Part 1

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.

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 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 2 heater hoses to the coolant outlet.





4. Install the 2 engine cover studs onto the valve cover studs.





5. Position the auxiliary coolant pump and bracket and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






6. Using the Floor Crane and Engine Lifting Bracket, position the engine and transaxle onto the Powertrain Lift.

7. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.
Using the Adjustable Grip Arm, secure the engine to the Powertrain Lift.






8. Raise the engine and transaxle into the vehicle.

9. Install the 3 nuts on the upper transaxle insulator.
- Tighten to 90 Nm (66 lb-ft).






10. Install the engine mount bracket and 3 nuts.
- Tighten to 103 Nm (76 lb-ft).






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






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






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






14. Connect the brake booster vacuum hose.





15. Connect the 2 engine wiring harness connectors and attach the wiring retainer.





16. Connect the 2 transaxle electrical connectors.





17. Position the master cylinder reservoir and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






18. Connect the transaxle harness electrical connector, attach the wiring retainer and install the bolt.
- Tighten to 10 Nm (89 lb-in).






19. Connect the Motor Electronics Cooling System (MECS) coolant expansion tank hose.





20. Install the MECS (Motor Electronics Cooling System) coolant expansion tank nut and bolt.
- Tighten to 10 Nm (89 lb-in).






21. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve.





22. Connect the fuel supply tube.





23. Connect the engine wiring harness connector and attach it to the bracket.





24. Attach the engine wiring harness retainer to the bracket.





25. Connect the 2 heater hoses.





26. Attach the 2 block heater (if equipped) and the high voltage electrical system wiring retainers to the valve cover stud bolts.





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






28. Install a new gasket and connect the A/C tube to the A/C condenser.
- Install the nut.

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






29. 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).






30. Install the A/C tube bracket bolt.
- Tighten to 6 Nm (53 lb-in).






31. Install the A/C tube bracket bolt to the strut tower.
- Tighten to 6 Nm (53 lb-in).






32. Install a new gasket and connect the A/C tube.
- Install the nut.

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






33. If equipped, attach the 3 block heater wiring retainers.





34. NOTE: Lower radiator hose shown, upper similar.
Connect the upper and lower radiator hoses and install the retaining clips.






35. NOTE: Lubricate the oil filter O-ring with clean engine oil before installation.
Tighten the oil filter three-fourths of a turn after the oil filter gasket makes contact with the oil filter adapter.