Engine - Manual Transmission

Engine - Manual Transmission









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. NOTE: Before installing the transmission, the input shaft must be cleaned and lubricated with a small amount of multi-purpose grease.
Using the Floor Crane and Spreader Bar, position the engine in the engine compartment.






2. Align the engine to the transmission and install LH bellhousing-to-oil pan bolt.
- Tighten the bolt, it will be torqued at a later step.






3. Install the engine-to-bellhousing bolt.
- Tighten the bolt, it will be torqued at a later step.






4. Install the RH engine mount bracket, bolt and 2 stud bolts (2 shown).
- Tighten to 55 Nm (41 lb-ft).






5. Install the LH engine mount bracket and the 3 bolts (2 shown).
- Tighten to 55 Nm (41 lb-ft).






6. Install the 4 upper bellhousing-to-engine bolt and stud bolts (2 shown).
- Tighten to 48 Nm (35 lb-ft).






7. Attach the 2 wiring harness retainers (1 shown) to the upper transmission stud bolts.





8. Install the ground wire and the bolt on the rear of the cylinder head.
- Tighten to 10 Nm (89 lb-in).






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






10. Tighten the engine-to-bellhousing bolt.
- Tighten to 48 Nm (35 lb-ft).






11. Install the LH bellhousing-to-engine bolt and LH bellhousing-to-oil pan stud bolt.
- Tighten to 48 Nm (35 lb-ft).






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






13. Remove the 3 bolts and lower the underbody shield.





14. Position the wiring harness retainer on the RH front engine mount bracket stud bolt.





15. Position the wiring harness retainer on the RH rear engine mount bracket stud bolt and install the nut.
- Tighten to 20 Nm (177 lb-in).






16. NOTE: LH shown, RH similar.
Install the new 2 LH and RH catalytic converter-to-exhaust manifold nuts.

- Tighten to 45 Nm (35 lb-ft).






17. Install the access cover and the 2 pin-type retainers.





18. Install the starter motor.

19. NOTE: RH shown, LH similar.
Install the front crossmember brace and the 4 nuts (2 shown).

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






20. NOTE: Do not lubricate the engine oil filter gasket.
Install a new engine oil filter.

- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.






21. Raise the underbody shield and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).






22. Position the A/C compressor and install the bolt and stud bolt.
- Do not torque at this time.






23. Install the A/C compressor stud and nut.
- Tighten the stud to 9 Nm (80 lb-in).

- Tighten the nut to 26 Nm (19 lb-ft).






24. Tighten the A/C compressor bolt and stud bolt.
- Tighten the nut to 26 Nm (19 lb-ft).






25. Attach the wiring harness retainer to the A/C compressor stud bolt.





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

27. Install the wiring harness bracket on the LH valve cover stud bolt and install the nut.
- Tighten to 10 Nm (89 lb-in).






28. Connect the generator electrical connector.
- Attach the generator wiring harness retainer to the valve cover stud bolt.






29. Connect the generator B+ cable and install the nut.
- Tighten to 17 Nm (150 lb-in).






30. NOTE: RH shown, LH similar.
Connect and attach the RH and LH Heated Oxygen Sensor (HO2S) electrical connectors.






31. Connect the 2 heater hose couplings (1 shown) at the RH rear of the engine.





32. Connect the middle PCM electrical connector.
- Attach the PCM wiring harness pin-type retainer.






33. Connect the engine wiring harness electrical connector.
- Attach the wiring harness pin-type retainer to the bracket.






34. Connect the brake booster vacuum hose to the engine.





35. Attach the fuel supply tube and EVAP (Evaporative Emission) tube retainer to the LH valve cover.





36. Position and connect the Evaporative Emission (EVAP) tube to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.
- Attach the EVAP (Evaporative Emission) tube retainer to the intake manifold.






37. Connect the fuel supply tube quick connect coupling to the fuel rail.





38. Connect the upper and lower radiator hoses to the thermostat housing.





39. NOTE: RH shown, LH similar.
Install the RH and LH engine mount bracket-to-engine mount nuts.

- Tighten to 63 Nm (46 lb-ft).






40. Install the accessory drive belt and A/C compressor belt.

41. Install the degas bottle.

42. Install the engine Air Cleaner (ACL) and ACL (Air Cleaner) outlet pipe.

43. Lift the cowl screen and install the ground strap and bolt.
- Tighten to 10 Nm (89 lb-in).

- Attach the wiring harness retainer to the cowl.






44. Install the 2 LH cowl vent screen plastic rivets.





45. If equipped, install the engine appearance cover.





46. NOTE: LH shown, RH similar.
If equipped, install the strut tower cross brace and the 4 nuts (2 shown).

- Tighten to 35 Nm (26 lb-ft).






47. NOTE: RH shown, LH similar.
Align the hood and install the 4 bolts (2 shown).

- Tighten to 12 Nm (106 lb-in).






48. Connect the 2 windshield washer hose C-Lock Couplers and attach the 2 windshield washer hose retainers.





49. Attach the 2 windshield washer hose retainers and install the 8 hood insulation pin-type retainer (2 shown).





50. Fill the engine with clean engine oil.

51. Fill the engine cooling system. For additional Information, refer Cooling System &/or Engine Block Heater.

52. Install the battery tray.

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