Part 1

Engine

Special Tool(s)





Material





All vehicles
1. Using the special tools, align the transaxle to the engine.





2. Install the 5 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 lb-ft).





3. Install the 2 engine-to-transaxle bolts.
^ Tighten to 48 Nm (35 lb-ft).





4. Using the special tools, position the engine and transaxle onto the lift table.





5. NOTE: Position a block of wood under the transaxle.

Install the special tools.





6. Install the starter, the stud bolt and bolt.
^ Tighten to 27 Nm (20 lb-ft).





7. Connect the wiring harness retainer to the starter motor stud bolt.





8. Attach the starter wire terminals and install the 2 nuts.
1. Tighten to 12 Nm (9 lb-ft).
2. Tighten to 5 Nm (44 lb-in).





9. If equipped, install the starter motor solenoid cover.





10. If equipped, connect the auxiliary coolant pump electrical connector and the wiring harness pin-type retainer.





11. Raise the engine and transaxle assembly into the vehicle.
12. Install the engine mount and the 3 bolts.
^ Tighten to 90 Nm (66 lb-ft).





13. Install the 4 engine mount nuts.
^ Tighten to 63 Nm (46 lb-ft).





14. Install the engine mount brace, nut and bolt.
^ Tighten to 20 Nm (15 lb-ft).





15. Install the transaxle mount bracket and the 4 nuts.
^ Tighten to 80 Nm (59 lb-ft).





16. Install the transaxle mount through bolt and nut.
^ Tighten to 175 Nm (129 lb-ft).





All wheel drive (AWD) vehicles
17. Position the power transfer unit (PTU) in place and install the 5 bolts.
^ Tighten to 90 Nm (66 lb-ft).





18. Position the PTU support bracket in place and install the 5 bolts.
^ Tighten to 70 Nm (52 lb-ft).





19. NOTE: A new PTU seal must be installed whenever the intermediate shaft is removed.

Install a new PTU seal.
20. Install the 4 new RH catalytic converter-to-exhaust manifold studs.
^ Tighten to 25 Nm (18 lb-ft).





21. Using a new gasket, install the RH catalytic converter and 4 new nuts.
^ Tighten to 40 Nm (30 lb-ft).





22. Connect the RH catalyst monitor electrical connector.





All vehicles
23. Install the RH halfshaft support bracket and the 4 bolts.
^ Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft).
^ Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (15 lb-ft).





24. Install the 2 halfshaft support bracket studs.
^ Tighten to 10 Nm (89 lb-in)





25. Install the RH halfshaft into the transaxle and the wheel hub and install the 2 carrier bearing nuts.
^ Tighten to 40 Nm (30 lb-ft).





26. Install the 4 oil pan-to-transaxle bolts.
^ Tighten to 48 Nm (35 lb-ft).





27. Install 3 new torque converter bolts.
^ Tighten to 55 Nm (41 lb-ft).





28. Install the inspection cover and the 2 fasteners.





29. Connect the transaxle cooling tubes and install the safety clips.





30. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.

Install the LH halfshaft into the transaxle.





31. Using the special tool, raise the subframe into the installed position.





32. NOTE: RH shown, LH similar.

Install the 2 front subframe bolts.
^ Tighten to 150 Nm (111 lb-ft).





33. NOTE: RH shown, LH similar.

Position the subframe brackets and install the 4 bolts finger-tight.





34. NOTE: RH shown, LH similar.

Install the 2 rear subframe bolts.
^ Tighten to 150 Nm (111 lb-ft).





35. NOTE: RH shown, LH similar.

Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).





36. NOTE: RH shown, LH similar.

Install new lower ball joint-to-wheel knuckle nuts.
^ Tighten to 115 Nm (85 lb-ft).





37. NOTE: The hex holding feature can be used to prevent turning of the stud while removing the nuts.

NOTE: RH shown, LH similar.

Install new tie-rod end nuts.
^ Tighten to 115 Nm (85 lb-ft).





38. NOTE: RH shown, LH similar.

Install new upper stabilizer bar link nuts.
^ Tighten to 55 Nm (41 lb-ft).





39. CAUTION: Install and tighten the new front axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause incorrect torque readings while tightening the front axle wheel end nut and lead to bearing failure. Always install a new front axle wheel end nut after loosening or when not tightened to specifications in a continuous rotation.

NOTE: Never use power tools to tighten the front axle wheel end nut.

NOTE: Apply the brake to keep the halfshaft from rotating.

Install the new halfshaft nut.
^ Tighten to 350 Nm (258 lb-ft).





40. Install the 2 engine roll restrictor-to-transaxle bolts.
^ Tighten to 103 Nm (76 lb-ft).