Installation Procedure
Engine Replacement
Tools Required
* J 38185 Hose Clamp Pliers
* J 43828 Ball Joint Remover
* J 44015 Steering Linkage Installer
* J 44015 Tie Rod Installer
* SA91100C Tie Rod Separator
Installation Procedure
1. Install a suitable lifting devise to the engine.
2. Using the lifting devise, position and install the engine to the transaxle.
Notice: Refer to Fastener Notice (Fastener Notice).
3. Install the transaxle bolts to the engine.
Tighten the bolts to 75 N.m (55 lb ft).
4. Install the torque converter to flexplate bolts (1).
Tighten the bolts to 60 N.m (44 lb ft).
5. Remove the engine lifting devise.
6. Install the starter motor and bolts.
Tighten the bolts to 53 N.m (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 N.m (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 cradle. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
27. Install the NEW cradle to body bolts.
Tighten the bolts to 155 N.m (114 lb ft).
28. Lower the vehicle.
29. Install the transaxle mount to transaxle bolts.
Tighten the bolts to 55 N.m (41 lb ft).
Important: The engine mount to bracket bolts must be hand started. Do not pry the engine mount to align the holes.
30. Install the engine mount to bracket bolts (1).
Tighten the bolts to 50 N.m (37 lb ft).
31. Raise and support the vehicle.
32. Install the wheel drive shafts. Refer to Wheel Drive Shaft Replacement (Wheel Drive Shaft Replacement).
33. Install the control arm ball studs into the steering knuckles.
34. Install the ball stud nuts
Tighten the nuts to 40 N.m (30 lb ft).
35. Continue to tighten the nuts only enough to align the castle nut slots with the ball stud, install NEW cotter pins.
36. Connect the stabilizer links to the stabilizer shaft and install the stabilizer link to stabilizer shaft nuts.
Tighten the nuts to 65 N.m (48 lb ft).
37. Connect the outer tie rods to the steering knuckles.
38. Use the J 44015 in order to seat the ball stud taper to 40 N.m (30 lb ft).
39. Remove the J 44015.
40. Install NEW outer tie rod to steering knuckle nuts.
Tighten the nuts to 25 N.m (48 lb ft) plus 90 degrees.
41. Position the intermediate shaft to the steering gear and install a NEW pinch bolt.
Tighten the bolt to 34 N.m (25 lb ft).
42. Install the catalytic converter.
43. Install the transaxle oil cooler lines to the transaxle.
44. Install the transaxle oil cooler line to transaxle nut (1).
Tighten the nut to 4 N.m (27 lb in).
45. Remove the wood from between the oil pan and the engine cradle.
46. Remove the wood from between the transaxle and the engine cradle.
47. Install the front fender liners. Refer to Front Fender Liner Replacement (Service and Repair).
48. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
49. Lower the vehicle.
50. Unsecure and position the radiator/condenser/fan assembly.
51. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
52. Install the transaxle shift cable to the range select lever.
53. Raise and support the vehicle.
54. Install the auxiliary heater water pump and bolt.
Tighten the bolt to 9 N.m (80 lb in).
55. Connect the engine wiring harness electrical connector (2) to the auxiliary heater water pump.
56. Position and install the positive battery cable between the starter and the engine.
57. Install the positive battery cable lead (1) to the starter motor.
58. Install the positive battery cable to starter motor nut (4).
Tighten the nut to 9 N.m (80 lb in).
59. Position the A/C compressor and install the bolts.
Tighten the bolts to 50 N.m (37 lb ft).
60. Install the generator control module coolant pump (2) and bolt (3).
Tighten the bolt to 25 N.m (18 lb ft).
61. Connect the engine wiring harness electrical connector (1) to the generator control module coolant pump.
62. Connect the engine wiring harness electrical connector (2) to the A/C compressor.
63. Lower the vehicle.
64. Install the coolant recovery reservoir/heater inlet hose (4) to the thermostat housing.
65. Position the coolant recovery reservoir/heater inlet hose clamp (3) at the thermostat housing.
66. Install the heater inlet hose (3) to the thermostat housing.
67. Position the heater inlet hose clamp (1) at the thermostat housing.
68. Connect the engine wiring harness electrical connector (1) to the transaxle auxiliary pump module.
69. Install the generator control module coolant hose to the generator control module.
70. Position the generator control module coolant hose clamp (1) at the generator control module.
71. Reposition the radiator inlet hose clamp using the J 38185.
72. Remove the radiator inlet hose from the cylinder head.
73. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LE5) (Service and Repair).
74. Position and install the coolant recovery inlet hose (1) to the cylinder head.
75. Install the coolant recovery inlet pipe clip to the fuel rail.
76. Install the coolant recovery inlet hose clamp (2) at the cylinder head.
77. Position and install the vacuum brake booster hose (2) to the intake manifold.
78. Position the vacuum brake booster hose clamp (1) at the intake manifold.
79. Install the generator starter.
80. Install the battery tray.
81. Install the transaxle shift cable clip (1) to the fuel line bracket.
82. Install the fuel feed pipe clip (2) to the fuel line bracket.
83. 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).
84. 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).
85. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1st Design) (Air Cleaner Assembly Replacement (1st Design))Air Cleaner Assembly Replacement (2nd Design) (Air Cleaner Assembly Replacement (2nd Design)).
86. Fill the transaxle with fluid.
87. Refill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
88. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Service and Repair).
89. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.