Installation

1. Remove engine from engine stand using Rotunda Floor Crane Positioning Sling 014-00036 and Rotunda Floor Crane 014-00071 or equivalents attached to the engine lifting eyes.
2. Install engine rear plate and flywheel. Tighten retaining bolts in alternating sequence to 73-87 Nm (54-64 ft. lbs.).
3. On manual transaxle-equipped vehicles, install clutch disc and clutch pressure plate. See Transmission and Drivetrain.
4. On manual transaxle-equipped vehicles, install transaxle to engine. Tighten retaining bolts to 34-46 Nm (25-34 ft. lbs.).
5. On automatic transaxle-equipped vehicles, align torque converter and flywheel and install transaxle to engine. Tighten transaxle retaining bolts to 34-46 Nm (25-34 ft. lbs.).
6. If removed, place front sub-frame Rotunda Powertrain Fixture 134-00250 or equivalent.
7. Install engine and transaxle assembly onto front sub-frame and Powertrain Fixture 134-00250 or equivalent. Do not allow powertrain weight to be on roll restrictors.
8. Install Powertrain Alignment Gauge T94P-6000-AH to LH front engine support bracket and front sub-frame. Tighten two vertical bolts, then through bolt to 27 Nm (20 ft. lbs.).
9. Install RH front engine support insulator. Retaining bolts to front sub-frame and through bolts should be finger-tight.
10. Remove Rotunda Floor Crane Positioning Sling 014-00036 and Rotunda Floor Crane 014-00071 or equivalent.
11. Install battery ground cable to engine-to-transaxle stud bolt. Tighten retaining nut to 20-30 Nm (15-22 ft. lbs.).
12. Route engine control sensor wiring across transaxle and install retaining clips for engine control sensor wiring onto transaxle.
13. Connect engine control sensor wiring to transaxle at connectors.
14. Install starter motor.
15. Install LH and RH halfshafts into transaxle.
16. Position engine and transaxle assembly under vehicle.
17. Partially lower vehicle on hoist.
18. Install engine and transaxle assembly into vehicle with front sub-frame using Powertrain Fixture 134-00250 or equivalent.

NOTE: Make sure engine and transaxle are firmly seated against front and rear insulator brackets.

19. Using new nuts install upper front engine support bracket and engine and transmission support insulator. Tighten nuts to 10 Nm (7 ft. lbs.).





20. Install front sub-frame to body.
21. Raise vehicle on hoist.
22. Remove Rotunda Powertrain Fixture 134-00250 or equivalent.
23. Lower vehicle on hoist.
24. Tighten front engine support bracket nuts to 70-95 Nm (52-70 ft. lbs.).
25. Tighten engine and transmission support insulator nuts to 41-55 Nm (30-41 ft. lbs.) with automatic transaxle or 70-95 Nm (52-70 ft. lbs.) with manual transaxle.
26. Raise and support vehicle.
27. Tighten RH front engine support insulator to subframe bolt to 10 Nm (7 ft. lbs.). Observe position of RH front engine support insulator. It must be centered in bracket and in perfect alignment front-to-rear. Retighten RH insulator to front subframe bolt to 41-55 Nm (30-40 ft. lbs.).
28. Tighten RH front engine support insulator through bolt to 103-137 Nm (75-102 ft. lbs.).
29. Remove Powertrain Alignment Gauge T94P-6000-AH.
30. Install LH front engine support insulator to front sub-frame with two bolts. Tighten bolts to 10 Nm (7 ft. lbs.). Observe LH front engine support insulator to ensure perfect front-to-rear alignment. Re-tighten bolts to 41-55 Nm (30-41 ft. lbs.).
31. Install LH front engine support insulator through bolt. Tighten to 103-137 Nm (75-102 ft. lbs.).
32. Connect wire harness to A/C compressor.
33. Install front bumper cover braces to LH and RH side of front sub-frame. Tighten retaining bolts securely.
34. Install radiator supports to front sub-frame. Tighten bolts to 8-11 Nm (71-97 inch lbs.).
35. Connect lower radiator hose to the radiator.
36. On automatic transaxle-equipped vehicles, install transmission oil cooler lines and retaining-brackets. Tighten nuts to 24-31 Nm (18-22 ft. lbs.) and stabilizer bar nut to 55 Nm (41 ft. lbs.).
37. On manual transaxle-equipped vehicles, install shift rod and stabilizer bar to transaxle. Tighten shift rod bolt to 23 Nm (17 ft. lbs.) and stabilizer bar nut to 55 Nm (41 ft. lbs.).
38. If equipped, connect A/C suction hose to A/C condenser core.
39. If equipped, connect A/C discharge hose to A/C accumulator.
40. Install heater water hoses to the heater core. Install heater hose spring clamp securely.
41. Lower vehicle.
42. If equipped, connect block heater power supply wiring to RH side of radiator support.
43. On manual transmission-equipped vehicles, connect clutch hydraulic line to clutch actuator. Install retainer clip. Fill and bleed hydraulic clutch system.
44. Connect positive battery cable retainer to battery tray.
45. Connect upper radiator hose to the radiator.
46. Connect the vacuum supply line to the power brake booster.
47. Connect ground strap to the transaxle case.
48. On automatic transaxle-equipped vehicles, install shift cable and bracket to transaxle. Tighten bolts to 20-25 Nm (15-19 ft. lbs.).
49. Connect fuel supply and return lines to fuel injection supply manifold.
50. Connect coolant hoses to radiator coolant recovery reservoir.
51. Install ground strap for engine control sensor wiring to RH cylinder head (6049). Tighten retainer securely.
52. Connect engine control sensor wiring to powertrain control module. Position engine control sensor wiring into retainer bracket located on RH side of dash panel.
53. Connect power steering pressure hose to power steering pump.
54. Install power steering pressure hose bracket to upper front engine support bracket. Tighten retainer securely.
55. Install power steering pump reservoir to bracket.
56. Install retainer for engine control sensor wiring to air cleaner bracket.
57. Connect the three connectors for the engine control sensor wiring together and to bracket located on the LH front fender apron.
58. Install the accelerator cable bracket to the throttle body and tighten retainer bolts to 8-12 Nm (71-106 inch lbs.). Connect cables to throttle body lever.
59. Remove safety wire retaining radiator to radiator support.
60. Raise and support vehicle.
61. On automatic transaxle-equipped vehicles, push torque converter into flywheel pilot and install four torque converter to flywheel retaining nuts. Tighten nuts in alternating sequence to 73-87 Nm (54-64 ft. lbs.).
62. On automatic transaxle-equipped vehicles, install access plug onto engine rear plate.
63. Connect vehicle speed sensor wiring harness at connector.
64. Install A/C accumulator retaining screws to front sub-frame. Tighten screws securely.
65. Install LH and RH halfshafts into front wheel knuckles and install front axle wheel hub retainers.
66. Install LH and RH tie rod ends to the front wheel knuckle. Install new nuts on tie rod end studs. Tighten nuts to 28 Nm (21 ft. lbs.) and continue tightening nuts to align the next castellation of the nut with the cotter pin hole in the stud. Install new cotter pins.
67. Install LH and RH front wheel knuckles onto front suspension lower arms at ball joint. Tighten bolts to 50-58 Nm (37-43 ft. lbs.).
68. Connect LH and RH front stabilizer bar link to front stabilizer bar. Tighten nuts to 48 Nm (35 ft. lbs.).
69. Install front wheel and tire assemblies. Tighten lug nuts to 85 Nm (62 ft. lbs.).
70. Install exhaust crossover and three way catalytic converter.
71. Install splash shield to front of front sub-frame and body. Tighten screws securely.
72. Rotate front bumper cover braces rearward. Install two screws to front sub-frame and tighten securely.
73. Lower vehicle.
74. Install engine air cleaner.
75. Connect steering shaft and joint in vehicle and install pinch-bolt. Tighten bolt to 24 Nm (18 ft. lbs.).
76. Install water pump pulley shield.
77. Connect positive and battery ground cable and wiring to battery.
78. Fill transaxle with approved fluid.
79. Fill engine cooling system.
80. Recharge A/C system. See Heating and Air Conditioning.
81. Run engine and check for oil, coolant or fuel leaks. Verify proper operation of the engine cooling fan motor (8K621) and A/C system.