Part 2

Engine Replacement (w/Manual Transmission)

Special Tools

J 45059 Angle Meter

Installation Procedure




1. Install the catalytic converter (3) and gasket (1) to the turbocharger and bracket (4).

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the catalytic converter nuts (2).

Tighten the nuts to 59 Nm (43 lb ft).




3. Install the catalytic converter to bracket bolts.

Tighten the bolts to 22 Nm (16 lb ft).




4. Install the A/C compressor and bolts.

Tighten the bolts in the sequence shown to 22 Nm (16 lb ft).




5. Install a suitable engine lifting devise to the engine.
6. Remove the engine from the stand.
7. Using a nylon bristle brush clean the thread adhesive from the flywheel bolt holes, if necessary.
8. Install the flywheel and bolts.

Tighten the bolts to 53 Nm (39 lb ft) plus an additional 25 degrees using the J 45059 .

9. Install the clutch pressure plate and disc. Refer to Clutch Pressure and Driven Plate Replacement (Service and Repair).




10. Install the engine to the vehicle.
11. Install the right engine mount upper nut.

Tighten the nut to 55 Nm (41 lb ft).




12. Install the left engine mount upper nut.

Tighten the nut to 55 Nm (41 lb ft).

13. If installed, remove the engine lift bracket from the engine.
14. Raise and support the vehicle.




15. Position the power steering pump bracket to the engine and install the bracket bolts.

Tighten the bolts to 58 Nm (43 lb ft).

16. Lower the vehicle.




17. Position the A/C compressor line and install the bolt.

Tighten the bolts to 22 Nm (16 lb ft).




18. Position the turbocharger coolant feed pipe to the vehicle.
19. Install the turbocharger coolant feed pipe bracket bolt (3) to the cylinder head.

Tighten the bolt to 10 Nm (89 lb in).

20. Install the turbocharger coolant feed pipe fitting (2) to the cylinder head.

Tighten the fitting to 35 Nm (26 lb ft).

21. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger.

Tighten the bolt to 35 Nm (26 lb ft).




22. Position the vacuum hose to the turbocharger.
23. Install the vacuum hose to the turbocharger.
24. Position the vacuum hose clamp (5) at the turbocharger.
25. Install the vacuum hose to the turbocharger coolant feed pipe clips (4).




26. Position the branches of the engine harness to the engine.
27. Install the engine harness clips (3, 4) to the front studs.




28. Install the engine wiring harness ground terminal (1) to the cylinder head.
29. Install the engine wiring harness ground bolt (2) to the cylinder head.

Tighten the bolt to 25 Nm (18 lb ft).




30. Connect the engine wiring harness electrical connector to the boost sensor.




31. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe tab.
32. Install the engine wiring harness clip (3) to the turbocharger coolant feed pipe stud (2).




33. Connect the engine harness clips (2) to the camshaft cover.
34. Connect the engine harness clip (1) to the camshaft cover.




35. Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
36. Connect the engine wiring harness electrical connector (3) to the ECT sensor.
37. Position the engine harness ground terminal (1) and install the engine harness ground terminal bolt (2).

Tighten the bolt to 25 Nm (18 lb ft).




38. Connect the engine wiring harness electrical connector (1) to the HO2S (3).




39. Connect the engine wiring harness electrical connectors to the ignition coils.




40. Install the engine harness clip (1) to the camshaft cover.




41. Connect the engine wiring harness electrical connector (2) to the intake CMP actuator.
42. Connect the engine wiring harness electrical connector (1) to the exhaust CMP actuator.




43. Connect the engine wiring harness electrical connector (2) to the intake CMP sensor.
44. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
45. Install the engine wiring harness clip (3) to the high pressure fuel pump bracket.




46. Connect the engine wiring harness electrical connector (1) to the windshield wiper motor.
47. Install the engine harness clip (2) to the wiper motor hole.




48. Connect the engine wiring harness electrical connector (1) to the brake booster vacuum sensor.




49. Connect the engine wiring harness electrical connector (1) to the A/C refrigerant pressure sensor.




50. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid valve.
51. Connect the engine wiring harness electrical connector (2) to the MAP sensor.




52. Connect the engine wiring harness electrical connector (1) to the throttle actuator.
53. Connect the engine wiring harness electrical connector (2) to the knock sensor.
54. Install the engine wiring harness clip (3) to the intake manifold brace.




55. Connect the engine wiring harness electrical connector (1) to the fuel injector jumper electrical connector.




56. Install the positive battery cable terminal (3) to the generator.
57. Install the generator terminal nut (1).

Tighten the nut to 20 Nm (15 lb ft).

58. Position the positive battery cable terminal boot (2).
59. Connect the engine wiring harness electrical connector (4) to the A/C compressor.




60. Connect the engine wiring harness electrical connector (1) to the generator.




61. Connect the engine wiring harness electrical connector (2) to the knock sensor.
62. Install the engine wiring harness clip (1) to the oil level indicator tube bracket.




63. Connect the engine wiring harness electrical connector (1) to the transmission oil cooler pump.




64. Position the negative/positive battery cable to the engine.
65. Install the negative battery cable ground terminal (5) to the engine lift bracket.
66. Install the negative battery cable ground bolt (6) to the front engine lift bracket.

Tighten the bolt to 25 Nm (18 lb ft).

67. Install NEW tie straps (1) to the engine wiring harness.




68. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
69. Raise the vehicle.




70. Install the engine wiring harness terminal (3) to the starter.
71. Install the engine wiring harness terminal (1) to the starter.
72. Install the engine wiring harness terminal nut (2) to the starter.

Tighten the nut to 3 Nm (27 lb in).

73. Install the engine wiring harness clip (4) to the oil level indicator tube.




74. Install the positive battery cable lead (3) to the starter.
75. Install the positive battery cable lead nut (2) at the starter.

Tighten the nut to 10 Nm (89 lb in).

76. Install the engine wiring harness clip (4) to the oil level indicator tube bracket.




77. Connect the engine wiring harness electrical connector (1) to the brake booster vacuum pump.




78. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
79. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
80. Lower the vehicle.




81. Install the heater inlet (1) and outlet (2) hoses to the thermostat housing.
82. Position the heater inlet and outlet hose clamps at the thermostat housing.




83. Position the air bleed hose to the engine.
84. Install the surge tank air bleed hose to the engine.
85. Install the surge tank air bleed hose clip (3) to the surge tank bracket.
86. Position the surge tank air bleed hose clamp (1) at the engine.




87. Install the surge tank clip (1) to the oil level indicator tube bracket.
88. Position the surge tank outlet hose clamp (2) at the surge tank.




89. Install the surge tank outlet hose to the thermostat housing and oil cooler.
90. Position the surge tank outlet hose clamp (1) at the oil cooler.
91. Position the surge tank outlet hose clamp (2) at the thermostat housing.




92. Position the outlet hose to the engine.
93. Install the radiator outlet hose clip (3) to the bracket.
94. Install the radiator outlet hose to the thermostat housing and oil cooler.
95. Position the radiator outlet hose clamp (1) at the oil cooler.
96. Position the radiator outlet hose clamp (2) at the thermostat housing.




97. Position the inlet hose to the engine.
98. Install the radiator inlet hose to the engine.
99. Position the radiator inlet hose clamp at the engine.




100. Remove the cap or plug from the turbocharger opening.
101. Install the charge air cooler pipe to the turbocharger.
102. Install the charge air cooler pipe to turbocharger bolts (1).

Tighten the bolts to 22 Nm (16 lb ft).




103. Install the turbocharger heat shield and bolts (1).

Tighten the bolts to 10 Nm (89 lb in).

104. Install the transmission. Refer to Transmission Replacement (With ZOK) (Aisin AR5 - Maunal Transmission)Transmission Replacement (Without ZOK) (Transmission Replacement (Without ZOK)).
105. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (SKY) (Service and Repair)Air Inlet Grille Panel Replacement (Solstice) (Service and Repair).
106. Install the charge air cooler inlet and outlet pipes. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe Replacement) and Charge Air Cooler Outlet Pipe Replacement (Charge Air Cooler Outlet Pipe Replacement).




107. Connect the fuel feed pipe (1) to the fuel line. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
108. Connect the EVAP canister purge solenoid tube to the valve (2). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
109. Install the radiator. Refer to Radiator Replacement (Service and Repair).
110. Install the drive belt. Refer to Drive Belt Replacement (Drive Belt Replacement).
111. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
112. Install the hood. Refer to Hood Replacement (Service and Repair).
113. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
114. Fill the engine with oil.