- Using a engine hoist, remove the engine from the engine stand.
- Install the following components:
• | The engine mount bracket |
• | The engine block heater |
- Install the clutch pressure plate and disc. Refer to
Clutch Pressure and Driven Plate Replacement
.
- Install the engine to the transaxle.
Notice: Refer to Fastener Notice in the Preface section.
- Install the transaxle to engine bolts/stud.
Tighten
Tighten the bolts/stud to 75 N·m (55 lb ft).
- Install the transaxle brace and bolts.
Tighten
Tighten the bolts to 50 N·m (37 lb ft).
- Install the starter. Refer to
Starter Installation
.
- Remove the engine lift hoist from the engine lift hooks.
- Slide the lift table under the vehicle.
- Slowly lower the vehicle until it aligns with the alignment marks made during the removal.
- Tighten/install the frame bolts.
Tighten
Tighten the bolts to 100 N·m (74 lb ft) plus and additional 180 degrees.
- Raise the vehicle until the lift table can be removed from under the vehicle.
- Remove the lift table.
- Connect the lower control arms to the steering knuckles. Refer to
Lower Control Arm Replacement
.
- Connect the intermediate shaft to the steering gear. Refer to
Intermediate Steering Shaft Replacement
.
- Connect the outer tie rod ends to the steering knuckles. Refer to
Steering Linkage Outer Tie Rod Replacement
.
- Connect the stabilizer links to the stabilizer bar. Refer to
Stabilizer Shaft Link Replacement
.
- Lower the vehicle.
- Install the transaxle mount to transaxle bolts.
Tighten
Tighten the bolts to 45 N·m (33 lb ft).
- Install the engine mount. Refer to
Engine Mount Replacement
.
- Remove the blocks of wood from between the powertrain and the frame.
- Install the catalytic converter. Refer to
Catalytic Converter Replacement
.
- Lower the vehicle.
Important: Ensure that the black cable is installed in the top notch of the transaxle bracket and the white cable in installed in the bottom notch of the transaxle bracket.
- Install the range selector and shift lever cables to the transaxle bracket.
- Connect the range selector and shift lever cables to the transaxle levers.
- Gather all engine harness branches and position the harness over the engine.
- Install the engine harness clip (6) to the transaxle.
- Connect the engine harness electrical connector (7) to the back up lamp switch.
- Connect the engine harness electrical connector (4) to the HO2S.
- Install the engine harness electrical connector clip (5) to the transaxle rear mount bracket.
- Install the engine harness clip (2) to the transaxle.
- Install the CPA retainer (3).
- Connect the engine harness electrical connector (1) to the VSS.
- Connect the engine harness electrical connector (3) to the HO2S.
- Install the CPA retainer (2).
- Connect the ECT sensor electrical connector (1).
- Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
- Connect the engine wiring harness electrical connector (3) to the ECT sensor.
- Position the engine harness ground terminal (1) and install the engine harness ground terminal bolt (2).
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Connect the engine wiring harness electrical connector (1) to the HO2S (3).
- Position the A/C compressor line and install the bolt.
Tighten
Tighten the bolts to 22 N·m (16 lb ft).
- Lower the vehicle.
- Install the engine harness clip (1) to the camshaft cover.
- Position the turbocharger coolant feed pipe to the vehicle.
- Install the turbocharger coolant feed pipe bracket bolt (3) to the cylinder head.
Tighten
Tighten the bolt to 10 N·m (89 lb in).
- Install the turbocharger coolant feed pipe fitting (2) to the cylinder head.
Tighten
Tighten the fitting to 35 N·m (26 lb ft).
- Install the turbocharger coolant feed pipe bolt (1) at the turbocharger.
Tighten
Tighten the bolt to 35 N·m (26 lb ft).
- Install the charge air bypass valve vacuum solenoid.
- Install the charge air bypass valve vacuum hose to the turbocharger coolant feed pipe clips.
- Position the charge air bypass valve vacuum hose clamp at the turbocharger.
- Place the charge air bypass valve solenoid out of the way.
- Connect the engine wiring harness electrical connector to the boost sensor.
- Connect the engine harness clips (2) to the camshaft cover.
- Connect the engine harness clip (1) to the camshaft cover.
- Connect the engine wiring harness electrical
connectors to the ignition coils.
- Connect the engine wiring harness electrical connector (2) to the intake CMP actuator.
- Connect the engine wiring harness electrical connector (1) to the exhaust CMP actuator.
- Connect the engine wiring harness electrical connector (1) to the high pressure
fuel pump.
- Install the engine wiring harness clip (3) to the high pressure fuel pump bracket.
- Connect the engine wiring harness electrical connector (2) to the knock sensor.
- Connect the engine wiring harness electrical connector (1) to the fuel injector
jumper electrical connector.
- Install the positive battery cable terminal (3) to the generator.
- Install the generator terminal nut (1).
Tighten
Tighten the nut to 20 N·m (15 lb ft).
- Position the positive battery cable terminal boot (2).
- Connect the engine wiring harness electrical connector (4) to the A/C compressor.
- Connect the engine wiring harness electrical connector (1) to the generator.
- Install the catalytic converter. Refer to
Catalytic Converter Replacement
.
- Connect the engine wiring harness electrical connector (1) to the CKP sensor.
- Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
- Lower the vehicle.
- Install the heater inlet (1) and outlet (2) hoses to the thermostat housing.
- Position the heater inlet and outlet hose clamps at the thermostat housing.
- Install the surge tank outlet hose to the surge tank.
- Position the surge tank outlet hose clamp at the surge tank.
- Install the radiator outlet hose. Refer to
Radiator Outlet Hose Replacement
.
- Install the radiator inlet hose. Refer to
Radiator Inlet Hose Replacement
.
- Remove the cap or plug from the turbocharger opening.
- Install the charge air cooler pipe to the turbocharger.
- Install the charge air cooler pipe to turbocharger bolts (1).
Tighten
Tighten the bolts to 22 N·m (16 lb ft).
- Install the engine drive belt. Refer to
Drive Belt Replacement
.
- Unsecure the cooling module from the upper body structure.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
- Install the turbocharger heat shield and bolts (1).
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Connect the fuel feed pipe (1) to the fuel line. Refer to
Metal Collar Quick Connect Fitting Service
.
- Connect the EVAP canister purge solenoid tube to the valve (2). Refer to
Plastic Collar Quick Connect Fitting Service
.
- Install the charge air cooler inlet and outlet pipes. Refer to
Charge Air Cooler Inlet Pipe Replacement
and
Charge Air Cooler Outlet Pipe Replacement
.
- Install the air cleaner assembly. Refer to
Air Cleaner Assembly Replacement
.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Fill the engine with oil.