Part 1

Engine









NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. Using the Floor Crane and Spreader Bar, align the transaxle to the engine.





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






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






4. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.





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

Install the Powertrain Lift and Adjustable Grip Arms.






6. Install the ground wire and the bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).






7. Attach the 2 wiring harness retainers to the transaxle stud bolts.





8. Attach the transaxle control wire harness retainer to the transaxle stud bolt.





9. Connect the transaxle control electrical connector.





10. Install the crankcase vent tube and connect the 2 quick connect couplings.





11. Install the LH exhaust manifold heat shield and the 3 bolts.
- Tighten to 14 Nm (124 lb-in).






12. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
- Tighten to 8 Nm (71 lb-in).






13. Attach the wiring harness retainer to the valve cover stud bolt.





14. Install the engine cover mounting stud to the LH valve cover stud bolt.
- Tighten to 6 Nm (53 lb-in).






15. Install the starter, the stud bolt and bolt.
- Tighten to 27 Nm (20 lb-ft).






16. Connect the wiring harness retainer to the starter motor stud bolt.





17. Attach the starter wire terminals and install the 2 nuts.
1. Tighten the B+ terminal nut to 12 Nm (106 lb-in).

2. Tighten the S-terminal nut to 5 Nm (44 lb-in).






18. Install the starter motor solenoid cover.





19. Raise the engine and transaxle assembly into the vehicle.

20. Install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).






21. Install the 4 engine mount nuts.
- Tighten to 63 Nm (46 lb-ft).






22. Install the bolt and the 3 nuts for the transaxle support insulator bracket-to-transaxle.
- Tighten the bolt to 80 Nm (59 lb-ft).

- Tighten the nuts to 63 Nm (46 lb-ft).






23. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.
Using a small screwdriver, remove the compression seal and discard.






24. Using a soft face hammer, install the new compression seal.





25. Position the PTU (Power Transfer Unit) in place and install the 5 bolts.
- Tighten to 90 Nm (66 lb-ft).






26. Position the PTU (Power Transfer Unit) support bracket in place and install the 3 bolts.
1. Tighten the 2 bolts to 70 Nm (52 lb-ft).

2. Tighten the bolt to 48 Nm (35 lb-ft).






27. Install the RH halfshaft support bracket and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).






28. Install the RH turbocharger lower bracket and the 3 bolts.
1. Tighten the bolt to 19 Nm (168 lb-in).

2. Tighten the 2 bolts to 48 Nm (35 lb-ft).






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






30. Install the 4 oil pan-to-transaxle bolts.
- Tighten to 48 Nm (35 lb-ft).






31. Install 3 new torque converter bolts.
- Tighten to 55 Nm (41 lb-ft).






32. Install the inspection cover and the 2 fasteners.





33. Connect the transaxle cooler tubes and install the 2 secondary latches.





34. Connect the lower radiator hose to the radiator.





35. Attach the lower radiator hose retainer to the cooling fan and shroud.





36. NOTE: Align the index marks for the LH Charge Air Cooler (CAC) tube.
Connect the lower LH CAC (Charge Air Cooler) tube to the LH turbocharger.

- Tighten to 5 Nm (44 lb-in).






37. Using a new O-ring seal and gasket seal, install the upper A/C tube to the A/C compressor and install the nut.
- Tighten to 15 Nm (133 lb-in).






38. Install the A/C tube bracket and bolt to the rear of the A/C compressor.
- Tighten to 25 Nm (18 lb-ft).






39. Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.






40. Line up the index marks on the rear driveshaft to the index marks on the PTU (Power Transfer Unit) flange made during removal and install the 4 new bolts.
- Tighten to 70 Nm (52 lb-ft).






41. Connect the fuel supply tube.





42. Install the Evaporative Emission (EVAP) tube assembly and connect the quick connect coupling to the intake manifold.





43. Connect the EVAP (Evaporative Emission) valve electrical connector and attach to the intake manifold.





44. Connect the EVAP (Evaporative Emission) tube quick connect coupling.





45. If equipped, attach the engine block heater harness to the radiator support wiring harness.

46. Connect the upper radiator hose to the intake manifold coolant tube.





47. Install the ground wire and bolt to the engine front cover.
- Tighten to 10 Nm (89 lb-in).






48. Connect the 2 heater hoses to the intake manifold.





49. NOTE: Align the index marks for the RH CAC (Charge Air Cooler) tube.

Install the RH CAC (Charge Air Cooler) tube and tighten the clamps.

- Tighten to 5 Nm (44 lb-in).






50. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.