Step 4. Engine, Transaxle & Cradle Installation
INSTALLATION1. Position the engine/transmission/cradle assembly under the vehicle. Align the dolly with the outline of the dolly legs and wheels drawn on the floor when the assembly was removed.
CAUTION: Ensure all hoses, vacuum lines and wire harnesses are positioned so that they will not snag and catch when the vehicle is lowered onto the cradle.
2. Lower the vehicle onto the cradle. Stop when the vehicle just touches the cradle bolt pads.
Fig. 25 Cradle Mounting Bolt:
3. Install cradle mounting bolts The cradle bolt has a rubber spacer and metal washer. They must be installed with the rubber spacer between the body and the washer. Tighten the bolts to 125 Nm (92 ft.lbs.) torque.
4. Raise the vehicle halfway.
5. Push the lower control arm down and reconnect the steering knuckle to the strut. Install the top bolt first. Then the lower bolt. The strut bolts are splined to the steering knuckles. Tighten the nuts, not the bolts. Tighten the nuts to 167 Nm (123 ft.lbs.) torque.
6. Install the disk brake pads and calipers.
7. Hold the hub in place and tighten the hub nuts to 245 Nm (181 ft.lbs.) torque.
8. Raise the vehicle the rest of the way up.
9. Remove the dolly from the cradle. Remove the special bolts from the cradle.
10. Connect the catalytic converter to the Y-pipe.
11. Connect the electrical connector to the oxygen (O2) sensor.
12. Connect the starter wires and the battery negative wire.
Fig. 26 Power Steering Pump:
13. Position the power steering pump against the engine. Finger tighten the rear bracket mounting bolts.
Fig. 27 Power Steering Pump Front Bracket:
14. Install the stud bolt through the timing cover and thread it into the rear bracket. Tighten the stud bolt to 40 Nm (30 ft.lbs.) torque.
15. Tighten the rear mounting bolts to 27 Nm(20 ft.lbs.) torque.
16. Pivot the power steering pump front bracket up over the stud bolt.
17. Thread the lower front mounting bolt in a couple of threads.
18. Start the nut on the stud. Finish tightening the lower front mounting bolt to 40 Nm (30 ft.lbs.) torque.
19. Tighten the stud nut to 40 Nm (30 ft. lbs.) torque.
Fig. 28 Upper Front Mounting Bracket Bolt:
20. Install the upper front mounting bolt. Tighten the bolt to 27 Nm (20 ft. lbs.) torque.
21. Connect the alternator output wire, the alternator connector and the wire harness clip at the alternator.
22. Connect the oil pressure sender wire to the sender.
23. Connect the oil level sensor electrical connectors.
24. Connect the knock sensor electrical connector to the knock sensor.
25. Position the splash shields in the wheelwells so that they hang straight down.
26. Install both front tires and wheels. Tighten the lug nuts to 85 Nm (63 ft.lbs.) torque.
27. Push the transmission shifter cable through the hole in the body and into the passengers compartment. Position the grommet in the hole.
28. Lower the vehicle.
29. Install the air conditioning compressor on the valve cover. Tighten the bolts to 27 Nm (20 ft. lbs.) torque.
Fig. 2 Engine Without A/C:
Fig. 3 3.0L Engine With A/C:
30. Position the accessory drive belt on the pulleys. Be sure that the belt is routed correctly.
31. Raise the vehicle.
32. Install a belt tension gauge on the accessory drive belt halfway between the air conditioning compressor and the alternator. On vehicles without air conditioning, install the gauge halfway between the water pump and the alternator.
Fig. 29 Belt Tensioning:
33. Tighten the adjusting bolt until the correct belt tension is obtained. If a new accessory drive belt is installed, it must be tensioned after 12,070 km (7500 miles) of usage. Correct belt tension is:
^ New Belt 180-200lbs.
^ Used Belt 140-160lbs.
34. Tighten the alternator pivot bolt to 50 Nm (37 ft.lbs.) torque.
35. Tighten the alternator locking bolt to 27 Nm (20 ft.lbs.) torque.
36. Install the splash shield under the alternator.
37. Lower the vehicle.
38. Connect the heater hoses at the dash panel.
39. Connect the coolant bottle lower hose.
Fig. 30 Fuel Tubes / Regulator / Fuel Rail:
40. Push the black fuel supply tube onto the fuel rail until a audible click is heard. Pull back to ensure that the connector is locked in place.
41. Push the grey fuel return tube onto fuel pressure regulator until an audible click is heard. Pull back to ensure that the connector is locked in place.
Fig. 31 MAP Line / Hevac Hose / Bulkhead Connector:
42. Connect the MAP sensor vacuum hose and the HVAC vacuum reservoir hoses.
43. Connect the bulkhead connector and secure with the bulkhead bolts. Connect the electrical connector at the dash panel.
Fig. 32 EGR Solenoid And Vacuum Hose:
44. Connect the EGR solenoid vacuum hoses.
45. Connect the front engine shock absorber to the engine bracket.
46. Install the upper and lower radiator hoses at the water pump.
47. Install the power steering reservoir to the engine.
48. Install the battery and battery holddown bracket.
49. Install the air cleaner.
Fig. 33 Hose Connections At Air Cleaner:
50. Install the air sensor vacuum hose at the air cleaner.
51. Route the coil wire through the clips on the air cleaner and install at the distributor cap.
52. Connect the evaporator canister hose and the crankcase ventilation fresh air inlet hose at the air cleaner.
Fig. 34 Hot Air Tube At Air Cleaner:
53. Connect the hot air tube to the air cleaner.
54. Connect the accelerator cable and cruise control cable to the throttle arm.
55. Close the radiator drain.
56. Connect the vacuum booster hose to the brake vacuum booster.
57. Connect the transmission shifter cable. Slide it through the holding bracket and attach it to the arm on the steering column. Install the section of instrument panel.
58. Install the throttle body bonnet.
59. If the engine oil was drained, refill the crankcase with clean oil.
60. Connect the battery positive cable first,then connect the battery negative cable.
61. Fill the cooling system and bleed it. Refer to Cooling System/Service and Repair. Service and Repair