Installation
EngineSpecial Tool(s):
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
All vehicles
1. NOTE: Due to packaging requirements the correct bolt must be used at the damper locations.
NOTE: The damper contains a clutch which is designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft. Should the damper become contaminated, it must be replaced.
Install the transaxle damper.
^ Tighten to 29 Nm (21 ft. lbs.).
2. CAUTION: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.
NOTE: Transaxle removed from view for clarity.
Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
3. Position the high voltage wiring harness and connect the 2 transaxle electrical connectors.
4. Connect the high voltage wiring harness electrical connector.
5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
6. CAUTION: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
Using the special tools, secure the engine to the lift table.
7. Raise the engine and transaxle into the vehicle.
8. Install the rear transaxle mount.
^ Tighten the nuts to 115 Nm (85 ft. lbs.).
^ Tighten the bolt to 90 Nm (66 ft. lbs.).
9. Install the rear transaxle mount brace.
^ Tighten to 25 Nm (18 ft. lbs.).
10. Install the RH transaxle mount bracket.
^ Tighten to 90 Nm (66 ft. lbs.).
11. Install the RH transaxle mount bracket nut.
^ Tighten to 90 Nm (66 ft. lbs.).
12. Install the engine mount bracket.
^ Tighten to 90 Nm (66 ft. lbs.).
13. Install the engine mount bracket bolt.
^ Tighten to 90 Nm (66 ft. lbs.).
14. Install the 2 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
15. Install the 2 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
16. Install the engine support crossmember.
^ Tighten to the bolts to 90 Nm (66 ft. lbs.).
^ Tighten to the nut to 175 Nm (129 ft. lbs.).
17. Install the rear roll restrictor bolt.
^ Tighten to 90 Nm (66 ft. lbs.).
18. Install the front roll restrictor bolt.
^ Tighten to 115 Nm (85 ft. lbs.).
19. Install the A/C compressor and connect the A/C compressor electrical connector.
^ Tighten to 25 Nm (18 ft. lbs.).
20. Connect the lower radiator hose to the radiator.
21. Install the motor electronics coolant pump.
^ Tighten to 7 Nm (62 inch lbs.).
22. Install the ground cable and nut.
^ Tighten to 20 Nm (15 ft. lbs.).
23. Connect the transaxle coolant hoses.
24. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
25. Position the transaxle control cable and connect the pin-type retainer.
26. Connect the pin-type retainer.
27. Connect the transaxle control cable.
^ Install the transaxle control cable bracket and the 2 nuts finger tight.
^ Attach the transaxle control cable to the control lever.
28. Position the control lever between the 2 casting ribs on the transaxle case.
29. Place the gear selector lever in the D position.
30. Tighten the transaxle control cable bracket nuts to 22 Nm (16 ft. lbs.).
31. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the gear selector lever to each range position ending in the D position.
32. Install the transaxle control snow shield.
^ Tighten to 22 Nm (16 ft. lbs.).
33. Install the auxiliary coolant pump and connect the electrical connector.
^ Tighten to 10 Nm (89 inch lbs.).
34. NOTE: Parts removed from view for clarity.
If equipped, install the block heater wiring harness.
^ Route the harness through the radiator support.
^ Attach the 3 harness retainer clips.
35. Install the fuel supply tube and evaporative emissions (EVAP) tube.
36. Connect the DC-to-DC converter electrical connector and pin-type retainer.
37. Connect the transaxle harness electrical connector and install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
38. Connect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
39. Connect the engine control harness.
^ Engage the powertrain control module (PCM) connector.
^ Install the harness retaining nut.
^ Tighten to 6 Nm (53 inch lbs.).
40. Connect the following electrical connectors:
^ Secondary air injection (AIR) solenoid
^ Transaxle mount control solenoid
^ Purge valve
41. Connect the upper radiator and coolant vent hoses.
42. Attach the heater hose retaining clip to the transaxle mount stud.
43. Connect the heater hoses to the heater core.
4x2 vehicles
44. Install the lateral support crossmember.
^ Tighten to 115 Nm (85 ft. lbs.).
45. Install the front drive intermediate halfshaft.
4x4 vehicles
46. Install the transfer case.
All vehicles
47. Install the LH front drive halfshaft.
48. Install the accessory drive belt.
49. Install the engine coolant degas bottle.
50. Install the catalytic converter.
51. Install the engine air cleaner.
52. Install the intake manifold.
53. Enable the vehicle high voltage electrical system.
54. Connect the battery ground cable.
55. Fill the engine with clean engine oil.
56. Fill and bleed the motor electronics cooling system.
57. Fill and bleed the cooling system.