Installation

Installation Procedure





1. Install the front engine mount bracket.
2. Carefully position the engine to the supported frame and transaxle assembly, aligning the engine dowels to the transaxle cover.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the bolts attaching the engine to the transaxle.
^ Tighten the engine to transaxle mounting bolts to 75 Nm (55 ft. lbs.).





4. Install the nut securing the front engine mount to the engine frame.
^ Tighten the front engine mount nut to 70 Nm (52 ft. lbs.).
5. Place a block of wood between the front of the engine oil pan and the engine frame.
6. Remove the engine lift chain from the engine lift brackets.





7. Remove the J 42504 from the cylinder head.





8. Install the four bolts securing the transaxle brace to the engine and transaxle.
^ Tighten the transaxle brace bolts to 50 Nm (37 ft. lbs.).





9. Install the retaining nuts (2,3) securing the vehicle speed sensor heat shield (1) to the transaxle.
^ Tighten the vehicle speed sensor heat shield nuts to 50 Nm (37 ft. lbs.).





10. Install the bolts (1,3) securing the front transaxle brace (2) to the transaxle and right cylinder head.
^ Tighten the front transaxle brace bolts (1,3) to 50 Nm (37 ft. lbs.).





11. Position the rear transaxle brace over the studs located at the rear of the right cylinder head.
12. Loosely install the nuts (3) securing the rear transaxle brace (1) to the cylinder head.
13. Install the bolt (2) securing the rear transaxle brace (1) to the transaxle.
^ Tighten the rear transaxle brace bolt (2) to 50 Nm (37 ft. lbs.).
^ Tighten the rear transaxle brace nuts (3) to 50 Nm (37 ft. lbs.).





14. Position the right engine mount bracket (1) to the engine.
15. Install the four bolts securing the right engine mount bracket (1) to the engine.
^ Tighten the right engine mount bracket bolts to 50 Nm (37 ft. lbs.).
16. Install the nut (2) securing the power steering pressure hose to the right engine mount bracket (1).
^ Tighten the power steering hose support nut to 9 Nm (80 inch lbs.).





17. Install the power steering pressure hose to the power steering pump.
^ Tighten the power steering hose to power steering pump to 27 Nm (20 ft. lbs.).





18. Connect the power steering hose to the power steering pump reservoir.
19. Install the power steering return hose retaining bolt to the cylinder head.
^ Tighten the power steering return hose retaining bolt to 50 Nm (37 ft. lbs.).





20. Connect the engine wiring harness to the engine.
21. Install the nut (3) securing the coil cassette ground wire to the cylinder head.
^ Tighten the coil cassette ground wire nut to 17 Nm (13 ft. lbs.).
22. Install the nut securing the intermediate hose to the secondary AIR valve at bank 1.
^ Tighten the intermediate hose to secondary AIR valve nut to 9 Nm (80 inch lbs.).
23. Connect the intermediate hose to the secondary AIR valve at bank 2.
24. Install the heater pipes.





25. Position the engine/transaxle assembly under the vehicle.

Important: Ensure clearance is maintained between the engine/transaxle assembly and the following:
^ The A/C accumulator hose
^ The A/C compressor hose
^ The brake pipes
^ The heater hoses
^ The radiator hoses
^ The wheel speed sensor leads
^ The wiring harnesses

26. Carefully lower the vehicle over the engine/transaxle assembly, aligning the struts to the strut towers.
27. Install the six frame mounting bolts (3) retaining the frame (2) to the vehicle.
Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.
^ Tighten the frame mounting bolts to 191 Nm (141 ft. lbs.).





28. Install the nut securing the right engine mount to the engine mount bracket.
^ Tighten the engine mount nut to 80 Nm (59 ft. lbs.).
29. Remove the block of wood between the front of the engine oil pan and the engine frame.





30. Install the nut (1) securing the left transaxle mount to the transaxle mount bracket.
^ Tighten the transaxle mount nut to 80 Nm (59 ft. lbs.).
31. Raise and support the vehicle. Refer to Vehicle Lifting.





32. Remove the ~ 39580 powertrain support dolly from under the engine frame.

Important: Line up the flywheel and converter, using the alignment marks made during disassembly.





33. Install the bolts securing the flywheel to the torque converter.
^ Tighten the flywheel to torque converter bolts to 60 Nm (44 ft. lbs.).
34. Install the torque converter cover.
35. Install the oil pan to transaxle brace.
^ Tighten the oil pan to transaxle brace bolts to 50 Nm (37 ft. lbs.).
36. Connect the post HO2S at the sensor pigtail.

Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.





37. Connect the intermediate shaft to the steering gear.
38. Install the pinch bolt.
^ Tighten the intermediate shaft to steering gear pinch bolt to 45 Nm (33 ft. lbs.).





39. Connect the A/C suction hose to the compressor.
^ Tighten the A/C suction hose nut to 20 Nm (15 ft. lbs.).





40. Connect the A/C discharge hose to the compressor.
^ Tighten the A/C discharge hose nut to 20 Nm (15 ft. lbs.).
41. Connect the A/C pressure sensor.





42. Connect the 2 rear brake pipes at the rear of the engine frame.
^ Tighten the brake pipes to 15 Nm (11 ft. lbs.).





43. Connect the front brake pipes to the retainers at the body frame rails.
44. Install the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.
^ Tighten the brake pipe frame brackets to 15 Nm (11 ft. lbs.).





45. Connect the secondary AIR inlet hose to the secondary AIR pump.
46. Install the wheelhouse extensions.
47. Install the front air deflector.





48. Attach the front wheel speed sensor electrical leads (2) to the body frame rail.
49. Install the rear exhaust manifold pipe.
50. Install the front wheels.





51. Lower the vehicle ONLY enough to allow the threaded holes in the strut to align with the holes in the strut towers.
52. Install the right and left side strut tower bolts.
^ Tighten the strut tower bolts to 40 Nm (30 ft. lbs.).
53. Lower the vehicle.





54. Remove the J 42640 from the steering column.





55. Connect the lower transaxle oil cooler pipe fitting to the radiator.

Important: Ensure the transaxle oil cooler pipe is positioned upwards while tightening.

^ Tighten the transaxle oil cooler pipe fitting to 35 Nm (26 ft. lbs.).





56. Install the upper transaxle oil cooler pipe retaining bolt to the fan shroud.
^ Tighten the transaxle oil cooler pipe retaining bolt to 6 Nm (53 inch lbs.).





57. Push the upper transaxle oil cooler pipe into the radiator quick connect fitting, until a click is heard.
58. Tug gently on the cooler pipe to ensure proper retention.
59. Slide the plastic cap (1) over the quick connect fitting.





60. Install the 2 master cylinder brake pipes (1) to the BPMV (2) using the location recorded during the removal procedure.
^ Tighten the brake pipes to 15 Nm (11 ft. lbs.).





61. Connect the heater hoses (1,2) to the heater pipes.





62. Connect the surge tank inlet hose (2) to the surge tank (1).





63. Position the J 38185 to the clamp in order to connect the radiator outlet hose (2) to the thermostat housing.
64. Position the J 37097-A to the clamp in order to connect the radiator inlet hose (1) to the engine.





65. Install the shift cable (1) to the manual shift lever (2) and the bracket.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.





66. Install a NEW accelerator control cable to the throttle body.
67. Install the cruise control cable (2) to the throttle body lever (1).
68. Slide the cruise control fully into the throttle body bracket until it snaps into place.





69. Install the bolt (1) securing the engine ground cable (2) to the right side body frame rail.
^ Tighten the engine ground cable bolt to 50 Nm (37 ft. lbs.).





70. Connect the wiring harness electrical connectors to the following components:
^ The PCM.
^ The C101 (1)
^ The engine electrical harness.





71. Install the nut (1) securing the battery positive cable to the remote positive terminal.
^ Tighten the battery positive cable to remote positive terminal nut to 12 Nm (106 inch lbs.).





72. Attach the secondary AIR relay (1) to the relay bracket.
73. Install the air cleaner assembly.





74. Connect the hose (4) to the evaporative emission canister purge valve (3).
75. Connect the fuel inlet and return quick-connect fittings at the fuel rail.





76. Connect the vacuum brake booster hose to the vacuum connection.





77. Position the intake manifold sight shield (1) to the engine.
78. Install the 2 intake manifold sight shield nuts (2).
^ Tighten the intake manifold sight shield nuts to 3 Nm (27 inch lbs.).
79. Connect the battery negative cable.
80. Fill the engine with oil.
81. Fill the cooling system.
82. Bleed the hydraulic brake system.
83. Recharge the A/C refrigerant system.
84. Bleed the power steering system.
85. Measure the wheel alignment.

Engine Final Test and Inspection
Complete the following procedure after the engine is installed in the vehicle:
1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle. Refer to Vehicle Lifting.
6. Inspect for oil, coolant and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP system variation learn procedure.
9. Perform a final inspection for the proper engine oil and coolant levels.
10. Road test the vehicle.