness electrical connector clip (4) to the transaxle rear mount bracket.
40. Install the CPA retainer (2).
41. Install the engine harness clip (1) to the transaxle stud.
42. Connect the engine harness electrical connector (6) to the neutral safety backup switch.





43. If equipped with a manual transaxle perform the following steps, connect the engine harness electrical connector (3) to the HO2S.
44. Install the CPA retainer (2).
45. Connect the ECT sensor electrical connector (1).





46. If equipped with a automatic transaxle perform the following steps, Connect the engine harness electrical connector (3) to the HO2S.
47. Install the CPA retainer (2).
48. Connect the ECT sensor electrical connector (1).





49. If equipped with a automatic transaxle, connect the engine harness to the transaxle.





50. Install the engine harness lead terminal (1) to the generator.
51. Install the generator nut (2).
Tighten the nut to 20 Nm (27 ft. lbs.).
52. Position the engine harness boot (3).
53. Raise the vehicle.
54. Position the engine harness ground (8) to the engine block.
55. Install the engine harness ground bolt (7).
Tighten the bolt to 25 Nm (18 ft. lbs.).
56. Install the engine harness lead terminal (5) to the starter solenoid.
57. Install the engine harness to starter solenoid "S" terminal nut (6).
Tighten the nut to 3 Nm (27 inch lbs.).





58. If equipped with a manual transaxle perform the following steps, install the positive battery cable terminal (3) to the starter.
59. Install the positive/negative battery cable lead nut (4) to the starter solenoid.
Tighten the nut to 17 Nm (13 ft. lbs.).





60. If equipped with a automatic transaxle perform the following steps, install the positive battery cable (3) terminal to the starter.
61. Install the positive/negative battery cable lead nut (4) to the starter solenoid.
Tighten the nut to 17 Nm (13 ft. lbs.).





62. If equipped with a automatic transaxle, install the engine harness clip (3) to the speed sensor.
63. Connect the VSS electrical connector (4).
64. Install the engine harness clip (1) to the stud.
65. Install the engine harness clip nut (2) to the engine stud.
Tighten the nut to 50 Nm (37 ft. lbs.).





66. Lower the vehicle.
67. Reposition and install the AC compressor.
Tighten the bolts to 50 Nm (37 ft. lbs.).
68. Connect the A/C compressor electrical connector (2).
69. Connect the A/C pressure switch electrical connector (1).





70. Install the engine harness clip (1) to the transaxle stud.
71. Install the engine harness clip nut (2).
Tighten the nut to 10 Nm (89 inch lbs.).





72. Install the engine harness clip (1) to the EVAP purge solenoid bracket.





73. Connect the EVAP purge solenoid electrical connector (1).





74. If equipped with a manual transaxle perform the following steps, install the engine harness ground terminal (4) to the stud.
75. Install the positive/negative cable (3) terminal to the stud.
76. Install the positive/negative battery cable ground nut (2).
Tighten the nut to 10 Nm (89 inch lbs.).
77. Connect the following electrical connectors:
^ CKP Sensor (1)
^ Oil Pressure Sensor (5)
^ Knock Sensor (6)





78. If equipped with a automatic transaxle perform the following steps, install the engine harness ground terminal (3) to the stud.
79. Install the positive/negative cable (2) terminal to the stud.
80. Install the positive/negative battery cable ground nut (1).
Tighten the nut to 10 Nm (89 inch lbs.).
81. Connect the following electrical connectors:
^ CKP Sensor (4)
^ Oil Pressure Sensor (5)
^ Knock Sensor (6)





82. Install the engine harness clips (2, 4) to the intake manifold.
83. Install the engine harness clip (1) to the oil level indicator tube bracket.





84. Install the engine harness clips (1, 2) to the camshaft cover.





85. Connect the intake (2) and exhaust (1) camshaft position actuator electrical connectors.
86. Connect the ignition coils electrical connectors (3).





87. Connect the following electrical connectors:
^ TAC (1)
^ MAP sensor
^ Fuel injector harness (2)
^ Generator (3)





88. Install the brake booster vacuum hose to the intake manifold.
89. Position the brake booster vacuum hose clamp at the intake manifold.





90. Position the engine coolant heater cord, if necessary.
91. Install the engine coolant heater cord straps to the engine harness, if necessary.





92. Connect the engine coolant heater cord, if necessary.





93. Install the heater inlet and outlet hoses to the thermostat housing.
94. Position the heater inlet and outlet hose clamps at the thermostat housing.





95. Install the radiator outlet hose to the oil cooler.
96. Install the radiator outlet hose to the water outlet.
97. Position the radiator outlet hose clamp (2) at the oil cooler.
98. Position the radiator outlet hose clamp (1) at the water outlet.





99. Install the radiator inlet hose to the engine.
100. Position the radiator inlet hose clamp at the engine.





101. Connect the cooling fan electrical connector.





102. Install the engine drive belt.
103. Unsecure the cooling module from the upper body structure.
104. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (GE 47716 Fill).





105. Connect the EVAP line to the EVAP purge solenoid.





106. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
107. Connect the fuel feed line to the fuel rail.
108. Install the air cleaner assembly.
109. Connect the negative battery cable.
110. Close the hood.
111. Road test the vehicle.