Engine - Manual Transaxle
Engine - Manual TransaxleSpecial Tool(s):
Material:
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
3. NOTE: Position a suitable block of wood under the transaxle.
Install the special tools onto the engine.
4. Connect the vehicle speed sensor (VSS) electrical connector.
5. Connect the backup lamp electrical connector.
6. Install the engine wiring harness bracket and nut.
^ Tighten to 20 Nm (15 ft. lbs.).
7. Install the ground wire and bolt.
^ Tighten to 10 Nm (89 inch lbs.).
8. Install the starter and the 2 stud bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
9. Connect the starter wires and install the 2 nuts.
^ Tighten the large nut to 12 Nm (9 ft. lbs.).
^ Tighten the small nut to 5 Nm (44 inch lbs.).
10. Attach the 2 wiring harness retainers to the starter stud bolts.
11. Raise the engine and transaxle into the vehicle.
12. Install the 2 transaxle mount bolts.
^ Tighten to 90 Nm (66 ft. lbs.).
13. Install the engine mount bracket, 2 nuts and the bolt.
^ Tighten the nuts to 103 Nm (76 ft. lbs.).
^ Tighten the bolt to 115 Nm (85 ft. lbs.).
14. Install the 2 oil pan-to-bellhousing bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
15. Install the bellhousing-to-oil pan bolt.
^ Tighten to 48 Nm (35 ft. lbs.).
16. Install the RH halfshaft into the transaxle.
17. Install the 2 RH halfshaft carrier bearing bracket bolts.
^ Tighten to 40 Nm (30 ft. lbs.).
18. CAUTION: Install a new circlip on the LH halfshaft is removed from the transaxle.
NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding.
Install a new circlip in the groove on the LH halfshaft.
19. Install LH halfshaft into the transaxle.
20. Connect the lower radiator hose and install the retaining clip.
21. Install the ground wire and the bolt on the engine mount bracket.
^ Tighten to 10 Nm (89 inch lbs.).
22. Connect the A/C tube to the condenser and install the nut.
^ Tighten to 8 Nm (71 inch lbs.).
23. Connect the A/C tubes and install the 2 nuts.
^ Tighten to 8 Nm (71 inch lbs.).
24. Install the 2 A/C tube bracket bolts.
^ Tighten to 10 Nm (89 inch lbs.).
25. Attach the coolant vent hose retaining clip to the A/C tube.
26. Install the radio frequency interference capacitor, ground wire and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
27. Connect the power steering cooler tube.
28. Attach the transaxle control cables to the bracket.
^ Connect the control cables to the control levers.
29. Install the clutch slave cylinder and the 2 bolts.
^ Tighten to 22 Nm (16 ft. lbs.).
30. Install the 2 clutch tube bracket bolts.
^ Tighten to 22 Nm (16 ft. lbs.).
31. Connect the heater hose inline connector.
32. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the heater hose.
33. Connect the upper radiator and heater hoses to the coolant bypass.
34. Attach the evaporative emissions (EVAP) tube bundle retaining clip to the bracket.
35. Connect the EVAP tube to the intake manifold.
36. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
37. Connect the crankcase vent tube to the valve cover.
38. Connect the fuel supply tube to the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.
39. Connect the powertrain control module (PCM) electrical connector and the pin-type retainer.
40. Install the ground wire and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
41. Connect the 2 engine wiring harness electrical connectors.
42. Connect the wire and install the nut on the battery cable.
^ Tighten to 10 Nm (89 inch lbs.).
43. Install the battery tray. For additional information, refer to Battery.
44. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
45. Install the generator air inlet duct, bolt and the 2 nuts.
^ Tighten to 6 Nm (53 inch lbs.).
46. Place the subframe assembly on the special tool and raise the subframe into the installed position.
47. NOTE: LH shown, RH similar.
Install the front subframe nuts.
^ Tighten to 150 Nm (111 ft. lbs.).
48. NOTE: LH shown, RH similar.
Position the subframe brackets and install the bolts finger-tight.
49. NOTE: LH shown, RH similar.
Install the subframe nuts.
^ Tighten to 150 Nm (111 ft. lbs.).
50. NOTE: LH shown, RH similar.
Tighten the subframe bracket-to-body bolts to 103 Nm (76 ft. lbs.).
51. NOTE: LH shown, RH similar.
Install the through bolts into the lower control arms.
^ Tighten to 103 Nm (76 ft. lbs.).
52. NOTE: LH shown, RH similar.
Install the lower ball joint nuts.
^ Tighten to 200 Nm (148 ft. lbs.).
53. NOTE: LH shown, RH similar.
Install the sway bar links and nuts to the struts.
^ Tighten to 40 Nm (30 ft. lbs.).
54. Connect the power steering cooler tube.
55. NOTE: LH shown, RH similar.
Install tie-rod ends and nuts.
^ Tighten to 48 Nm (35 ft. lbs.).
^ Install the cotter pin.
56. Install the LH splash shield and the 6 pin-type retainers (4 shown).
57. Position the LH fender splash shield and install the 4 screws.
58. Install the RH splash shield and the 6 pin-type retainers (4 shown).
59. Position the RH fender splash shield and install the 4 screws.
60. Install the engine roll restrictor bolt.
^ Tighten to 90 Nm (66 ft. lbs.).
61. Route the power steering pressure (PSP) tube up into the engine compartment.
62. 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 dash.
63. Install the oil filter element.
64. If equipped, install the underbody cover and the 7 screws.
65. Install the exhaust flexible pipe. For additional information, refer to Catalytic Converter.
66. Connect the PSP tube to the power steering pump and install the bolt.
^ Tighten to 35 Nm (26 ft. lbs.).
67. NOTE: Align the index marks made during removal.
Install the steering intermediate shaft onto the steering gear and install the bolt.
^ Tighten to 23 Nm (17 ft. lbs.).
68. Install the steering joint cover and the 2 nuts.
69. Fill the engine with clean engine oil.
70. Connect the battery ground cable. For additional information, refer to Battery.
71. Fill and bleed the cooling system. For additional information, refer to Cooling System.
72. Fill the power steering system.
73. Recharge the air conditioning system. For additional information, refer to Heating and Air Conditioning.