Engine - Manual Transaxle
Engine - Manual TransaxleSpecial Tool(s):
Material:
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. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 5 transaxle-to-engine bolts.
2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
3. Using the special tools, secure the engine to the lift table.
4. Install the starter motor.
^ Tighten to 35 Nm (26 lb-ft).
5. Install the starter motor harness connector.
1. Install the starter motor solenoid battery nut.
- Tighten to 12 Nm (9 lb-ft).
2. Install the starter motor solenoid nut.
- Tighten to 5 Nm (44 lb-in).
6. Install the wire harness clip retainer and the ground wire and nut to the starter bolts.
^ Tighten to 25 Nm (18 lb-ft).
7. Raise the engine and transaxle into the vehicle.
8. Install the bolt in the LH transaxle mount.
^ Tighten to 103 Nm (76 lb-ft).
9. Install the bolt in the rear transaxle mount.
^ Tighten 115 Nm (85 lb-ft).
10. Install the engine mount bracket and nuts.
^ Tighten 115 Nm (85 lb-ft).
11. Install the engine mount bracket bolt.
^ Tighten to 115 Nm (85 lb-ft).
12. Install the 2 engine-to-transaxle bolts.
^ Tighten to 48 Nm (35 lb-ft).
13. Install the 2 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 lb-ft).
14. Install the engine support crossmember and new nut.
^ Tighten to 175 Nm (129 lb-ft).
15. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt.
^ Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft).
^ Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
16. Position the A/C compressor and install the bolts.
^ Tighten the bolts to 25 Nm (18 lb-ft).
^ Connect the A/C compressor electrical connector.
17. Connect the lower radiator hose to the radiator.
18. Connect the PCM electrical connectors.
^ Position the harness and install the nut.
- Tighten to 6 Nm (53 lb-in).
19. Install the ground wire and bolt.
^ Tighten to 10 Nm (89 lb-in).
20. Attach the electrical connector retainers.
21. Connect the fuel supply tube quick connect coupling.
22. Connect the fuel vapor return tube and retainer.
23. Connect the vacuum supply tube.
24. Position the accelerator control cable and bracket and install the nut.
^ Tighten to 6 Nm (53 lb-in).
25. Install the accelerator control cable and bracket and nut.
^ Tighten to 6 Nm (53 lb-in).
26. Install the accelerator cable and speed control cable (if equipped).
1. Connect the accelerator and speed control cable (if equipped) to the throttle body.
2. Install the accelerator cable bracket and bolts.
- Tighten to 10 Nm (89 lb-in).
27. Install the accelerator cable snow shield and retainers.
^ Tighten to 4 Nm (35 lb-in).
28. Connect the heater hoses to the heater core.
29. Attach the heater hose support strap to the stud.
30. Connect the upper radiator hose.
31. If equipped, route the block heater wiring harness and attach all retainers.
^ Connect the block heater electrical connector.
32. Install the shift cable bracket.
1. Position the shift cable bracket.
2. Install the 3 bolts.
- Tighten to 22 Nm (16 lb-ft).
33. Connect the shift cables.
34. Connect the reversing lamp indicator switch.
35. Connect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
36. Install the wiring harness bracket nut.
^ Tighten to 12 Nm (9 lb-ft).
37. Connect the clutch hydraulic line.
1. Position the clutch hydraulic line.
2. Connect the clutch hydraulic line to the clutch slave cylinder.
- Tighten to 25 Nm (18 lb-ft).
3. Install the clutch hydraulic line bracket-to-transaxle bolt.
- Tighten to 3 Nm (27 lb-in).
38. Attach the wiring harness retainers to the battery tray bracket.
39. Connect the 34-pin electrical connector.
40. Install the ground strap and bolt.
^ Tighten to 10 Nm (89 lb-in).
41. Connect the electrical connector to the power distribution box (PDB).
42. Connect the cable to the PDB and install the nut.
^ Tighten to 12 Nm (9 lb-ft).
43. Install the PDB cover.
44. Install the intermediate shaft.
45. Install the intermediate shaft retaining nuts.
^ Tighten to 27 Nm (20 lb-ft).
46. Install the LH halfshaft in the transaxle and the RH halfshaft to the intermediate shaft.
^ Install the ball joints in the knuckles.
47. Connect the RH suspension.
1. Install the lower ball joint-to-knuckle bolt.
- Tighten to 63 Nm (46 lb-ft).
2. Position the tie-rod end and install the retaining nut.
- Tighten to 55 Nm (41 lb-ft).
3. Connect the stabilizer bar link.
- Tighten to 63 Nm (46 lb-ft).
48. Install the RH brake hose retainer and the anti-lock brake system (ABS) sensor bolt.
^ Tighten to 15 Nm (11 lb-ft).
49. Connect the LH suspension.
1. Install the lower ball joint-to-knuckle bolt.
- Tighten to 63 Nm (46 lb-ft).
2. Position the tie-rod end and install the retaining nut.
- Tighten to 55 Nm (41 lb-ft).
3. Connect the stabilizer bar link.
- Tighten to 63 Nm (46 lb-ft).
50. Install the LH brake hose retainer and the ABS sensor bolt.
^ Tighten to 15 Nm (11 lb-ft).
51. Install the lateral support crossmember and bolts.
^ Tighten to 115 Nm (85 lb-ft).
52. Install the generator shield, the nut and the pin-type retainer.
^ Tighten to 20 Nm (15 lb-ft).
^ Attach the wire retainers.
53. Install the lower air duct.
54. Install the accessory drive belt tensioner.
55. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
56. Install the exhaust flexible pipe.
57. Install the front wheels and tires.
58. Install the battery tray.
59. Install the engine air cleaner and air cleaner outlet pipe.
60. Fill the engine with clean engine oil.
61. Fill and bleed the cooling system.
62. Bleed the clutch system.