Part 1
EngineSpecial Tool(s):
Special Tool(s):
Material:
Installation
CAUTION: If the oil pan was removed during engine disassembly, it must be installed after engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.
All vehicles
1. Using the special tools and a suitable engine crane, align the transaxle to the engine.
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 (HO2S) electrical connector and pin-type retainer.
16. Connect the LH catalyst monitor sensor 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. Connect the transmission control module (TCM) electrical connector.
20. Install the catalyst monitor sensor bracket and the bolt.
^ Tighten to 12 Nm (9 ft. lbs.).
21. Install the ground wire and the bolt.
^ Tighten to 12 Nm (9 ft. lbs.).
22. Using the special tools and a suitable engine crane, position the engine and transaxle onto the lift table.
23. NOTE: Position a suitable block of wood under the transaxle.
Install the special tools.
Front wheel drive (FWD) vehicles
24. Install the catalytic converter bracket assembly and the 2 bolts.
^ Tighten to 35 Nm (26 ft. lbs.).
25. Install the catalytic converter bracket and the 2 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
26. Install the heat shield and the 2 bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
All vehicles
27. Using a new gasket, install the EGR valve and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
28. NOTE: FWD shown, AWD similar.
Install the EGR tube.
^ Tighten both EGR tube nuts to 40 Nm (30 ft. lbs.).
29. Connect the EGR valve electrical connector.
30. 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.).
31. Using a new banjo bolt and 2 seals, connect the PSP hose to the power steering pump.
^ Tighten to 37 Nm (27 ft. lbs.).
32. Attach the PSP hose bracket to the cylinder head and install the bolt.
^ Tighten to 9 Nm (80 inch 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 wiring harness retainer to the PSP hose bracket.
35. Raise the engine and transaxle up into the vehicle.
36. Install the engine mount bracket, 3 nuts and the bolt.
^ Tighten the nuts to 63 Nm (46 ft. lbs.).
^ Tighten the bolt to 115 Nm (85 ft. lbs.).
37. Install the damper and bolt.
^ Tighten to 23 Nm (17 ft. lbs.).
38. Install the 2 transaxle mount bolts.
^ Tighten to 90 Nm (66 ft. lbs.).
39. Install the 3 torque converter nuts.
^ Tighten to 36 Nm (27 ft. lbs.).
40. Install the torque converter nut access plug.
All wheel drive (AWD) vehicles
41. Install the power transfer unit (PTU) and the 5 bolts.
^ Tighten to 90 Nm (66 ft. lbs.).
42. Install the PTU support bracket and the 5 bolts.
^ Tighten to 70 Nm (52 ft. lbs.).
43. CAUTION: A new power transfer unit (PTU) seal must be installed whenever the intermediate shaft is removed.
Install a new PTU seal.
44. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
Position the RH driveshaft in place and install the 2 bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
45. Using a new gasket, install the RH catalytic converter and 3 new nuts.
^ Tighten to 48 Nm (35 ft. lbs.).
46. Install the RH exhaust heat shield bracket (inboard half) and the 2 bolts.
^ Tighten to 40 Nm (30 ft. lbs.).
47. Install the RH exhaust heat shield bracket (outboard half) and the 3 nuts.
^ Tighten to 20 Nm (15 ft. lbs.).
48. Install the RH exhaust heat shield and the 6 bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
49. Using the special tool, install the RH HO2S.
^ Tighten to 48 Nm (35 ft. lbs.).
50. Connect the RH HO2S electrical connector.
51. Using the special tool, install the RH catalytic monitor sensor.
^ Tighten to 48 Nm (35 ft. lbs.).
52. Connect the RH catalyst monitor sensor electrical connector and attach the wiring harness retainer.
FWD vehicles
53. Install the RH halfshaft into the transaxle.
54. Install the 2 RH halfshaft carrier bearing bracket bolts.
^ Tighten to 55 Nm (41 ft. lbs.).
Early build FWD vehicles
55. Connect the catalyst monitor sensor electrical connector and pin-type retainer.
56. Connect the PSP switch electrical connector.
57. Connect the crankshaft position (CKP) sensor electrical connector and pin-type retainer.
