Part 1
EngineInstallation (Steps 1-42)
Special Tool(s):
Material:
CAUTION: If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.
All vehicles
1. Using the special tools, align the engine with the transaxle.
2. Install the 5 transaxle-to-engine bolts (3 shown).
^ Tighten to 48 Nm (35 lb-ft).
3. Using the special tools, secure the engine and transaxle to the powertrain lift.
4. Install the EGR regulator and the 2 stud bolts.
^ Tighten to 6 Nm (53 lb-in).
5. Attach the wiring harness retainer and install the nut.
^ Tighten to 6 Nm (53 lb-in).
All wheel drive (AWD) vehicles
6. Position the power transfer unit (PTU) and install the bolt.
^ Tighten to 45 Nm (33 lb-ft).
7. Install the 3 PTU bolts.
^ Tighten to 45 Nm (33 lb-ft).
8. Install the PTU vent tube, the pin-type retainer and the bolt.
^ Tighten to 14 Nm (10 lb-ft).
9. Install the halfshaft support bracket and the 6 bolts.
^ Tighten to 48 Nm (35 lb-ft).
10. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
11. Using a new gasket, install the RH exhaust manifold and 6 new nuts.
^ Tighten in the sequence shown to 20 Nm (15 lb-ft).
12. Connect the RH heated oxygen sensor (HO2S) electrical connector.
All vehicles
13. Connect the turbine speed sensor (TSS) electrical connector.
^ Attach the wiring harness retainer.
14. Attach the transaxle control harness to the bracket.
15. Connect the transaxle wiring harness electronic control switch electrical connector.
16. Connect the transmission range (TR) sensor electrical connector.
17. Attach the pin-type retainers to the transaxle support bracket and connect the HO2S and catalyst monitor sensor electrical connectors.
18. Position the powertrain into the vehicle.
19. Install the engine support bracket, the bolt and the 3 nuts.
^ Tighten the nuts to 55 Nm (41 lb-ft) and the bolt to 90 Nm (66 lb-ft).
20. Install the rear transaxle support through bolt.
^ Tighten to 103 Nm (76 lb-ft).
21. Position the RH transaxle support insulator and install the bolt and nuts.
^ Tighten to 80 Nm (59 lb-ft).
22. Install the RH transaxle support insulator through bolt.
^ Tighten to 115 Nm (85 lb-ft).
23. Install the transaxle-to-engine stud and 2 nuts.
^ Tighten to 48 Nm (35 lb-ft).
24. NOTE: Clean and degrease all sealing surfaces with metal surface cleaner.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of the sealant application.
Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing surface.
25. NOTE: Install a new oil pan gasket.
Position the oil pan and gasket and loosely install the bolts and stud bolts.
26. Install the 2 oil pan-to-transaxle bolts.
^ Tighten to 40 Nm (30 lb-ft).
27. Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
28. Install the 4 torque converter nuts.
^ Tighten to 40 Nm (30 lb-ft).
29. Install the torque converter inspection cover.
30. Install the output shaft speed (OSS) sensor and the bolt and connect the electrical connector.
^ Tighten to 13 Nm (10 lb-ft).
31. If equipped, connect the engine block heater electrical connector.
32. Install the ground wire eyelet and nut to the engine mount stud.
^ Tighten to 25 Nm (18 lb-ft).
33. Install the wire and nut to the battery cable.
^ Tighten to 10 Nm (89 lb-in).
34. Attach the wiring harness retainers from the battery tray bracket.
35. Position the ground strap and the electrical connector and install the bolts.
^ Tighten to 10 Nm (89 lb-in).
36. Connect the electrical connector to the power distribution box.
37. Install the cable and the nut.
^ Tighten to 12 Nm (9 lb-ft).
38. Attach the ground wire and install the bolt.
^ Tighten to 10 Nm (89 lb-in).
39. Position the wiring and install the nut. Connect the PCM electrical connectors.
^ Tighten to 8 Nm (71 lb-in).
40. Connect the manifold absolute pressure (MAP) sensor electrical connector and vacuum tube.
41. Connect the brake booster vacuum tube.
42. Connect the evaporative emissions (EVAP) purge valve tube to the intake manifold.
