Part 1
EngineInstallation (Steps 1-61)
Special Tool(s) (Part 1):
Special Tool(s) (Part 2):
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 lb-ft).
3. Attach the wiring harness retainer to the stud bolt.
4. Install the 3 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 lb-ft).
5. Install the engine-to-transaxle bolt.
^ Tighten to 48 Nm (35 lb-ft).
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 prep 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 lb-ft).
10. Tighten the 15 oil pan-to-engine bolts and stud bolts in the sequence shown to 25 Nm (18 lb-ft).
11. Install 6 new LH catalytic converter studs.
^ Tighten to 12 Nm (9 lb-ft).
12. Install a new gasket, the LH catalytic converter and 6 new nuts.
^ Tighten to 20 Nm (15 lb-ft) in the sequence shown.
13. Install the LH catalytic converter bracket and the 2 bolts.
^ Tighten to 20 Nm (15 lb-ft).
14. Install the heat shield and the 4 bolts.
^ Tighten to 11 Nm (8 lb-ft).
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 lb-ft).
18. Connect the starter motor wiring and install the 2 nuts.
^ Tighten the large nut to 12 Nm (9 lb-ft).
^ Tighten the small nut to 5 Nm (44 lb-inch).
19. Connect the transmission control module (TCM) electrical connector.
20. Install the catalyst monitor sensor bracket and the bolt.
^ Tighten to 12 Nm (9 lb-ft).
21. Install the ground wire and the bolt.
^ Tighten to 12 Nm (9 lb-ft).
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 lb-ft).
25. Install the catalytic converter bracket and the 2 bolts.
^ Tighten to 20 Nm (15 lb-ft).
26. Install the heat shield and the 2 bolts.
^ Tighten to 11 Nm (8 lb-ft).
All vehicles
27. Using a new gasket, install the EGR valve and the 2 bolts.
^ Tighten to 25 Nm (18 lb-ft).
28. NOTE: Front wheel drive (FWD) shown, all wheel drive (AWD) similar.
Install the EGR tube.
^ Tighten both EGR tube nuts to 40 Nm (30 lb-ft).
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 lb-inch).
31. Using a new banjo bolt and 2 seals, connect the PSP hose to the power steering pump.
^ Tighten to 35 Nm (26 lb-ft).
32. Attach the PSP hose bracket to the cylinder head and install the bolt.
^ Tighten to 9 Nm (80 lb-inch).
33. Attach the PSP hose bracket to the cylinder head and install the bolt.
^ Tighten to 9 Nm (80 lb-inch).
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 lb-ft).
^ Tighten the bolt to 115 Nm (85 lb-ft).
37. Install the damper and bolt.
^ Tighten to 23 Nm (17 lb-ft).
38. Install the 2 transaxle mount bolts.
^ Tighten to 90 Nm (66 lb-ft).
39. Install the 3 torque converter nuts.
^ Tighten to 36 Nm (27 lb-ft).
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 lb-ft).
42. Install the PTU support bracket and the 5 bolts.
^ Tighten to 70 Nm (52 lb-ft).
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 lb-ft).
45. Using a new gasket, install the RH catalytic converter and 3 new nuts.
^ Tighten to 48 Nm (35 lb-ft).
46. Install the RH exhaust heat shield bracket (inboard half) and the 2 bolts.
^ Tighten to 40 Nm (30 lb-ft).
47. Install the RH exhaust heat shield bracket (outboard half) and the 3 nuts.
^ Tighten to 20 Nm (15 lb-ft).
48. Install the RH exhaust heat shield and the 6 bolts.
^ Tighten to 11 Nm (8 lb-ft).
49. Using the special tool, install the RH HO2S.
^ Tighten to 48 Nm (35 lb-ft).
50. Connect the RH HO2S electrical connector.
51. Using the special tool, install the RH catalyst monitor sensor.
^ Tighten to 48 Nm (35 lb-ft).
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 lb-ft).
All vehicles
55. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding.
Install a new circlip in the groove on the LH halfshaft.
56. Install the LH halfshaft into the transaxle.
57. Position the A/C manifold onto the A/C compressor and install the bolt.
^ Tighten to 15 Nm (11 lb-ft).
58. Install the ground wire and bolt to the engine mount bracket.
^ Tighten to 10 Nm (89 lb-inch).
59. Connect the A/C tubes and install the 2 nuts.
^ Tighten to 8 Nm (71 lb-inch).
60. Install the 2 A/C tube bracket bolts.
^ Tighten to 10 Nm (89 lb-inch).
61. Attach the coolant hose retaining clip.
