Part 1

Engine













Installation

NOTICE: If the oil pan was removed during engine disassembly, it must be installed after 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 Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, align the transaxle to the engine.





2. Install the 4 transaxle-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





3. Install the transaxle-to-engine bolt.
- Tighten to 48 Nm (35 lb-ft).





4. Connect the 2 transmission electrical connectors and attach the wiring harness retainer to the stud bolt.





5. Attach the wiring harness retainer to the transmission indicator tube.





6. Install the starter and the 2 stud bolts.
- Tighten to 27 Nm (20 lb-ft).





7. Install the starter wiring and the 2 nuts.
- Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in).

- Tighten the large starter motor solenoid battery cable nut to 12 Nm (106 lb-in).





8. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Use a plastic scraping tool to remove all traces of the oil pan gasket.

- Clean all sealing surfaces with metal surface prep and install a new oil pan gasket.

9. Install the starter wiring ground wire and nut.
- Tighten to 18 Nm (159 lb-in).





10. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, position the engine and transaxle onto the lift table.





11. NOTE: Position a suitable block of wood under the transaxle.

Install the Universal Adapter Brackets and the Powertrain Lift to the engine.





12. Raise the engine and transaxle up into the vehicle.

13. Install the engine support insulator bracket, 3 nuts and the bolt.
- Tighten the nuts to 63 Nm (46 lb-ft).

- Tighten the bolt to 115 Nm (85 lb-ft).





14. Install the damper and bolt.
- Tighten to 23 Nm (17 lb-ft).





15. Install the ground strap and bolt on the engine mount bracket.
- Tighten to 10 Nm (89 lb-in).





16. Install the rear transaxle support through bolt.
- Tighten to 103 Nm (76 lb-ft).





17. Install the transaxle-to-engine stud and 2 nuts.
- Tighten to 48 Nm (35 lb-ft).





18. NOTE: Clean and degrease all sealing surfaces with metal surface prep.

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.





19. NOTE: Install a new oil pan gasket.

Position the oil pan and gasket and loosely install the bolts and stud bolts.





20. Install the 2 oil pan-to-transaxle bolts.
- Tighten to 40 Nm (30 lb-ft).





21. Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).





22. Install the 4 torque converter nuts.
- Tighten to 40 Nm (30 lb-ft).





23. Install the access cover.





All-Wheel Drive (AWD) vehicles

24. Install the Power Transfer Unit (PTU) and the 5 bolts.
- Tighten to 90 Nm (66 lb-ft).





25. Install the PTU support bracket and the 5 bolts.
- Tighten to 55 Nm (41 lb-ft).





26. NOTE: A new PTU seal must be installed whenever the intermediate shaft is removed.
Install a new PTU seal. For additional information, refer to Transfer Case.

27. Using a new gasket, install the RH catalytic converter and 3 new nuts.
- Tighten to 40 Nm (30 lb-ft).





28. Install the RH exhaust heat shield bracket (inboard half) and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).





29. Install the RH exhaust heat shield bracket (outboard half) and the 3 nuts.
- Tighten to 20 Nm (177 lb-in).





30. Install the RH exhaust heat shield and the 6 bolts.
- Tighten to 10 Nm (89 lb-in).





31. Using the Exhaust Gas Oxygen Sensor Socket, install the RH Heated Oxygen Sensor (HO2S).
- Calculate the correct torque wrench setting for the following torque.

- To install, tighten to 48 Nm (35 lb-ft).





32. Connect the RH HO2S electrical connector.





33. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.





All vehicles

34. Position the A/C manifold onto the A/C compressor and install the bolt.
- Install a new gasket.

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





35. Install 6 new LH catalytic converter studs.
- Tighten to 12 Nm (106 lb-in).





36. Install a new gasket, the LH catalytic converter and 6 new nuts.
- Tighten to 20 Nm (177 lb-in) in the sequence shown.





37. Install the heat shield and the 4 bolts (3 shown).
- Tighten to 10 Nm (89 lb-in).





38. Connect the LH CMS electrical connector.





39. Connect the A/C tube and install the nut.
- Install a new gasket.

- Tighten to 8 Nm (71 lb-in).





40. Install the A/C tube/windshield washer bottle bracket bolt.
- Tighten to 10 Nm (89 lb-in).





41. Position the transaxle control cable bracket in place, install the 2 bolts.
- Tighten to 23 Nm (17 lb-ft).





42. Connect the gearshift cable to the transaxle.





43. Connect the 2 heater hoses.





44. Connect the upper and lower radiator hoses.





45. Connect the LH HO2S electrical connector.





46. Connect the Evaporative Emission (EVAP) tube-to-EVAP canister purge valve quick connect coupling and the brake booster vacuum tube to the upper intake manifold.
- Attach the fuel tube and EVAP tube-to- EVAP canister purge valve tube retainer to the upper intake manifold.





47. Connect the fuel supply tube to the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.

48. Connect the 3 PCM electrical connectors.





49. Position the PCM ground wire and install the bolt.
- Tighten to 10 Nm (89 lb-in).





50. Attach the 2 wiring harness retainers to the battery tray bracket and transaxle mount.