Part 1

Engine

Special Tool(s):

Special Tool(s):

Material:

Installation (Steps 1-34)





1. Using the special tools and a suitable engine crane, align the engine to the transaxle.





2. Install the transaxle-to-engine stud bolt, bolt and nut.
^ Tighten to 48 Nm (35 ft. lbs.).





3. Attach the wiring harness retainer to the stud bolt.





4. Install the 3 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





5. Install the engine-to-transaxle bolt.
^ Tighten to 48 Nm (35 ft. lbs.).

6. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Use a plastic scraping tool to remove all traces of the oil pan gasket.
^ Clean all sealing surfaces with metal surface cleaner and install a new oil pan gasket.

7. NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.





Apply a 10 mm (0.39 inch) diameter dot of silicone sealant to the areas indicated.
8. Position the oil pan and install the 10 bolts and 5 stud bolts finger tight.





9. Install the 2 oil pan-to-transaxle bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





10. Tighten the 15 oil pan-to-engine bolts and stud bolts in the sequence shown to 25 Nm (18 ft. lbs.).





11. Install 6 new LH catalytic converter studs.
^ Tighten to 12 Nm (9 ft. lbs.).





12. Install a new gasket, the LH catalytic converter and 6 new nuts.
^ Tighten to 20 Nm (15 ft. lbs.) in the sequence shown.





13. Install the LH catalytic converter bracket and the 2 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





14. Install the heat shield and the 4 bolts.
^ Tighten to 11 Nm (8 ft. lbs.).





15. Connect the LH heated oxygen sensor (H02S) electrical connector and pin-type retainer.





16. Connect the LH catalyst monitor sensor (CMS) electrical connector.





17. Install the starter motor and the 2 bolts.
^ Tighten to 27 Nm (20 ft. lbs.).





18. Connect the starter motor wiring and install the 2 nuts.
^ Tighten the large nut to 12 Nm (9 ft. lbs.).
^ Tighten the small nut to 5 Nm (44 inch lbs.).





19. Attach the wiring harness pin-type retainer.





20. Connect the transmission control module (TCM) electrical connector.





21. Install the CMS bracket and the bolt.
^ Tighten to 12 Nm (9 ft. lbs.).





22. Install the ground wire and the bolt.
^ Tighten to 12 Nm (9 ft. lbs.).





23. Using the special tools and a suitable engine crane, position the engine and transaxle onto the lift table.

24. NOTE: Position a suitable block of wood under the transaxle.





Install the special tools.





25. Install the catalytic converter bracket assembly and the 2 bolts.
^ Tighten to 35 Nm (26 ft. lbs.).





26. Install the catalytic converter bracket and the 2 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





27. Install the heat shield and the 2 bolts.
^ Tighten to 11 Nm (8 ft. lbs.).





28. Using a new gasket, install the EGR valve and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





29. Install the EGR tube.
^ Tighten both EGR tube nuts to 40 Nm (30 ft. lbs.).





30. Connect the EGR valve electrical connector.





31. Position the power steering pressure (PSP) hose on the engine and install the PSP hose bracket-to-power steering reservoir bolt.
^ Tighten to 9 Nm (80 inch lbs.).





32. Using a new banjo bolt and 2 seals, connect the PSP hose to the power steering pump.
^ Tighten to 35 Nm (26 ft. lbs.).





33. Attach the PSP hose bracket to the cylinder head and install the bolt.
^ Tighten to 9 Nm (80 inch lbs.).





34. Attach the H02S electrical connector to the PSP bracket.