Engine - Installation

Engine









WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious 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 lb-ft).





2. NOTE: 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 Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.

- Tighten to 48 Nm (35 lb-ft).





3. Connect the high-voltage wiring harness electrical connector.
- Engage the electrical connector locking tab.





4. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift.

5. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.

Using the Universal Adapter Brackets, secure the engine to the Powertrain Lift.





6. Raise the engine and transaxle into the vehicle.

7. Install the upper transaxle insulator.

1. Tighten the nuts to 90 Nm (66 lb-ft).

2. Tighten the through bolt to 103 Nm (76 lb-ft).





8. Install the upper transaxle insulator bracket.
- Tighten to 25 Nm (18 lb-ft).





9. Install the 3 engine mount bracket nuts.
- Tighten to 115 Nm (85 lb-ft).





10. Install the engine mount bracket bolt.
- Tighten to 115 Nm (85 lb-ft).





11. Using the Powertrain Lift, raise the subframe into position.





12. NOTE: RH shown, LH similar.

Install the 2 subframe nuts.

- Tighten to 150 Nm (111 lb-ft).





13. NOTE: When installing the subframe bolts, make sure both of the subframe bolts are fully engaged in their cage nuts before tightening to specification.

NOTE: RH shown, LH similar.

Tighten the 2 subframe bolts.

- Tighten to 175 Nm (129 lb-ft).





14. Install the rear roll restrictor, bracket and bolts.
- Tighten to 90 Nm (66 lb-ft).





15. Connect the steering column coupling to the steering gear and install the new steering column coupling pinch bolt.
- Tighten to 63Nm (46 lb-ft).





16. Install the rear transaxle insulator through bolt.
- Tighten to 115 Nm (85 lb-ft).





17. Install the 2 transaxle-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





18. Install the 2 transaxle-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





19. Install the engine support crossmember.
- Tighten the bolts to 90 Nm (66 lb-ft).

- Tighten the new nut to 175 Nm (129 lb-ft).





20. Install the rear roll restrictor-to-crossmember through bolt.
- Tighten to 90 Nm (66 lb-ft).





21. Install the lower transaxle insulator through bolt.
- Tighten to 115 Nm (85 lb-ft).





22. Connect the lower radiator hose to the radiator.
- Install the retaining clip.





23. Install the auxiliary coolant pump and the 2 bolts.
- Connect the auxiliary coolant pump electrical connector.

- Tighten to 10 Nm (89 lb-in).





24. Install a new gasket and connect the A/C tube to the A/C compressor.
- Install the nut.

- Tighten to 15 Nm (133 lb-in).





25. Install a new gasket and connect the A/C tube to the A/C compressor.
- Install the nut.

- Tighten to 15 Nm (133 lb-in).





26. Install the Motor Electronics Cooling System (MECS) pump and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).





27. Connect the vacuum pump electrical connector and attach the harness retainer.





28. Install the wiring harness fasteners, the ground cable and nut.
- Tighten to 20 Nm (177 lb-in).





29. 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.





30. Position the control lever between the 2 casting ribs on the transaxle case.





31. Place the gear selector lever in the D position.

32. Tighten the transaxle control cable bracket nuts.
- Tighten to 22 Nm (16 lb-ft).

33. 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.

34. Install the transaxle control snow shield and the 2 bolts.
- Tighten to 22 Nm (16 lb-ft).





35. Attach the transaxle selector lever cable fastener to the A/C compressor mounting bracket.





36. Attach the transaxle selector lever cable fastener to the engine front cover stud bolt.





37. Connect the transaxle coolant hoses.





38. Connect the transaxle coolant temperature sensor electrical connector.
- Attach the wiring retainer to the transaxle stud bolt.





39. Attach the 2 high-voltage electrical system wiring retainers to the valve cover stud bolts.





40. Connect the 2 vehicle high-voltage electrical system electrical connectors.
- Attach the wiring harness retainer.





41. Position the DC-to-DC converter in place and install the 3 nuts.
- Tighten to 12 Nm (106 lb-in).





42. Connect the DC-to-DC converter electrical connector and 2 wire harness retainers (1 shown).
- Engage the electrical connector locking tab.





43. Connect the coolant vent hose.





44. Connect the 2 low-voltage electrical connectors and the engine harness-to-body harness retainer.





45. Connect the transaxle harness electrical connector and install the stud bolt.
- Tighten to 10 Nm (89 lb-in).





46. Connect the upper evaporative emissions Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to Fuel Delivery and Air Induction.





47. Connect the engine control harness electrical connector.
- Attach the engine control harness wiring retainer to the intake manifold.





48. If equipped, connect the block heater electrical connector.
- Attach the harness retainer clips.





49. Connect the PCM electrical connector.
- Position the harness and install the wiring harness retainer.





50. Connect the brake booster vacuum hose to the brake booster.





51. Connect the upper radiator hose to the radiator.





52. Connect the heater hoses to the heater core.





53. Install the spin-on engine oil filter.
- Tighten the spin-on oil filter three-fourths of a turn after the oil filter gasket makes contact with the oil filter adapter.





All-Wheel Drive (AWD) vehicles

54. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.





55. Position the Power Transfer Unit (PTU) in place and install the 4 bolts.
- Tighten to 45 Nm (33 lb-ft).





56. Connect the PTU vent hose.





57. Install the PTU heat shield and the bolts.
- Tighten to 11 Nm (97 lb-in).





58. NOTE: Catalytic converter manifold is removed for clarity.

Position the PTU-to-engine support bracket and install the bolts.

- Tighten to 40 Nm (30 lb-ft).





59. Install the 2 exhaust bracket bolts.
- Tighten to 25 Nm (18 lb-ft).





60. Install the driveshaft. For additional information, refer to Drive/Propeller Shafts, Bearings and Joints.

All vehicles

61. Install the intermediate shaft.





62. Install the 2 intermediate shaft bearing retainer nuts.
- Tighten to 27 Nm (20 lb-ft).





63. Install the RH and LH halfshafts. For additional information, refer to Drive Axles, Bearings and Joints.

64. NOTE: RH side shown, LH similar.

Connect the RH and LH suspension.

1. Position the tie-rod end and install the retaining nut.
- Tighten to 55 Nm (41 lb-ft).

2. Connect the stabilizer bar link and install the nut.
- Tighten to 63 Nm (46 lb-ft).





65. Install the RH brake hose retainer and the ABS sensor bolt.
- Tighten to 15 Nm (133 lb-in).





66. Install the LH brake hose retainer and the ABS sensor bolt.
- Tighten to 15 Nm (133 lb-in).





67. Install the exhaust intermediate pipe. For additional information, refer to Exhaust System &/or Catalytic Converter.

68. Install the lateral support crossmember and the bolts.
- Tighten to 115 Nm (85 lb-ft).





69. Install the front wheels and tires. For additional information, refer to Wheels and Tires.

70. Connect the fuel supply tube. For additional information, refer to Fuel Delivery and Air Induction.





71. Install the engine Air Cleaner (ACL). For additional information, refer to Fuel Delivery and Air Induction.

72. Install the engine coolant degas bottle. For additional information, refer to Cooling System.

73. Install the battery and the battery tray. For additional information, refer to Battery.

74. Fill the engine with clean engine oil.

75. Enable the vehicle high-voltage electrical system. For additional information, refer to Hybrid Drive Systems.

76. Reset the Passive Anti-Theft System (PATS). For additional information, refer to Antitheft and Alarm Systems.

77. Fill and bleed the MECS. For additional information, refer to Transmission Cooler, A/T.

78. Fill and bleed the cooling system. For additional information, refer to Cooling System.

79. Fill the transaxle with fluid. For additional information, refer to Automatic Transmission/Transaxle &/or Transmission Control Systems.

80. Recharge the A/C system. For additional information, refer to Heating and Air Conditioning.