Operation CHARM: Car repair manuals for everyone.

Part 2

Engine continued

40. Install the 4 oil pan-to-transaxle bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





41. Using new gaskets, install the Y-pipe assembly and 6 new nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





42. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

Install a new engine oil filter.
^ Tighten to 5 Nm (44 inch lbs.) and then rotate an additional 180 degrees.





43. Connect the 2 transmission fluid cooler hoses.





44. Connect the power steering cooler tube.





45. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
^ From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the body.





46. If equipped, install the under body shield and the 6 screws.





47. Install the LH splash shield and the 6 pin-type retainers (4 shown).





48. Position the LH fender splash shield and install the 4 screws.





49. NOTE: Align the index marks made during removal.

Install the steering intermediate shaft onto the steering gear and install a new bolt.
^ Tighten to 23 Nm (17 ft. lbs.).





50. Install the steering joint cover and the 2 nuts.





51. Using a new banjo bolt and 2 new seals, install the power steering pressure (PSP) tube onto the steering gear.
^ Tighten to 37 Nm (27 ft. lbs.).





52. Install the PSP tube bracket and bolt.
^ Tighten to 10 Nm (89 inch lbs.).





53. Connect the powertrain control module (PCM) electrical connectors and pin-type retainers.





54. Install the engine mount brace and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





55. Install the ground wire and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





56. Connect the fuel supply tube from the fuel rail.





57. Attach the power steering reservoir onto the cowl.





58. Connect the hose to the power steering reservoir.
^ Attach the pin-type retainer to the engine mount brace.





59. Install the oil level indicator.





60. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.





61. Connect the 2 engine wiring harness electrical connectors.





62. Attach the 2 wiring harness retainers.





63. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
^ Tighten to 8 Nm (71 inch lbs.).





64. Install the A/C tube bracket bolt.
^ Tighten to 8 Nm (71 inch lbs.).





65. Install the 2 A/C tube bracket bolts.
^ Tighten to 10 Nm (89 inch lbs.).





66. Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
^ Tighten to 8 Nm (71 inch lbs.).





67. Attach the coolant tube retainer clips to the A/C tube.





68. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
69. Install the ground wire and bolt.
^ Tighten to 12 Nm (9 ft. lbs.).





70. Position the transaxle control cable bracket in place and install the 3 nuts.
^ Tighten to 12 Nm (9 ft. lbs.).





71. Connect the transaxle control cable to the control lever.





72. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.





73. Connect the vacuum hose and the evaporative emissions (EVAP) tube to the upper intake manifold.





74. Install the ground wire and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





75. Connect the power feed to the battery terminal and install the nut.
^ Tighten to 6 Nm (53 inch lbs.).





76. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.





77. Connect the 2 engine wiring harness electrical connectors.





78. Install the battery tray.
79. Install the engine air cleaner and the air cleaner outlet pipe.
80. Install the degas bottle.
81. Install the accessory drive belt and the power steering belt.
82. Fill the engine with clean engine oil.
83. Fill and bleed the cooling system.
84. Fill the power steering system.
85. Check the transaxle fluid and add fluid if necessary.
86. Recharge the air conditioning system.