Installation

1. Attach a suitable lifting device and remove the engine from the stand.
2. Reassemble the engine and transaxle. Refer to Transmission and Drivetrain.
3. Lower the engine and transaxle assembly into the engine compartment.





4. Install the RH engine support insulator through bolt and tighten to 67-93 Nm (50-69 ft. lbs.).
5. Remove the universal lifting eye from the transaxle, if necessary.





6. Install the four motor mount nuts. Tighten nuts to 67-93 Nm (50-68 ft. lbs.).





7. Install Three-Bar Engine Support D88L-6000-A or equivalent and remove the lifting device.
8. Raise and support the vehicle.





9. Install the transaxle mounts and support crossmember. Tighten transaxle mounts to 38-51 Nm (28-38 ft. lbs.). Tighten crossmember nuts and bolt to 64-89 Nm (48-65 ft. lbs.).





1O. Remove Engine Lifting Bracket T7OP-6000 from the cylinder head.
11. Route the generator and starter motor wiring harness behind the engine.





12. Connect the generator connectors.
A) Connect the two generator electrical connectors (1).
B) Connect the battery positive cable (3) and install the battery positive nut and washer. Tighten nut and washer to 9-12 Nm (7-9 ft. lbs.).
13. Install the radiator assembly. Refer to Cooling System.
14. Install the upper radiator hose.
15. Install the heater hose at the bulkhead.
16. Install the heater hose at the water outlet connection.
17. Raise and support the vehicle.
18. Install the crankshaft pulley and tighten bolt to 110-120 Nm (81-96 ft. lbs.).
19. Install the lower radiator hose and clamp.
20. Install the A/C compressor and manifold lines. Tighten mounting bolts to 20-30 Nm (15-22 ft. lbs.).
21. Connect the A/C compressor electrical connector.





22. Connect the oil pressure switch electrical connector.





23. Connect the starter motor S-terminal wire and the B-terminal cable and nut. Tighten nut to 9-13.5 Nm (80-120 inch lbs.) and reinstall the protective cover.
24. Install the front wheel driveshafts and joints Refer to Transmission and Drivetrain.





25. Position the three way catalytic converter (TWC) and install a new exhaust converter outlet gasket between the TWC and the muffler inlet pipe (B) and resonator (SA289).
26. Install the two TWC-to-muffler inlet pipe and resonator bolts and nuts (A). Tighten to 40-55 Nm (30-40 ft. lbs.).





27. Install the two TWC bracket bolts and tighten to 20-28 Nm (15-20 ft. lbs.).





28. Install the crossmember and tighten bolts to 94-131 Nm (69-97 ft. lbs.).
29. Install the RH and LH splash shields. Tighten bolts to 7.8-11 Nm (69-98 inch lbs.).
30. Install the front wheel and tire assemblies. Tighten in a star/cross pattern to 89-117 Nm (66-86.7 ft. lbs.).
31. Lower the vehicle.





32. Connect the (A) power steering reservoir pump hose and the (B) power steering pressure hose. Tighten fitting to 20-25 Nm (15-18 ft. lbs.).
33. Install the automatic tensioner, the accessory drive belt and, if vehicle is equipped with A/C, the accessory drive belt idler.
34. Connect the A/C line at the suction accumulator/drier and the condenser. Refer to Heating and Air Conditioning.





35. Install the A/C line bracket bolt and tighten to 20-25 Nm (15-18 ft. lbs).





36. Connect the transaxle cooler lines to the transaxle.





37. Install the starter motor bolt and tighten to 25-27 Nm (18-20 ft. lbs.).





38. Install the four exhaust manifold-to-TWC nuts and tighten to 34-47 Nm (26-34 ft. lbs.).
39. Install the exhaust manifold heat shield. Tighten nuts to 5-7 Nm (45-61 inch lbs.).

WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.

40. Connect the fuel supply line and the fuel return line to the fuel injection supply manifold.





41. Install the power steering pressure hose and bracket. Tighten bolts to 7.8-10.8 Nm 964-87 inch lbs.).





42. Install the ground strap to the generator bracket and tighten to 7.8 Nm (64-87 inch lbs.).
43. Connect the engine cooling fan electrical connector.





44. Connect the downstream heated oxygen sensor (H02S) electrical connector.





45. Connect the upstream H02S electrical connector.





46. Connect the vehicle speed sensor (VSS) electrical connector.





47. Connect the (A) transmission range sensor electrical connector, the (B) transaxle solenoid electrical connector, and the (C) turbine speed sensor electrical connector.





48. Install the EGR backpressure transducer and connect the electrical connector and the two pressure hoses. Tighten mounting nuts to 8-11.5 Nm (70-101 inch lbs.).





49. Install the constant control relay module (CCRM) and bracket and reconnect the CCRM electrical connector (B). Tighten mounting nuts (A) to 8-11.5 Nm (70-101 inch lbs.).





50. Connect the two main engine/fuel charging wiring electrical connectors.





51. Install the (A) shift cable and (B) clip.





52. Install the (A) speed control cable, the (B) accelerator cable, and the (C) throttle valve control actuating cable from the throttle control lever.





53. Install the vacuum tree (C) and connect the two vacuum lines (A). Tighten two bolts (B) to 8-11.5 Nm (70-101 inch lbs.).





54. Connect the vacuum hoses to the (A) EGR valve, the (B) brake booster, the (C) throttle body, the (D) fuel pressure regulator and the (E) intake manifold.
55. Install the air cleaner outlet tube. Refer to Powertrain Management.
56. Install the battery tray and the battery. Refer to Starting and Charging.
57. Recharge the A/C system. Refer to Heating and Air Conditioning.
58. Refill the cooling system.
59. Fill the engine with oil to the proper level.
60. Install the hood and align. Refer to Body and Frame.