Installation
INSTALLATION1. Install transaxle into position. Install two (2) transaxle-to-engine lower bolts and torque to 95 Nm (70 ft. lbs.).
2. Remove transmission jack.
3. Lower vehicle.
4. Raise engine/transaxle assembly into position with overhead fixture.
5. Install and torque four (4) transaxle-to-engine upper bolts and torque to 95 Nm (70 ft. lbs.).
6. Raise vehicle.
7. Install four (4) torque converter-to-driveplate bolts and torque to 88 Nm (65 ft. lbs.).
Fig. 183 Torque Converter Dust Shield:
8. Install torque converter dust shield (Fig. 183).
Fig. 184 Oil Pan-to-Transaxle Collar:
9. Loosely assemble engine-to-transmission collar (Fig. 184).
10. AWD models:
a. Install PTU lower bracket.
Fig. 185 Power Transfer Unit Lower Bolts:
b. Install PTU into position. Install two (2) lower PTU-to-bracket bolts and torque to 28 Nm (21 ft. lbs.) (Fig. 185).
Fig. 186 Power Transfer Unit Mounting:
c. Install PTU-to-transaxle upper bolts and torque to 54 Nm (40 ft. lbs.) (Fig. 186).
Fig. 187 PTU Bracket/Rear Mount Assembly:
d. Install PTU/rear mount bracket. Install and torque six (6) bolts to 54 Nm (40 ft. lbs.). (Fig. 187)
e. Install PTU heat shield (Fig. 187).
f. Install propeller shaft assembly.
Fig. 188 Starter Motor and Shim:
11. Install starter motor and shim (Fig. 188). Install and torque bolts to 47 Nm (35 ft. lbs.).
12. Install starter motor electrical connectors.
Fig. 189 Engine Front Mount/Bracket:
13. Install engine front mount/bracket assembly and torque to 67 Nm (50 ft. lbs.) (Fig. 189).
14. Install cradle and fixture into position under vehicle.
Fig. 190 Driveline Support Table in Position:
15. Slowly lower vehicle (Fig. 190). Have helper guide power steering and brake hydraulic lines into position, while aligning cradle to body While lowering vehicle, align engine front and rear mount studs to their respective thru-holes in cradle.
16. Aligning index/scribe mark placed upon disassembly, Install four (4) cradle-to-body bolts and torque to 162 Nm (120 ft. lbs.).
17. Verify that power steering and brake hydraulic lines can be properly routed and installed.
18. Remove overhead powertrain support fixture from engine compartment:
a. Remove rear support/lift bracket and connect coolant temperature sensor.
b. Remove front support/lift bracket. Install and torque engine oil dipstick fastener.
19. Raise vehicle on hoist and remove driveline support table.
20. Install and torque engine front and rear mount-to-cradle nuts to 54 Nm (40 ft. lbs.).
Fig. 191 Intermediate Shaft Extension at Gear:
Fig. 192 Roll Pin Installation:
21. Using Tool 6831A, install steering shaft-to-gear coupler (Fig. 191) (Fig. 192).
Fig. 193 Hoses at Steering Gear:
22. Connect power steering hoses to steering gear (Fig. 193). Torque fittings to 31 Nm (23 ft. lbs.).
Fig. 194 Cooler Mounting Screws:
23. Install power steering cooler and fasten to cradle (Fig. 194).
Fig. 195 Hose Routing Clip at Cradle:
24. Fasten steering hose routing clip to cradle (Fig. 195).
25. Install torque strut and torque two (2) bolts to 54 Nm (40 ft. lbs.).
26. Install halfshaft assemblies.
Fig. 196 Stabilizer Bar Link To Strut:
27. Install sway bar links to strut attaching points (Fig. 196). Torque link-to-strut nuts to 88 Nm (65 ft. lbs.).
Fig. 197 Wheel Speed Sensor Mounting To Strut:
28. Install ABS sensor brackets to struts (Fig. 197).
Fig. 198 Sensor Mounting To Front Hub And Bearing:
29. Connect ABS sensors (Fig. 198).
30. Install both front tire/wheel assemblies.
Fig. 199 Brake Lines at Hydraulic Control Unit:
31. Connect front brake lines to hydraulic control unit (Fig. 199).
32. Install coolant bypass tube fasteners.
Fig. 200 Transmission Connectors:
33. Connect solenoid/pressure switch connector (Fig. 200). Torque screw to 4 Nm (35 inch lbs.).
34. Connect transaxle range sensor connector (Fig. 200).
35. Connect input speed sensor connector (Fig. 200).
36. Connect output speed sensor connector (Fig. 200).
Fig. 201 Transmission Harness/Retainers:
37. Secure transaxle harness with respective retainers (Fig. 201).
Fig. 202 Crankshaft Position Sensor:
38. Install and connect crankshaft position sensor (Fig. 202).
39. Install ground cable to case and torque bolt.
40. Connect oil cooler lines to transaxle. An audible "click" should be heard. Verify connection by pulling outward.
41. Connect gearshift cable to transaxle manual valve lever. Verify adjustment.
Fig. 203 Battery Tray:
42. Install battery tray (Fig. 203). Connect battery temperature sensor.
Fig. 204 Battery:
43. Install battery (Fig. 204).
44. Install battery hold-down clamp.
45. Connect battery cables.
46. Bleed brake hydraulic system.
47. Add power steering fluid as required.
48. Check and adjust transaxle fluid level.
49. AWD models: Check and adjust PTU fluid level.
50. Align front end.