Part 1
Engine - Manual TransaxleInstallation (Steps 1-32)
Special Tool(s)
Special Tool(s):
Material
Material:
1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 7 bellhousing-to-engine fasteners.
^ Tighten to 48 Nm (35 lb-ft).
2. Using the special tools, raise the engine and transaxle assembly onto the lift table.
3. Using the special tools, secure the engine and transaxle assembly to the lift table.
4. Install the 7 new catalytic converter manifold studs.
^ Tighten to 17 Nm (13 lb-ft).
5. Install the starter motor isolator.
6. Install the starter motor, stud bolt and the bolt.
^ Install the upper bolt and lower stud bolt finger tight.
^ Tighten the upper bolt to 35 Nm (26 lb-ft).
^ Tighten the lower stud bolt to 35 Nm (26 lb-ft).
7. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.
8. Install the engine ground wire and the bolt.
^ Tighten to 48 Nm (35 lb-ft).
9. Install the power steering tube bracket on the starter motor stud bolt and install the nut.
^ Tighten to 20 Nm (15 lb-ft).
10. Attach the starter wire harness retainer to the starter motor stud bolt.
11. Connect the starter motor electrical terminals and install the 2 nuts.
^ Tighten the small nut to 5 Nm (44 lb-in).
^ Tighten the large nut to 12 Nm (9 lb-ft).
12. Connect the crankshaft position (CKP) sensor electrical connector.
13. Attach the 2 CKP sensor wire harness retainers.
14. Connect the power steering pressure (PSP) switch electrical connector.
15. Connect the A/C compressor electrical connector.
16. Connect the reversing lamp switch electrical connector.
17. Connect the vehicle speed sensor (VSS) electrical connector.
18. Position the heated oxygen sensor (HO2S) and catalyst monitor sensor wire connector bracket and install the nut.
^ Tighten to 25 Nm (18 lb-ft).
19. Install the nut for the HO2S and catalyst monitor sensor wire connector bracket.
^ Tighten to 25 Nm (18 lb-ft).
20. Using the lift table, position the engine and transaxle assembly in the vehicle.
21. Install the transaxle mount plate and the 5 nuts.
^ Tighten the center nut to 150 Nm (111 lb-ft).
^ Tighten the 4 outer nuts to 48 Nm (35 lb-ft).
22. Install the engine mount and the 2 bolts and the stud bolt.
^ Tighten to 48 Nm (35 lb-ft).
23. Install the 2 motor mount nuts.
^ Tighten to 90 Nm (66 lb-ft).
24. Install the 2 oil pan-to-bellhousing bolts.
^ Tighten to 48 Nm (35 lb-ft).
25. Install the 2 lower bellhousing-to-oil pan bolts.
^ Tighten to 48 Nm (35 lb-ft).
26. NOTE: The bolts are different lengths, make sure the bolts are in the correct location.
Install the transaxle roll restrictor and the 2 bolts.
1 Install the transaxle roll restrictor.
2 Install the short bolt.
3 Install the long bolt.
^ Tighten to 70 Nm (52 lb-ft).
27. Connect the throttle control electrical connector.
28. Connect the heater hose to the coolant tube.
29. Connect the upper radiator hose and the heater hose to the coolant bypass.
30. Install the power steering pump.
31. Clean and inspect the catalytic converter flange.
^ Using a straightedge and a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
32. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
Using a new gasket and 7 new nuts, install the catalytic converter and tighten in 2 stages in the sequence shown.
^ Stage 1: Tighten to 55 Nm (41 lb-ft).
^ Stage 2: Tighten to 55 Nm (41 lb-ft).
