Engine - Installation - Manual Transaxle

Engine - Manual Transaxle









WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the bellhousing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).

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

Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.

3. Install the Powertrain Lift and Universal Adapter Brackets onto the engine.





4. Position the generator wiring harness and attach the 4 wiring harness retainers (3 shown) to the valve cover stud bolts.





5. Connect the generator B+ wiring harness and install the nut.
- Tighten to 12 Nm (106 lb-in).





6. Connect the generator electrical connection.





7. Install the generator air duct.





8. Install the starter motor isolator.





9. Install the starter, bolt and stud bolt.
- Tighten to 25 Nm (18 lb-ft).





10. Position the wiring harness and install the ground wire to the starter motor stud bolt and install the nut.
- Tighten to 18 Nm (159 lb-in).





11. Connect the starter wires and install the 2 nuts.
- Tighten the large starter motor B+ wire nut to 12 Nm (106 lb-in).

- Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in).





12. Attach the A/C compressor wiring harness pin-type retainer to the intake manifold.





13. Connect the A/C compressor electrical connector.





14. Raise the engine and transaxle into the vehicle.

15. Raise the engine and transaxle into the vehicle.

16. Install the 2 transaxle mount bolts.
- Tighten to 90 Nm (66 lb-ft).





17. Install the engine mount bracket, 2 nuts and the bolt.
- Tighten the nuts to 103 Nm (76 lb-ft).

- Tighten the bolt to 115 Nm (85 lb-ft).





18. Install the 2 oil pan-to-bellhousing bolts.
- Tighten to 48 Nm (35 lb-ft).





19. Install the bellhousing-to-oil pan bolt.
- Tighten to 48 Nm (35 lb-ft).





20. Attach the lower radiator hose pin-type retainer to the cooling fan shroud.





21. If equipped, connect the block heater electrical connector and position back the block heater shield.
- Attach the 8 block heater wiring harness retainers (1 shown).





22. Install the lower radiator hose to the thermostat housing.





23. Attach the Knock Sensor (KS) electrical connector to the intake manifold.





24. Install a new O-ring seal and connect the upper A/C tube to the condenser and install the nut.
- Tighten to 8 Nm (71 lb-in).





25. Attach the coolant vent hose retaining clip to the A/C tube.





26. Install a new O-ring seal and connect the upper A/C tube and install the nut.
- Tighten to 8 Nm (71 lb-in).





27. Install the A/C tube/windshield washer reservoir bracket bolt.
- Tighten to 7 Nm (62 lb-in).





28. Install the ground wire on the engine mount and the bolt.
- Tighten to 10 Nm (89 lb-in).





29. Attach the transaxle control cables to the bracket.
- Connect the control cables to the control levers.





30. Install the clutch slave cylinder and the 2 bolts.
- Tighten to 22 Nm (16 lb-ft).





31. Install the 2 clutch tube bracket bolts.
- Tighten to 22 Nm (16 lb-ft).





32. Connect the heater hose in-line connector and connect the upper radiator and heater hoses to the coolant outlet.





33. Attach the coolant hoses retainer.





34. Connect the fuel supply tube quick connect coupling. For additional information, refer to Fuel System - General Information Quick Connect Coupling.





35. Connect the fuel vapor return tube.





36. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.





37. Connect the crankcase vent tube to the valve cover.





38. Install the exhaust flexible pipe. For additional information, refer to Exhaust System Exhaust Flexible Pipe.

39. Install the engine oil filter.
- Lubricate the engine oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.

40. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.





41. NOTE: LH shown, RH similar.

Install the front subframe nuts.

- Tighten to 150 Nm (111 lb-ft).





42. NOTE: LH shown, RH similar.

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





43. NOTE: LH shown, RH similar.

Install the subframe nuts.

- Tighten to 150 Nm (111 lb-ft).





44. NOTE: LH shown, RH similar.

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





45. NOTE: LH shown, RH similar.

Install the sway bar links and nuts to the struts.

- Tighten to 40 Nm (30 lb-ft).





46. NOTE: LH shown, RH similar.

Install tie-rod ends and nuts.

- Tighten to 48 Nm (35 lb-ft).

- Install the cotter pin.





47. Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt.
- Tighten to 12 Nm (106 lb-in).





48. Attach the EPAS system wiring harness pin-type retainer to the subframe under the LH fender splash shield.





49. Attach the 2 EPAS system wiring harness pin-type retainers to the subframe.





50. Connect the 2 EPAS system electrical connectors.





51. Install the LH halfshaft and the intermediate shaft.

52. Install the LH splash shield and the 6 pin-type retainers (4 shown).





53. Position the LH fender splash shield and install the 4 screws.





54. Install the RH splash shield and the 6 pin-type retainers (4 shown).





55. Position the RH fender splash shield and install the 4 screws.





56. Install the engine roll restrictor bolt.
- Tighten to 90 Nm (66 lb-ft).





57. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown) into the body.
- From under the vehicle, verify that the seal is correctly installed on the steering gear and the retaining clips are fully engaged into the dash.





58. If equipped, install the 7 screws and the underbody cover.





59. Install the steering column shaft onto the steering gear and install the bolt.
- Tighten to 20 Nm (177 lb-in).





60. Install the steering joint cover and the 2 nuts.





61. Connect the 2 engine harness electrical connectors.





62. Attach the 2 negative battery cable pin-type retainers to the transaxle mount and battery tray bracket.





63. Install the ground wire-to-body and the bolt.
- Tighten to 12 Nm (106 lb-in).





64. Connect the engine wiring harness electrical connector.





65. Install the 2 battery cables to the positive battery cable and the 2 nuts.
- Tighten to 9 Nm (80 lb-in).





66. Install the battery tray. For additional information, refer to Battery, Mounting and Cables Battery Tray.

67. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering - 2.5L Air Cleaner and Air Cleaner Outlet Pipe.

68. Fill the engine with clean engine oil.

69. Fill and bleed the cooling system. For additional information, refer to Engine Cooling Service and Repair.

70. Recharge the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.

71. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.