Part 3

Engine continued

107. Install new gaskets, the intake manifold and the 8 bolts.
^ Tighten the bolts to 18 Nm (13 ft. lbs.).





108. Connect the electronic throttle body electrical connector.





109. Attach the 2 wiring harness pin-type retainers to the intake manifold.





110. Connect the 2 swirl control valve electrical connectors.





111. Connect the intake manifold runner control (IMRC) actuator electrical connector.





112. Connect the temperature manifold actual pressure (MAP) sensor electrical connector.





113. Connect the oil pressure sender electrical connector.





114. Connect the exhaust gas recirculation (EGR) coolant hose and electrical connector.





115. Connect the coolant temperature sender electrical connector.





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





117. If equipped, install the block heater.
^ Tighten to 21 Nm (15 ft. lbs.).





118. If equipped, connect the block heater electrical connector.





119. Install 7 new catalytic converter studs in the cylinder head.
^ Tighten to 17 Nm (13 ft. lbs.).

120. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.

CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.

NOTE: Make sure to tighten the nuts in the sequence in 2 stages.

Install a new gasket, the catalytic converter and 7 new nuts. Tighten the nuts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 55 Nm (41 ft. lbs.).
^ Stage 2: Tighten to 55 Nm (41 ft. lbs.).





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





122. NOTE: Vehicles equipped with AIR did not require removal of the heat shield.

Install the heat shield and the 6 screws.
^ Tighten to 10 Nm (89 inch lbs.).





123. Attach the wiring harness retainer to the valve cover stud.





124. Attach the wiring harness bracket to the valve cover stud.





125. Connect the heated oxygen sensor (HO2S) electrical connector.





126. NOTE: Vehicles equipped with secondary air injection (AIR) have 2 catalyst monitor sensors (CMS).

Connect the CMS electrical connector(s).





Vehicles with secondary air injection (AIR)

127. Position the AIR valve, hoses and pump assembly onto the engine and install the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





128. Connect the AIR valve electrical connector.





129. Connect the AIR valve vacuum supply tube to the intake manifold.





130. Connect the AIR hose to the catalytic converter.





All vehicles

131. Install the generator, bolt and 2 stud bolts.
^ Tighten to 47 Nm (35 ft. lbs.).





132. Connect the pin-type retainer, generator electrical connections and install the nut.
^ Tighten to 6 Nm (53 inch lbs.).
^ Install the rubber boot.





133. Install the generator splash shield and the 2 nuts.
^ Tighten to 25 Nm (18 ft. lbs.).





134. Connect the CKP sensor electrical connector and harness pin-type retainer.





135. Install the accessory drive belt idler pulley.
^ Tighten to 25 Nm (18 ft. lbs.).





136. NOTE: Clean the coolant pump mating surface with metal surface cleaner.

NOTE: Lubricate the new coolant pump O-ring with clean engine coolant.

Install the new O-ring, coolant pump and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





137. Install the coolant pump pulley and the 3 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





138. Install the A/C compressor and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





139. Install the A/C manifold and the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).





140. Connect the A/C compressor electrical connector.





141. Position the coolant hose on the engine and connect the coolant hose to the throttle body.





142. Connect the lower radiator and heater hoses to the thermostat housing.





143. Connect the KS electrical connector and the 2 harness pin-type retainers.





144. Install the power steering pump and the lower bolt.
^ Finger tighten the bolt.





145. Install the 2 upper power steering pump bolts.
^ Tighten all 3 power steering bolts to 25 Nm (18 ft. lbs.).





146. Connect the power steering pressure (PSP) switch electrical connector.





147. Install the accessory drive belt tensioner and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





148. Position the accessory drive belt onto the tensioner and all of the accessory drive pulleys except the coolant pump pulley.

149. Using the hex feature, rotate the accessory drive belt tensioner clockwise and install the accessory drive belt onto the coolant pump pulley.





150. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.

Vehicles with automatic transaxle

151. Install the flexplate and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (59 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.).





Vehicles with manual transaxle

152. Install the flywheel and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten to 80 Nm (59 ft. lbs.).
^ Stage 3: Tighten to 112 Nm (83 ft. lbs.).





153. Install the starter motor isolator.





154. Lubricate the transaxle input shaft pilot bearing with front axle grease.





155. Using the special tool, position the clutch disc on the flywheel.





156. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.

Position the clutch pressure plate and install the 6 bolts.
^ Tighten to 29 Nm (21 ft. lbs.) in a star pattern sequence.