Installation

Engine

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Material(s)






Installation

1. NOTICE: Use caution not to damage the transmission wiring harness or sensors.

NOTE: If using the existing automatic transmission clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.

NOTE: Automatic transmission shown, manual transmission similar.
Using 300-OTC1819E and 303-D089 (D93P-6001-A3) , lift the engine and position the engine and transaxle together. If automatic transmissions, install the 4 bellhousing-to-engine fasteners. If manual transmission equipped, install the 5 bellhousing-to-engine fasteners.
- Tighten to 45 Nm (33 lb-ft).






2. Install the ground cable and the nut.
- Tighten to 20 Nm (177 lb-in).





3. NOTE: Automatic transmission shown, manual transmission similar.

Install the 2 rear engine-to-transmission bolts.
- Tighten to 45 Nm (33 lb-ft).






4. Using 300-OTC1819E and 303-D089 (D93P-6001-A3) , raise the engine and transaxle assembly onto the lift table.





5. NOTE: Position a block of wood under the transmission.

Using 014-00001 , attach the powertrain to the 300-OTC1585AE.






6. NOTICE: Rotate the engine in a clockwise direction only or engine damage may occur.

NOTICE: Tighten the flexplate-to-clutch nuts in a star pattern or transmission damage can occur.

NOTE: To prevent the flexplate-to-clutch nuts from falling into the clutch housing and causing damage, use a magnetic socket to install the 6 flexplate-to-clutch nuts.

NOTE: Align the index mark on the clutch stud made during removal.
If equipped with an automatic transmission, install the 6 new flexplate-to-clutch nuts. Tighten the nuts in a star pattern in 2 stages.

1. Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm (106 lb-in).

2. Stage 2: Tighten all nuts to 25 Nm (18 lb-ft).






7. Install the starter motor isolator.





8. Install the starter motor. REFER to Starter Motor - 2.0L GDI .

9. Attach the battery power supply cable wiring harness retainer to the starter motor support bracket.






10. If equipped with automatic transmission, connect the transmission wiring harness electrical connector.





11. Position the powertrain into the vehicle.

12. Install the transmission mount bolt.
- Tighten the bolt to 150 Nm (111 lb-ft).





13. Install the engine mount and the 2 bolts and the 2 nuts.
- Tighten the nuts to 80 Nm (59 lb-ft).
- Tighten the bolts to 90 Nm (66 lb-ft).





14. Install the engine mount clip and install the A/C (Air Conditioning) line.





15. Install the roll restrictor mounting bracket and the 2 bolts.
- Tighten to 86 Nm (63 lb-ft).





16. NOTE: Automatic transmission shown, manual transmission similar.
Install the 2 transmission bellhousing-to-oil pan bolts.
- Tighten to 48 Nm (35 lb-ft).





17. NOTE: Automatic transmission shown, manual transmission similar.
Install the 2 oil pan-to-transmission bellhousing bolts.
- Tighten to 48 Nm (35 lb-ft).





18. Install the cooling fan and shroud. REFER to Cooling Fan Motor and Shroud - 2.0L GDI .

19. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
Install a new engine oil filter.
- Tighten to 8 Nm (71 lb-in) plus an additional 180 degrees.





20. Connect the lower radiator hose to the radiator.





21. Using 2 new O-ring seals, connect the A/C (Air Conditioning) tubes to the compressor and install the 2 nuts and the A/C (Air Conditioning) tube support bracket bolt.
- Tighten the nuts to 20 Nm (177 lb-in).
- Tighten the bolt to 25 Nm (18 lb-ft).






22. Install the A/C (Air Conditioning) tube support bracket bolt.
- Tighten the bolt to 18 Nm (159 lb-in).





23. Install the RH and LH halfshafts. REFER to Halfshaft - RH and REFER to Halfshaft - LH .

24. If equipped with a manual transmission, position aside the cable and bracket assembly and install the 2 nuts and connect the 2 gearshift cables.
- Tighten the nuts to 48 Nm (35 lb-ft).





25. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

If equipped with a manual transmission, connect the clutch hydraulic line.





26. If equipped with an automatic transmission, position the shift control cable and bracket assembly and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





27. If equipped with an automatic transmission, connect the shift cable to the retainer.






28. If equipped with an automatic transmission, install the transmission control cable to the support bracket.






29. If equipped with an automatic transmission, connect the selector lever cable to the manual control lever.






30. Connect the brake booster vacuum tube to the intake manifold.





31. Connect the FTP (Fuel Tank Pressure) sensor electrical connector and the EVAP (Evaporative Emission) tube quick connect coupling. REFER to Quick Connect Coupling - Type 1 .





32. Connect the fuel supply tube to the fuel injection pump. REFER to Quick Connect Coupling - Type 1 .





33. Install the 5 catalytic converter-to-cylinder head studs.
- Tighten to 17 Nm (150 lb-in).





34. NOTICE: Failure to tighten the catalytic converter manifold nuts to specification a second time may cause the converter to develop an exhaust leak.

NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket installation to make sure of proper sealing.
Using a new gasket, position the catalytic converter and install the 5 catalytic converter manifold-to-cylinder head nuts and tighten in 2 stages in the sequence shown.
- Stage 1: Tighten to 55 Nm (41 lb-ft).
- Stage 2: Tighten to 55 Nm (41 lb-ft).





35. Install the 2 bolts for the catalytic converter hanger.
- Tighten to 25 Nm (18 lb-ft).





36. Install the 2 nuts to the catalytic converter-to-muffler.
- Tighten the first nut to 48 Nm (35 lb-ft).
- Tighten the second nut to 48 Nm (35 lb-ft).
- Re-tighten the first nut to 48 Nm (35 lb-ft).





37. Install the 2 bolts for the catalytic converter lower bracket.
- Tighten to 25 Nm (18 lb-ft).





38. Install the catalytic converter heat shield, CMS (Catalyst Monitor Sensor) wiring harness bracket and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





39. Connect the CMS (Catalyst Monitor Sensor) electrical connector.

- Attach the CMS (Catalyst Monitor Sensor) wire to the wiring harness retainer.






40. Install the HO2S (Heated Oxygen Sensor) sensor. REFER to Heated Oxygen Sensor (HO2S) .

41. If equipped, connect the block heater electrical connector.





42. Connect the 2 heater coolant hoses to the heater core.

- Install the 2 coolant hoses to the retainer.






43. Connect the degas bottle coolant hose and upper radiator hose to the coolant outlet.

- Attach the upper coolant hose retainer clip.






44. Connect the wiring harness to the BJB (Battery Junction Box).





45. Connect the 2 wiring harness retainers to the transmission mount and frame rail.





46. Position the engine wiring harness ground cables and install the 2 bolts.
- Tighten to 48 Nm (35 lb-ft).

- Attach the ground cable wiring harness retainer to the frame rail.






47. NOTE: The electrical connector is located behind the PCM (Powertrain Control Module) case.

Connect the electrical connector.





48. Install the PCM. REFER to Powertrain Control Module (PCM) .

49. Attach the generator power supply cable retainer to the transmission.





50. Install the generator power supply cable and the nut to the high current BJB (Battery Junction Box).
- Tighten to 12 Nm (106 lb-in).





51. If equipped with automatic transmission, attach the transmission vent hose retainer from the crankcase vent tube.





52. Install the ACL (Air Cleaner) outlet pipe. REFER to Intake Air System Components - Exploded View and REFER to Air Cleaner Outlet Pipe - 2.0L GDI .

53. Install the battery tray. REFER to Battery and Battery Tray - Exploded View .

54. Install the degas bottle. REFER to Degas Bottle .

55. If equipped with manual transmission, fill and bleed the clutch system. REFER to Clutch System Bleeding .

56. Fill and bleed the cooling system. REFER to Cooling System Filling And Bleeding - With A Vacuum Cooling System Filler or REFER to Cooling System Filling And Bleeding - Without A Vacuum Cooling System Filler .

57. Install the underbody insulator and the 8 retainers.





58. Evacuate and charge the A/C (Air Conditioning) system. REFER to Air Conditioning (AC) System Recovery, Evacuation, and Charging .