Installation Procedure

Installation Procedure




1. Install a suitable lifting devise to the engine.
2. Using the lifting devise, position and install the engine to the transaxle.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the transaxle bolts to the engine and tighten the bolts to 75 Nm (55 lb ft).




4. Install the torque converter to flexplate bolts (1) and tighten to 60 Nm (44 lb ft).
5. Remove the engine lifting devise.




6. Install the starter motor and bolts and tighten the bolts to 53 Nm (39 lb ft).




7. Gather all branches of the engine wiring harness and position the harness to the engine.
8. Position the engine wiring harness ground terminal to the engine and install the engine wiring harness ground bolt (1).
Tighten the bolt to 20 Nm (15 lb ft).




9. Connect the engine wiring harness electrical connector (1) to the ECT sensor.
10. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector.
11. Install the engine wiring harness clip (5) to the stud.




12. Connect the engine wiring harness electrical connector (1) to the exhaust CMP sensor.




13. Connect the engine wiring harness electrical connector (1) to the intake CMP sensor.
14. Connect the engine wiring harness electrical connector (2) to the EVAP emission canister purge solenoid valve.




15. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
16. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
17. Connect the engine wiring harness electrical connector (3) to the knock sensor.




18. Connect the engine wiring harness electrical connectors (1) to the ignition coils.
19. Connect the engine wiring harness electrical connectors (2, 3) to the camshaft actuators.




20. Connect the engine wiring harness electrical connector (1) to the throttle actuator.
21. Connect the engine wiring harness electrical connector (8) to the fuel injector wiring harness electrical connector (7).
22. Install the engine wiring harness clip (3) to the oil level indicator tube bracket.




23. Position the powertrain and support table under the vehicle.
24. Raise the powertrain into position under the vehicle.
25. With the table positioned, if required, lower the vehicle over the powertrain.
26. Align the lower radiator pins with the frame. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
27. Install the NEW frame to body bolts and tighten to 155 Nm (114 lb ft).
28. Lower the vehicle.




29. Install the transaxle mount to transaxle adapter bolts and tighten to 55 Nm (41 lb ft).




30. Install the engine mount to engine mount bracket bolts (2).
31. Tighten the engine mount to bracket bolts in the following sequence:

1. Middle
2. Rear
3. Front
Tighten the bolts to 50 Nm (37 lb ft).

32. Raise and support the vehicle.
33. Install the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement (Front Wheel Drive Shaft Replacement).




34. Install the control arm ball studs into the steering knuckles.
35. Install the ball stud nuts and tighten to 40 Nm (30 lb ft).
36. Continue to tighten the nuts only enough to align the castle nut slots with the ball stud, install NEW cotter pins.




37. Connect the stabilizer links to the stabilizer shaft and install the stabilizer link to stabilizer shaft nuts.
Tighten the nuts to 65 Nm (48 lb ft).




38. Connect the outer tie rods to the steering knuckles.
39. Use the J 44015
40. Remove the J 44015 .




41. Install NEW outer tie rod to steering knuckle nuts and tighten to 25 Nm (48 lb ft) plus 90 degrees.




42. Position the intermediate shaft to the steering gear and install a NEW pinch bolt.
Tighten the bolt to 34 Nm (25 lb ft).
43. Install the catalytic converter. Refer to Catalytic Converter Replacement (Service and Repair).




44. Install the transaxle oil cooler lines to the transaxle.
45. Install the transaxle oil cooler line to transaxle nut (1) and tighten to 4 Nm (27 lb in).




46. Remove the wood from between the oil pan and the engine cradle.
47. Remove the wood from between the transaxle and the engine cradle.
48. Install the front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement (Service and Repair).
49. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
50. Lower the vehicle.




51. Unsecure and position the radiator/condenser/fan assembly.




52. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
53. Install the transaxle shift cable to the range select lever.
54. Raise and support the vehicle.
55. Install the oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (Service and Repair) and Heated Oxygen Sensor Replacement - Sensor 2 (Service and Repair).
56. Instal the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LAT or LE5) (Service and Repair).




57. On LAT engine, install the auxiliary heater water pump and bolt and tighten the bolt to 9 Nm (80 lb in).




58. Connect the engine wiring harness electrical connector (2) to the auxiliary heater water pump.
59. Install the engine control module. Refer to Engine Control Module Replacement (Service and Repair).




60. On all engines, position and install the positive battery cable between the starter and the engine.
61. Install the positive battery cable lead (1) to the starter motor.
62. Install the positive battery cable to starter motor nut (4) and tighten the nut to 9 Nm (80 lb in).




63. Position the negative battery cable and install the negative battery cable lead (2) to the transaxle stud.
64. Install the engine wiring harness ground lead nut (1) to the transaxle stud and tighten the nut to 50 Nm (37 lb ft).




65. Position the A/C compressor and install the bolts and tighten to 50 Nm (37 lb ft).




66. On LAT engine, install the generator control module coolant pump and bolt and tighten the bolt to 25 Nm (18 lb ft).




67. Connect the engine wiring harness electrical connector (1) to the generator control module coolant pump.
68. On all engines, connect the engine wiring harness electrical connector (2) to the A/C compressor.
69. Lower the vehicle.




70. Install the coolant recovery reservoir/heater inlet hose (2) to the thermostat housing.
71. Position the coolant recovery reservoir/heater inlet hose (2) clamp at the thermostat housing.
72. Install the heater inlet hose (3) to the thermostat housing.
73. Position the heater inlet hose clamp at the thermostat housing.
74. Install the auxiliary heater water pump hose clip (1) to the heater outlet hose.




75. On LAT engine, connect the engine wiring harness electrical connector (1) to the transaxle auxiliary pump module.




76. Install the generator control module coolant hose to the generator control module.
77. Position the generator control module coolant hose clamp (1) at the generator control module.




78. On all engines, reposition the radiator inlet hose clamp using the J 38185 .
79. Remove the radiator inlet hose from the cylinder head.
80. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LAT) (Service and Repair)Radiator Outlet Hose Replacement (LY7) (Service and Repair)Radiator Outlet Hose Replacement (LZ4) (Service and Repair)Radiator Outlet Hose Replacement (LE5) (Service and Repair)Radiator Outlet Hose Replacement (HP5) (Service and Repair).




81. Position and install the coolant recovery inlet hose (1) to the cylinder head.
82. Install the coolant recovery inlet pipe clip to the fuel rail.
83. Install the coolant recovery inlet hose clamp (2) at the cylinder head.




84. Position and install the vacuum brake booster hose (2) to the intake manifold.
85. Position the vacuum brake booster hose clamp (1) at the intake manifold.
86. Install the generator starter. Refer to Generator with Starter Replacement (Service and Repair).
87. For the LAT, install the battery tray. Refer to Battery Tray Replacement (HP7) (Battery Tray Replacement).
88. For the LE5, install the battery box. Refer to Battery Box Replacement (Battery Box Replacement).




89. Install the transaxle shift cable clip (1) to the fuel line bracket.




90. Install the throttle body. Refer to Throttle Body Assembly Replacement (Removal and Replacement).
91. Install the fuel feed pipe clip (2) to the fuel line bracket.
92. Connect the EVAP line (3) quick connect fitting to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
93. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
94. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).
95. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
96. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill With HP5) (Service and Repair)Cooling System Draining and Filling (Static Fill Without HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill With HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill Without HP5) (Service and Repair).
97. For the LAT engine, reconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).
98. Fill the transaxle with fluid. Refer to Transmission Fluid Check (4T45-E Automatic Transaxle).
99. Refill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
100. Recharge the A/C system with refrigerant. Refer to Refrigerant Recovery and Recharging (With HP5) (Refrigerant Recovery and Recharging)Refrigerant Recovery and Recharging (Without HP5) (Refrigerant Recovery and Recharging).
101. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Service and Repair).
102. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.
103. Install the hood. Refer to Hood Replacement (Service and Repair).