Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Engine

Print

REMOVAL & INSTALLATION



See Figure 1

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this information.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible additions to any repair procedure. Be absolutely sure to tag any wire or hose before it is disconnected, so that you can be assured of proper connection during installation.



Click image to see an enlarged view

Fig. Fig. 1: When removing nuts, bolts and other parts, place them in a tray or other container

Except Premier

See Figures 2 through 6

Click image to see an enlarged view

Fig. Fig. 2: The lower left-hand engine mount is attached to the front, lower radiator support-1986 Reliant



Click image to see an enlarged view

Fig. Fig. 3: The lower engine mount changes very little throughout the models years-1991 Acclaim



Click image to see an enlarged view

Fig. Fig. 4: Make sure to tighten the engine mount fasteners to the torque values shown-1981-90 models (except Premier)



Click image to see an enlarged view

Fig. Fig. 5: Install all engine mount fasteners finger-tight, then tighten them to their specified values-1991-92 models (except Premier)



Click image to see an enlarged view

Fig. Fig. 6: Although these specifications seem similar to the 1991-92 models, there are a few differences-1993-95 models


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

The following procedure can be used on all years and models. Slight variations may occur due to extra wires, hoses, etc. because of model-specific options.

  1. Relieve the fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable and all engine ground straps.
  4.  
  5. Mark the hood hinge outlines on the hood and remove the hood. For more information, refer to Body & Trim .
  6.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Drain the cooling system and engine oil. Remove the radiator hoses, fan assembly, radiator and intercooler, if equipped.
  2.  
  3. Remove the air cleaner, duct hoses and oil filter.
  4.  


CAUTION
Do not disconnect the A/C lines unless the A/C system was discharged by a qualified automotive technician using a refrigerant recovery/recycling machine, otherwise A/C system damage or personal injury could be the result.

  1. Unbolt the air conditioning compressor from its mount, if equipped, and position it aside without disconnecting the refrigerant lines.
  2.  
  3. Remove the power steering pump mounting bolts and position the pump aside without disconnecting any fluid lines.
  4.  
  5. Label and disengage all electrical connectors from the engine, alternator and fuel system.
  6.  
  7. Disconnect and plug the fuel lines and heater hoses.
  8.  
  9. Disconnect the throttle body or carburetor linkage.
  10.  
  11. Apply the parking brake and block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  12.  
  13. Disconnect the exhaust system from the exhaust manifold.
  14.  
  15. Remove the starter motor and set it aside. Do not allow it to hang suspended from its wires.
  16.  
  17. Perform the following on vehicles equipped with manual transaxles:
    1. Disconnect the clutch cable from the transaxle.
    2.  
    3. Remove the transaxle case lower cover.
    4.  
    5. Support the transaxle with a hydraulic floor jack or a special transaxle holding fixture.
    6.  

  18.  
  19. If the vehicle is equipped with an automatic transaxle, perform the following:
    1. Remove the transaxle case lower cover.
    2.  
    3. Matchmark the flexplate to the torque converter for reinstallation.
    4.  
    5. Remove the torque converter-to-flexplate bolts. The crankshaft must be turned to access all of the bolts; turn the crankshaft with a wrench on the crankshaft front pulley bolt.
    6.  
    7. Attach a C-clamp on the front bottom of the torque converter housing to prevent the torque converter from falling out of the transaxle.
    8.  
    9. Support the transaxle with a hydraulic floor jack or a special transaxle holding fixture.
    10.  

  20.  
  21. Lower the vehicle and support the transaxle with either a hydraulic floor jack or a special transaxle holding fixture. Attach an engine lifting hoist to the engine and raise the hoist until it just starts to take the weight off of the engine mounts.
  22.  
  23. Remove the right inner splash shield.
  24.  
  25. Remove the engine ground strap.
  26.  
  27. Remove the long through-bolt from the right engine bracket yoke and insulator.
  28.  

If removing the engine insulator-to-side rail screws, first mark the position of the insulator on the side rail to insure proper alignment during reinstallation.

  1. Remove the transaxle-to-engine mounting bolts.
  2.  


WARNING
Make sure that the clutch cable has been disconnected on manual transaxle models.

  1. Remove the front engine mount bolt and nut.
  2.  
  3. If equipped, remove the manual transaxle damper.
  4.  
  5. Remove the left side insulator (engine mount) through-bolt from inside of the wheel well, or remove the insulator bracket-to-transaxle bolts.
  6.  
  7. Carefully lift the engine from the vehicle with the engine hoist. Make sure that all wires, hoses and other components are completely disconnected and that nothing gets snagged during engine removal. Once the engine is raised high enough to clear the front radiator support, carefully roll the engine hoist and engine from the vehicle.
  8.  

To install:
  1. Lower the engine into the engine compartment. Make sure the lifting device is supporting the full weight of the engine and loosely install all of the mounting bolts until all are threaded. Then tighten all bolts to the torque values shown in the accompanying illustrations.
  2.  
  3. Install and tighten the transaxle-to-engine case bolts to 70 ft. lbs. (95 Nm).
  4.  
  5. Remove the engine lifting hoist and transaxle support.
  6.  
  7. Install the engine ground strap.
  8.  
  9. Install the right inner splash shield.
  10.  
  11. Install the starter motor, as described in Engine Electrical .
  12.  
  13. Attach the exhaust system to the exhaust manifold, as described at the end of this section.
  14.  
  15. For vehicles equipped with manual transaxles, perform the following:
    1. Install the transaxle lower case cover.
    2.  
    3. Connect the clutch cable to the clutch fork. For more details, refer to Drive Train .
    4.  

  16.  
  17. For automatic transaxle-equipped vehicles, remove the C-clamp from the torque converter housing. Align the flexplate to the torque converter, then install the attaching bolts. Tighten the attaching bolts in several steps to 55 ft. lbs. (75 Nm). Turn the crankshaft with a wrench on the crankshaft front pulley to gain access to all of the torque converter-to-flexplate bolts.
  18.  
  19. Install the power steering pump. For more information, refer to Suspension & Steering .
  20.  
  21. Install and adjust the power steering pump drive belts, as described in Routine Maintenance .
  22.  
  23. Install the fuel lines, the heater hoses and the accelerator cable.
  24.  
  25. Install all electrical connections and harnesses to the engine and throttle body.
  26.  
  27. Install a new oil filter, install the oil drain plug, then fill the engine crankcase with the proper amount and type of engine oil. For more details, refer to Routine Maintenance .
  28.  
  29. If equipped, install the A/C compressor. For more details, refer to Chassis Electrical .
  30.  
  31. Install the air cleaner assembly and related hoses.
  32.  
  33. Install the radiator and shroud assembly. Install the radiator hoses, close the radiator drain, then fill the cooling system, as described in Routine Maintenance .
  34.  
  35. Install the hood, as outlined in Body & Trim .
  36.  
  37. Connect the positive battery cable, then connect the negative battery cable. Make sure that the cables are installed in this order.
  38.  
  39. Start the engine and run until operating temperature is reached. Check for fuel, oil, coolant, or vacuum leaks. If necessary, adjust the transaxle linkage, as described in Drive Train .
  40.  

Premier

See Figures 7 through 29

Click image to see an enlarged view

Fig. Fig. 7: Remove the air cleaner housing retaining nuts, then remove the air cleaner housing from the engine



Click image to see an enlarged view

Fig. Fig. 8: Disconnect the accelerator cable and cruise control cable (if equipped), then detach the cables from the cable holding bracket



Click image to see an enlarged view

Fig. Fig. 9: The hot air door vacuum line is attached to the side of the air cleaner assembly



Click image to see an enlarged view

Fig. Fig. 10: The locations of the fuel return and supply hoses-for proper quick-disconnect fitting release procedures



Click image to see an enlarged view

Fig. Fig. 11: The CCV hose is attached to the top of the rocker arm cover



Click image to see an enlarged view

Fig. Fig. 12: Open the clamp and remove the molded vacuum manifold assembly



Click image to see an enlarged view

Fig. Fig. 13: Detach the bulkhead connector by removing the bulkhead retaining bolt, then separating the two connector halves



Click image to see an enlarged view

Fig. Fig. 14: Make sure to disengage the connector on the dash wall, located near the vacuum brake booster hose



Click image to see an enlarged view

Fig. Fig. 15: After draining the cooling system, detach the two heater hoses from the heater core at the dash wall



Click image to see an enlarged view

Fig. Fig. 16: Remove the power steering pump drive belt by loosening the pivot bolt, the locking nut and the adjusting bolt



Click image to see an enlarged view

Fig. Fig. 17: Remove the power steering pump mounting bolts, then set the pump aside without disconnecting the fluid hoses



Click image to see an enlarged view

Fig. Fig. 18: The oil pressure sender unit is mounted in the engine between the rear face of the A/C compressor and the distributor



Click image to see an enlarged view

Fig. Fig. 19: After removing the brake calipers, hang them from the front springs with strong cord or wire



Click image to see an enlarged view

Fig. Fig. 20: Separate the steering knuckle from the lower end of the strut-make sure to loosen the strut bolt nuts, not the bolts themselves



Click image to see an enlarged view

Fig. Fig. 21: Disconnect the transaxle shift lever from the transaxle shift cable



Click image to see an enlarged view

Fig. Fig. 22: Remove the transaxle shifter cable bracket by removing the mounting bolts



Click image to see an enlarged view

Fig. Fig. 23: The oil level sensor is mounted in the bottom of the engine block-detach the level sensor wiring harness connector



Click image to see an enlarged view

Fig. Fig. 24: Disconnect the pitch resistor from the bracket, then remove the pitch resistor bracket from the crossmember



Click image to see an enlarged view

Fig. Fig. 25: The transaxle solenoid is located near the transaxle drain plug-remove the mounting screws to extract the solenoid from the transaxle



Click image to see an enlarged view

Fig. Fig. 26: The Transaxle Control Unit harness connector must be disengaged from the transaxle-TCU connector and multi-function switch locations



Click image to see an enlarged view

Fig. Fig. 27: After the TCU, solenoid and sensor are disconnected, stow the wiring harness in the engine compartment



Click image to see an enlarged view

Fig. Fig. 28: Install the dolly-to-cradle special attaching bolts from the topside of the cradle (threaded end should point down) in the holes shown-make sure that the angle iron part of the attaching bolts sit flush in the cradle



Click image to see an enlarged view

Fig. Fig. 29: Install the dolly to the cradle with the wheels to the rear of the vehicle-tighten the attaching nuts until secure

The manufacturer recommends removing the engine by dropping it out of the vehicle from the bottom. Removing the engine in this manner requires raising the vehicle high enough (approximately 3 ft./91cm) so that the engine and transaxle assembly can be rolled out from underneath the vehicle on a special engine dolly. Although this could also be accomplished by raising the vehicle with hydraulic floor jacks and then rolling the vehicle, while on the jacks, back from the engine, we DO NOT recommend this technique because of the inherent dangers of rolling a vehicle on floor jacks. Read this entire procedure before commencing with the engine removal to be sure of the plausibility of performing this job yourself.

A necessity for this procedure is an engine dolly (and special fasteners) specifically sized, or designed, for the Premier. Since the engine, transaxle and front cradle (sub-frame assembly) are removed as one unit, the dolly provides structural integrity to hold these components together during the removal procedure.

  1. If your vehicle is equipped with Air Conditioning (A/C) and you feel it will be easier to remove the engine by disconnecting the A/C lines (the manufacturer recommends NOT disconnecting the lines), then have the A/C system discharged by a reputable, qualified automotive technician utilizing a refrigerant recovery/recycling machine.
  2.  


CAUTION
Please refer to Routine Maintenance before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Disconnect the negative battery cable, then disconnect the positive battery cable.
  2.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Drain the radiator into a large catch pan. For more information, refer to Routine Maintenance .
  2.  
  3. Label and detach all vacuum hoses from the engine and transaxle. The electrical wires do not need to be disconnected from the engine since the engine wiring harness will later be detached from the vehicle.
  4.  
  5. Remove the air cleaner housing retaining nuts, then remove the cleaner housing and air inlet tube.
  6.  


WARNING
When disconnecting the cruise control cable from the throttle lever, use finger pressure to push the connector off. Use of pliers can damage the connector.

  1. Disconnect the accelerator cable at the throttle lever. If equipped, disconnect the cruise control cable at the throttle lever.
  2.  
  3. Compress the tabs on the accelerator and cruise control cables and push them through the holding bracket. Lay the cables to the side of the engine compartment.
  4.  
  5. Detach the pre-heated air tube and air supply tube from the air cleaner.
  6.  
  7. Remove the air cleaner housing from the vehicle.
  8.  
  9. Loosen the battery hold-down nut, then remove the hold-down bracket. Remove the battery from the engine compartment.
  10.  
  11. Remove and reinstall the fuel tank filler cap to relieve the fuel tank pressure.
  12.  
  13. Disconnect the black fuel supply tube and grey return tube from the throttle body. For more information regarding the quick-disconnect fittings found on the Premier models, please refer to Fuel System .
  14.  
  15. Disconnect the CCV hose at the rocker arm cover.
  16.  
  17. Unscrew the bulkhead connector retaining bolt and pull the bulkhead connector off. Lay it on top of the engine.
  18.  
  19. Detach the electrical connector at the dash panel.
  20.  
  21. Disconnect the heater hoses from the heater core at the dash panel. Lay the hoses on top of the engine.
  22.  
  23. Disconnect the upper radiator hose from the thermostat housing and lay the hose to the side of the engine compartment.
  24.  
  25. Detach the coil wire at the ignition coil/module.
  26.  
  27. Disconnect the lower hose from the coolant pressure bottle, then lay the hose on the engine.
  28.  
  29. Remove the power steering locknut, then loosen the power steering pivot bolt. Loosen the bolts at the rear of the power steering pump and loosen the adjusting bolt.
  30.  
  31. Remove the accessory drive belt from the power steering pump, then remove the pump pivot bolt.
  32.  
  33. Remove the power steering pump and stow it to the side of the engine compartment.
  34.  
  35. Remove the lower radiator hose from the radiator.
  36.  
  37. Disconnect the engine wiring from the starter motor.
  38.  
  39. Detach the A/C wire connector from the compressor.
  40.  
  41. Remove the A/C compressor from the engine without disconnecting the refrigerant lines, if the A/C system was not discharged. Stow the compressor in the passenger's side of the engine compartment by securing it with strong cord or wire.
  42.  
  43. Disconnect the alternator wiring and the oil pressure sender wire(s).
  44.  
  45. Detach the Throttle Position Sensor (TPS) electrical connector.
  46.  


WARNING
Raise and safely support the vehicle on a side mount lift or large jackstands. Do not support the vehicle by the lower control arms. For specific jacking and support points on the Premier, refer to Routine Maintenance .

  1. Raise and safely support the vehicle on large jackstands.
  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Drain the engine oil into a large drain pan.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the brake calipers and hang them from the springs with strong wire or cord. Do not allow them to hang from the hydraulic fluid lines. For more information, refer to Brakes .
  6.  
  7. Hold the hub steady and loosen the hub nut on both sides of the vehicle.
  8.  


WARNING
The steering knuckle bolts are splined into the knuckle. Do not turn the bolts to loosen, instead loosen the nuts.

  1. Remove the steering knuckle-to-strut attaching bolt nuts on both sides of the vehicle.
  2.  


WARNING
Use a brass hammer to tap the steering knuckle bolts out. Do not use a steel hammer as damage to the threads will occur.

  1. On both sides of the vehicle, tap the top steering knuckle bolts out first, then pull the strut out, pivoting the steering knuckle on the lower bolt.
  2.  
  3. Tap the lower steering knuckle bolt out and separate the steering knuckle from the strut.
  4.  
  5. Remove the transaxle shield by removing the 4 bolts.
  6.  
  7. Disconnect the transaxle shift cable from the linkage arm by prying the cable up.
  8.  
  9. Remove the transaxle shifter cable bracket mounting bolts and let the cable and bracket hang.
  10.  
  11. Disconnect the exhaust system at the catalytic converter by removing the 4 nuts. Pull the pipe hook out of the hanger and let the converter and pipe assembly hang.
  12.  
  13. Remove the splash shield.
  14.  
  15. Disengage the oil level sensor connector.
  16.  
  17. Disconnect the pitch resistor (lower engine mount) from its bracket on the body front lower crossmember, then remove the pitch resistor bracket.
  18.  
  19. Open the drain plug and drain the automatic transaxle fluid into a large catch pan. Install the drain plug after the fluid has drained completely.
  20.  
  21. Loosen the solenoid mounting screws and remove the solenoid. The wire harness is attached to the dipstick tube by clips; remove the clips and stow the solenoid and harness to the side of the engine compartment.
  22.  
  23. Disengage the Transaxle Control Unit (TCU) wiring harness connector at the transaxle by squeezing the tabs and pulling it out.
  24.  
  25. Disconnect the multi-function switch from the transaxle by removing the retainer bolt and retainer and pulling the switch out.
  26.  
  27. Disconnect the transaxle sensor by removing the bolt and clip.
  28.  
  29. Disengage the wiring harness clip and ground wire from the transaxle.
  30.  
  31. Stow the multi-function switch, TCU harness, sensor and wiring harness in the engine compartment.
  32.  
  33. Attach the special attaching bolts into the cradle by pushing the large end of the channel iron into the hole in the cradle. Jiggle the bolt until the channel iron lays flat in the hole. Do the same with the other bolt.
  34.  
  35. Install the engine dolly to the cradle (sub-frame assembly) with the dolly wheels toward the rear of the vehicle. Tighten the nuts until secure.
  36.  
  37. Lower the vehicle until the dolly rests on the floor.
  38.  
  39. While laying on a mechanic's creeper or on the floor, remove the 4 cradle-to-vehicle mounting bolts.
  40.  

Ensure that all hoses, vacuum lines and wiring harnesses are positioned so that they will not snag and/or catch when the vehicle is lifted off of the engine.

  1. Slowly raise the vehicle off of the engine.
  2.  
  3. Mark the positions of the dolly legs and the center line of the wheels on the floor. This will help position the dolly during installation.
  4.  
  5. To move the dolly, position a floor jack under the center of the front bar of the dolly. Jack up the dolly until the front legs are approximately 1 in. (25mm) off the floor. Push the dolly/floor jack to the desired location.
  6.  

To install:
  1. Position the engine/transaxle/cradle assembly under the vehicle. Align the dolly with the matchmarks drawn on the floor when the assembly was removed.
  2.  

Ensure that all hoses, vacuum lines and wiring harnesses are positioned so that they will not snag and/or catch when the vehicle is lowered onto of the cradle and dolly.

  1. Lower the vehicle onto the cradle. Stop when the vehicle just touches the cradle bolt pads.
  2.  
  3. Install the cradle mounting bolts. The cradle bolt has a rubber spacer and metal washer. They must be installed with the rubber spacer between the body and the washer. Tighten the bolts to 92 ft. lbs. (125 Nm).
  4.  
  5. Raise the vehicle and safely support on jackstands. Make sure to support the vehicle only on the positions shown in Routine Maintenance . Do not support the vehicle on the lower control arms.
  6.  
  7. Push the lower control arm down and connect the steering knuckle to the strut. Install the top bolt first, then the lower bolt. The strut bolts are splined to the steering knuckles; tighten the nuts, not the bolts. Tighten the nuts to 123 ft. lbs. (167 Nm).
  8.  
  9. Install the disc brake calipers. For more details, refer to Brakes .
  10.  
  11. Hold the hub in place and tighten the hub nut to 181 ft. lbs. (245 Nm). To hold the hub steady, have an assistant depress the brake pedal to hold the rotor, however DO NOT depress the brake pedal until the brake calipers have been installed.
  12.  
  13. Remove the dolly from the cradle. remove the special bolts from the cradle.
  14.  
  15. Install the multi-function cable, the transaxle shifter cable, the transaxle solenoid and the transaxle sensor to the transaxle. Secure the transaxle solenoid wire to the dipstick tube with the clips.
  16.  
  17. Install the pitch resistor (lower front engine brace/mount) bracket, then tighten the bolt to 32 ft. lbs. (43 Nm).
  18.  
  19. Connect the pitch resistor to the bracket on the body lower front crossmember. Tighten the bolt to 75 ft. lbs. (102 Nm).
  20.  
  21. Install the transaxle shield. Tighten the attaching bolts to 21 ft. lbs. (28 Nm).
  22.  
  23. Attach the oil level sensor connector.
  24.  
  25. Install the splash shield below the alternator.
  26.  
  27. Connect the exhaust system at the catalytic converter and attach the pipe hook to the hanger.
  28.  
  29. Install the transaxle shifter cable bracket. Tighten the mounting bolts to 15 ft. lbs. (21 Nm).
  30.  
  31. Connect the transaxle shifter cable to the linkage arm.
  32.  
  33. Install the lower radiator hose. For more information on the correct positioning of the hose clamps, refer to Routine Maintenance .
  34.  
  35. Mount the front engine support bracket on the lower body crossmember. Tighten the bolts to 32 ft. lbs. (43 Nm).
  36.  
  37. Install the engine support on the support bracket. Tighten the bolt and nut to 75 ft. lbs. (102 Nm).
  38.  
  39. Ensure that the wheel well splash shields hang straight down.
  40.  
  41. Connect the starter motor wires.
  42.  
  43. Connect the ground cable at the starter motor mounting bolt. Tighten the bolt and nut to 31 ft. lbs. (42 Nm).
  44.  
  45. Install the front tires and wheels. Tighten the wheel lug nuts to 63 ft. lbs. (85 Nm) in a star-shaped pattern. Have an assistant depress the brake pedal while tightening the wheel lug nuts.
  46.  
  47. Lower the vehicle.
  48.  
  49. Attach the grey fuel return tube to the connector next to the pressure regulator. Connect the black fuel supply tube to the connector next the throttle linkage. Push them into the fitting until a click is heard. Verify that the connections are complete by first ensuring that only the retainer tabs protrude from the connectors and, second by pulling out on the fuel tubes to ensure that they are locked in place.
  50.  
  51. Connect the alternator, A/C compressor clutch and oil pressure sensor wires.
  52.  
  53. Install the A/C compressor and tighten the mounting bolts to 20 ft. lbs. (27 Nm).
  54.  
  55. Install the power steering pump. Finger-tighten the power steering pivot bolt and the rear power steering pump mounting bolts. Install the power steering belt and adjust its tension, as described in Routine Maintenance . Tighten the power steering pump bolts to 20 ft. lbs. (27 Nm).
  56.  
  57. Connect all vacuum hoses to the engine.
  58.  
  59. Connect the heater hoses to the heater core at the dash panel. For precise information regarding heater hose clamp positioning, refer to Routine Maintenance .
  60.  
  61. Install the coolant overflow bottle lower hose.
  62.  
  63. Install the upper radiator hose. For more information on the correct positioning of the hose clamps, refer to Routine Maintenance .
  64.  
  65. Attach the following wiring connectors: coil wire to the ignition module/coil unit, the bulkhead connector, the connector at the dash panel, and the TPS connector.
  66.  
  67. Install the battery into the vehicle, then tighten the hold-down nut until secure.
  68.  
  69. Install the air cleaner and the air inlet tube. Make sure to connect the vacuum hose to the air door on the side of the air cleaner assembly.
  70.  
  71. Connect the pre-heated air tube to the air cleaner.
  72.  
  73. Install the CCV fresh air hose and the EVAP canister hose to the air cleaner.
  74.  
  75. Tighten the hose clamps on the air cleaner housing, then install the air cleaner housing. Tighten the retaining bolts to 35 inch lbs. (4 Nm).
  76.  
  77. Connect the accelerator cable and, if equipped, the cruise control cable.
  78.  
  79. Close the radiator drain.
  80.  
  81. Connect the positive battery cable, then connect the negative battery cable. It is important to connect the battery cables in this order.
  82.  
  83. Fill the transaxle with 2 qts. (1.9L) of fresh automatic transaxle fluid. When filling the transaxle, use the correct fluid, as described in Routine Maintenance .
  84.  
  85. Fill the cooling system, as described in Routine Maintenance .
  86.  
  87. Start the engine and check for fuel, vacuum, coolant or oil leaks.
  88.  
  89. Check the transaxle fluid level; add or drain as required.
  90.  

 
label.common.footer.alt.autozoneLogo