Engine

Special Tool(s)

	2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Adjustable Grip Arm, 1735A 014-00001 or equivalent
	Powertrain Lift 300-OTC1585AE or equivalent
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

1. Using the Floor Crane and Spreader Bar, align the transaxle to the engine.

2. Install the 3 engine-to-transaxle bolts.
   • Tighten to 48 Nm (35 lb-ft).

3. Install the LH engine-to-transaxle bolt.
   • Tighten to 48 Nm (35 lb-ft).

4. Install the 2 LH bottom transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).

5. Install the RH halfshaft support bracket and the 2 bolts.
   • Tighten to 40 Nm (30 lb-ft).

6. Install the intermediate shaft bracket 2 studs and the 2 nuts.
   • Tighten the studs to 10 Nm (89 lb-in).
   • Tighten the nuts to 25 Nm (30 lb-ft).

7. NOTE: LH shown, RH similar.

   Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

8. Using the Floor Crane and Spreader Bar, install the powertrain and subframe as an assembly on the powertrain lift table.

9. NOTE: LH shown, RH similar.

   Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

10. Install the Adjustable Grip Arm.

11. Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.

12. Attach the transaxle control wire harness retainer to the transaxle stud bolt.

13. Connect the transaxle control electrical connector.

14. Connect the generator electrical connector.

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

16. Connect the A/C electrical connector and attach the wiring harness retainer.

17. Install the ground wire and the bolt to the RH cylinder head.
    • Tighten to 10 Nm (89 lb-in).

18. Position the PTU support bracket in place and install the 3 bolts.
    1. Tighten the 2 bolts to 70 Nm (52 lb-ft).
    2. Tighten the bolt to 48 Nm (35 lb-ft).

19. Install the RH turbocharger lower bracket and the 3 bolts.
    1. Tighten the bolt to 19 Nm (168 lb-in).
    2. Tighten the 2 bolts to 48 Nm (35 lb-ft).

20. Install the starter, the stud bolt and bolt.
    • Tighten to 27 Nm (20 lb-ft).

21. Connect the wiring harness retainer to the starter motor stud bolt.

22. Attach the starter wire terminals and install the 2 nuts.
    1. Tighten the B+ terminal nut to 12 Nm (106 lb-in).
    2. Tighten the S-terminal nut to 5 Nm (44 lb-in).

23. Install the starter motor solenoid cover.

24. Remove the Heavy Duty Floor Crane and Spreader Bar.

25. Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to Section 310-00 .

26. Remove the Engine Lift Eye from the LH cylinder head.

27. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).

28. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
    • Tighten to 8 Nm (71 lb-in).

29. Attach the 4 wiring harness retainer to the valve cover stud bolt.

30. Install the engine cover mounting stud to the LH valve cover stud bolt.
    • Tighten to 6 Nm (53 lb-in).

31. Remove the ratchet strap from the RH knuckle to subframe.

32. Raise the subframe and powertrain assembly into the vehicle.

33. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).

34. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).

35. Install the bolt and the 3 nuts for the transaxle support insulator bracket-to-transaxle.
    • Tighten the bolt to 80 Nm (59 lb-ft).
    • Tighten the nuts to 63 Nm (46 lb-ft).

36. NOTE: RH shown, LH similar.

    Install the 2 front subframe bolts.
    • Tighten to 200 Nm (148 lb-ft).

37. NOTE: RH shown, LH similar.

    Position the subframe brackets and install the 4 bolts finger-tight.

38. NOTE: RH shown, LH similar.

    Install the 2 rear subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).

39. NOTE: RH shown, LH similar.

    Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).

40. Remove the ratchet strap from the front of the subframe to the rear of the subframe.

41. Remove the Adjustable Grip Arm and the powertrain lift table.

42. NOTE: LH shown, RH similar.

    Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.
    • Tighten to 250 Nm (184 lb-ft).

43. NOTE: LH shown, RH similar.

    Install the brake caliper and the guide pin bolts.
    • 432 mm (17 in) brakes: Tighten to 72 Nm (53 lb-ft).
    • 457 mm (18 in) brakes: Tighten to 75 Nm (55 lb-ft).

44. NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.

    NOTE: LH shown, RH similar.

    NOTE: Apply the brake to keep the halfshaft from rotating.

    Using the previously removed wheel hub nut, seat the LH and RH halfshafts.
    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nuts.

45. NOTICE: The wheel hub nut contains a one time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.

    NOTE: LH shown, RH similar.

    NOTE: Apply the brake to keep the halfshaft from rotating.

    Install a new wheel hub nuts.
    • Tighten to 350 Nm (258 lb-ft).

46. NOTE: RH shown, LH similar.

    Install new upper stabilizer bar link nuts.
    • Tighten to 150 Nm (111 lb-ft).

47. NOTE: LH shown, RH similar.

    Install the wheel speed sensor and the bolt.
    • Tighten to 15 Nm (133 lb-in).

48. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).

49. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).

50. Install the inspection cover and the 2 fasteners.

51. Connect the transaxle cooler tubes and install the 2 secondary latches.

52. If equipped, connect the 2 PTU coolant hoses.

53. Connect the lower radiator hose to the radiator.

54. Attach the lower radiator hose retainer to the cooling fan and shroud.

55. NOTE: Align the index marks for the LH Charge Air Cooler (CAC) tube.

    Connect the lower LH CAC tube to the LH turbocharger.
    • Tighten to 5 Nm (44 lb-in).

56. Using a new O-ring seal and gasket seal, install the upper A/C tube to the A/C compressor and install the nut.
    • Tighten to 15 Nm (133 lb-in).

57. Install the A/C tube bracket and bolt to the rear of the A/C compressor.
    • Tighten to 25 Nm (18 lb-ft).

58. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

59. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.
    • Tighten to 70 Nm (52 lb-ft).

60. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Section 501-20B .

    Install the steering intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 20 Nm (177 lb-in).

61. Install the RH and LH catalytic converters. For additional information, refer to Section 309-00 .

62. Install the 3 scrivets in the rubber shield.

63. Install the front valance, 7 bolts and 3 pin-type retainers.

64. Install the underbody shield and the 4 retainers.

65. Install the front wheels and tires. For additional information, refer to Section 204-04 .

66. Connect the fuel supply tube. For additional information, refer to Section 310-00 .

67. Install the Evaporative Emission (EVAP) tube assembly and connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00 .

68. Connect the EVAP valve electrical connector and attach to the intake manifold.

69. Connect the EVAP tube quick connect coupling. For additional information, refer to Section 310-00 .

70. If equipped, attach the engine block heater harness to the radiator support wiring harness.

71. Connect the upper radiator hose to the intake manifold coolant tube.

72. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).

73. Connect the 2 heater hoses to the intake manifold.

74. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube and tighten the clamps.
    • Tighten to 5 Nm (44 lb-in).

75. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.

76. Connect the transaxle control cable to the control lever.

77. Connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00 .

78. Connect the battery power feed wire to the positive battery terminal and install the nut.
    • Connect the electrical connector.
    • Tighten to 6 Nm (53 lb-in).

79. Connect the engine wiring harness electrical connector.

80. Position back the ground wire and install the bolt.
    • Tighten to 6 Nm (53 lb-in).

81. Install the battery tray. For additional information, refer to Section 414-01 .

82. NOTE: Align the index marks for the CAC outlet pipe.

    Install the CAC outlet pipe and tighten the clamps.
    • Tighten to 5 Nm (44 lb-in).

83. Connect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) sensor electrical connector.

84. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section 303-12 .

85. Install the degas bottle. For additional information, refer to Section 303-03 .

86. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).

87. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.
    • Tighten to 15 Nm (133 lb-in).

88. Install the engine wiring harness retainer to the bulkhead.
    1. Slide the wiring harness in the bulkhead.
    2. Make sure the wiring harness retainer tab is below the bulkhead lip.

89. Connect the PCM electrical connector.
    

90. Connect the engine harness electrical connector.

91. Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).

92. Attach the 2 brake booster vacuum hose retainers to the strut tower brace.

93. Install the cowl panel grille. For additional information, refer to Section 501-02 .

94. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    • Attach the HO2S connector retainer to the bracket.

95. Fill the engine with clean engine oil.

96. Fill and bleed the cooling system. For additional information, refer to Section 303-03 .

97. Recharge the A/C system. For additional information, refer to Section 412-00 .

98. Perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.