Part 4

Engine

Assembly

125. NOTE: Vehicles equipped with secondary air injection (AIR) have 2 catalyst monitor sensors (CMS).





Connect the CMS electrical connector(s).

Vehicles with secondary air injection (AIR)





126. Position the AIR valve, hoses and pump assembly onto the engine and install the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





127. Connect the AIR valve electrical connector.





128. Connect the AIR valve vacuum supply tube to the intake manifold.





129. Connect the AIR hose to the catalytic converter.

All vehicles





130. Install the generator, bolt and 2 stud bolts.
^ Tighten to 47 Nm (35 ft. lbs.).





131. Connect the pin-type retainer, generator electrical connections and install the nut.
^ Tighten to 6 Nut (53 inch lbs.).
^ Install the rubber boot.





132. Install the generator splash shield and the 2 nuts.
^ Tighten to 25 Nm (18 ft. lbs.).





133. Connect the CKP sensor electrical connector and harness pin-type retainer.





134. Install the accessory drive belt idler pulley.
^ Tighten to 25 Nm (18 ft. lbs.).

135. NOTE: Clean the coolant pump mating surface with metal surface cleaner.

NOTE: Lubricate the new coolant pump O-ring with clean engine coolant.





Install the new O-ring, coolant pump and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





136. Install the coolant pump pulley and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





137. Install the A/C compressor and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





138. Install the A/C manifold and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





139. Connect the A/C compressor electrical connector.





140. Position the coolant hose on the engine and connect the coolant hose to the throttle body.





141. Connect the lower radiator and heater hoses to the thermostat housing.





142. Connect the KS electrical connector and the 2 harness pin-type retainers.





143. Install the power steering pump and the lower bolt.
^ Finger tighten the bolt.





144. Install the 2 upper power steering pump bolts.
^ Tighten all 3 power steering bolts to 25 Nm (18 ft. lbs.).





145. Connect the power steering pressure (PSP) switch electrical connector.





146. On late build engines, install the accessory drive belt tensioner and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





147. On early build vehicles, install the shield, pin-type retainer, tensioner and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

148. Position the accessory drive belt onto the tensioner and all of the accessory drive pulleys except the coolant pump pulley.





149. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
1 On early build engines, use the pulley bolt to rotate the tensioner.
2 On late build engines, use the hex feature to rotate the tensioner.

150. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.

Vehicles with automatic transaxle





151. Install the flexplate and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (50 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.).

Vehicles with manual transaxle





152. Install the flywheel and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (50 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.).





153. Install the starter motor isolator.





154. Lubricate the transaxle input shaft pilot bearing with front axle grease.





155. Using the special tool, position the clutch disc on the flywheel.

156. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.

Position the clutch pressure plate and install the 6 bolts.
^ Tighten to 29 Nm (21 ft. lbs.) in a star pattern sequence.