ION 2006-2007

Engine

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. With the tires in the straight forward position, remove the key from the ignition.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air outlet duct .
  8.  
  9. Secure the cooling module to the upper body structure.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Disconnect the fuel line from the fuel rail.
  14.  
  15. Remove the supercharger.
  16.  
  17. Drain the cooling system.
  18.  
  19. Remove the radiator inlet hose.
  20.  
  21. Remove the surge tank to cylinder head pipe.
  22.  
  23. Remove the radiator outlet hose.
  24.  
  25. Remove the inlet and outlet heater hoses.
  26.  
  27. Disconnect the following harness connectors:

    Tmap sensor
     
    Electronic Temperature Control (ETC) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Barometric Pressure (BARO) sensor
     
    Crankshaft Position (CKP) sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil modules
     
    Oxygen (O 2 s) sensor
     
    Vehicle speed sensor
     
    Engine temperature sensor
     
    Boost solenoid
     
    Back up lamp switch
     

  28.  
  29. Remove the drive belt.
  30.  
  31. Disconnect the charge air cooler hoses.
  32.  
  33. Recover the refrigerant.
  34.  
  35. Disconnect the compressor and condenser hose assembly from the compressor.
  36.  
  37. Remove the AC compressor bolts and set the compressor aside.
  38.  
  39. Disconnect the starter harness connectors.
  40.  
  41. Disconnect the alternator harness connectors.
  42.  
  43. Drain the engine oil.
  44.  
  45. Disconnect the front exhaust pipe from the exhaust manifold.
  46.  
  47. Disconnect the transmission shift cable from the transmission.
  48.  
  49. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  50.  
  51. Remove the engine mount.
  52.  
  53. Remove the left transmission mount as follows:
    1. Remove the right hand hood electrical center bracket from the vehicle and reposition the electrical center.
    2.  
    3. Support the transmission with a floor jack. Use a piece of wood between the jack and the transmission.
    4.  
    5. Remove the transmission mount-to-transmission bracket bolts.
    6.  
    7. Remove the transmission mount to mid-rail bolts.
    8.  
    9. Using a floor jack, slowly lower the transmission enough to remove the transmission mount from the vehicle
    10.  

  54.  
  55. Disconnect the stabilizer links from the stabilizer bar.
  56.  
  57. Disconnect the outer tie rod ends from the steering knuckles.
    NOTE
    In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

  58.  
  59. Disconnect the intermediate shaft from the steering gear.
  60.  
  61. Disconnect the lower control arms from the steering knuckles.
  62.  
  63. Disconnect the drive axles from the steering knuckle.
  64.  
  65. Use a paint pen or magic marker in order to mark the frame to body position.
  66.  
  67. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
  68.  
  69. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  70.  
  71. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2.  
    3. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
    4.  
    5. Slowly lower the table to the floor.
    6.  
    7. Attach the engine lift hoist to the engine lift hooks.
    8.  

  72.  
  73. Remove the starter.
  74.  
  75. Remove the transmission to engine bolts.
  76.  
  77. Separate the engine from the transmission.
  78.  
  79. Remove the clutch pressure plate and disk.
  80.  
  81. Remove the following components:

    Exhaust manifold
     
    Exhaust manifold studs
     
    Engine mount bracket
     
    Fuel rail
     
    Thermostat housing and feed pipe
     
    Alternator
     

  82.  
  83. Remove the engine from the engine lift.
  84.  

To install:

  1. Attach the engine lift hoist to the engine lift hooks.
  2.  
  3. Install the exhaust manifold
  4.  
  5. Install the engine mount bracket as follows:
  6.  
  7. Install the intermediate bracket to the engine.
  8.  
  9. Hand tighten the engine mount intermediate bracket bolts with the long bolts in the forward and front lower holes and the short bolt in the rear upper hole.
  10.  
  11. Tighten the intermediate bracket bolts to 74 ft. lbs. (100 Nm).
  12.  
  13. Install the fuel rail.
  14.  
  15. Install the idler pulley.
  16.  
  17. Install the drive belt tensioner.
  18.  
  19. Install the thermostat housing and feed pipe.
  20.  
  21. Install the alternator.
  22.  
  23. Install the flywheel.
  24.  
  25. Install the clutch and pressure plate if equipped.
  26.  
  27. Install the A/C compressor.
  28.  
  29. Align the engine to the transmission. Tighten the transmission to engine bolts to 55 ft. lbs. (75 Nm).
  30.  
  31. Install the starter.
  32.  
  33. Remove the engine lift from the engine.
  34.  
  35. Raise and position the frame and powertrain assembly to the vehicle.
  36.  
  37. Hand start all the frame bolts while aligning the frame to the paint marks.
  38.  
  39. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus an additional 100 degree turn.
  40.  
  41. Remove the lift table.
  42.  
  43. Connect the drive axles to the steering knuckles. Tighten the nut to 155 ft. lbs. (210 Nm).
  44.  
  45. Connect the lower control arm to the steering knuckle and tighten the retainer as follows:
    1. Install the ball stud pinch bolt and nut.
    2.  
    3. First Pass: Tighten the nut to 37 ft. lbs. (50 Nm), the back off 3 / 4 turn.
    4.  
    5. Second Pass: Tighten the nut to 37 ft. lbs. (50 Nm plus an additional 30 degrees.
    6.  

  46.  
  47. Connect the intermediate steering shaft to the steering gear. Tighten the bolt to 25 ft. lbs. (35 Nm).
  48.  
  49. Connect the outer tie rod ends to the steering knuckles. Tighten the nut to 44 ft. lbs. (60 Nm).
  50.  
  51. Connect the stabilizer links to the stabilizer bar. Tighten the retainers to 81 ft. lbs. (110 Nm).
  52.  
  53. Install the left transmission mount as follows:
    1. Install the transmission mount to the mid-rail.
    2.  
    3. Install the transmission mount to mid-rail bolts and tighten to 20 ft. lbs. (27 Nm).
    4.  

  54.  
  55. Using a floor jack, raise the transmission until it contacts the transmission mount.
    NOTE
    The transmission mount to transmission bolts must be hand started. Do not pry the transmission or mount to align the holes.

  56.  
  57. Hand start the transmission mount to bracket bolts using the following sequence:

    Rear bolt
     
    Middle bolt
     
    Front bolt
     

    1. Using the previous sequence, tighten the transmission mount bolts to 37 ft. lbs. (50 Nm).
    2.  
    3. Install the right hand hood electrical center bracket to the vehicle and install the electrical center into position on the bracket
    4.  

  58.  
  59. Install the engine mount as follows:
    1. Place the engine mount onto the midrail and hand start the nuts.
    2.  
    3. Tighten the engine mount to midrail nuts to 74 ft. lbs. (100 Nm).
      NOTE
      The engine mount to intermediate bracket bolts must be hand started. Do not pry the engine mount to align the holes.

    4.  
    5. Hand start the engine mount to intermediate bracket bolts.
    6.  
    7. Tighten the engine mount to intermediate bracket bolts, starting with the center bolt to 37 ft. lbs. (50 Nm).
    8.  

  60.  
  61. Remove the wood blocks between the powertrain and frame.
  62.  
  63. Connect the transmission shift cable to the transmission.
  64.  
  65. Connect the exhaust takedown pipe to the exhaust manifold and tighten the nuts to 22 ft. lbs. (30 Nm).
  66.  
  67. Connect the alternator harness connectors. Tighten to 15 ft. lbs. (20 Nm).
  68.  
  69. Connect the starter harness connectors.
  70.  
  71. Install the compressor and condenser hose assembly to the compressor.
  72.  
  73. Evacuate and charge the refrigerant system.
  74.  
  75. Install the supercharger.
  76.  
  77. Install the engine drive belt.
  78.  
  79. Connect the charge air cooler hoses.
  80.  
  81. Connect the following harness connectors:

    Tmap sensor
     
    Electronic Temperature Control (ETC) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Barometric Pressure (BARO) sensor
     
    Crankshaft Position (CKP) sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil modules
     
    O 2 s sensor
     
    Vehicle speed sensor
     
    Engine temperature sensor
     
    Boost solenoid
     
    Back up lamp switch
     

  82.  
  83. Install the inlet heater hose and outlet heater hose.
  84.  
  85. Install the radiator outlet hose.
  86.  
  87. Connect the fuel line to the fuel rail.
  88.  
  89. Install the surge tank to the cylinder head pipe.
  90.  
  91. Release the cooling module from the upper body structure.
  92.  
  93. Install the air outlet duct .
  94.  
  95. Connect the negative battery cable.
  96.  
  97. Fill the engine with engine oil to the proper level.
  98.  
  99. Fill the cooling system.
  100.  
  101. Road test the vehicle.
  102.  

2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the power steering fluid.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and intake duct assembly
     

  12.  
  13. Secure the cooling module to the upper body.

    Throttle cable
     
    Fuel feed and return lines from the rail
     
    Radiator upper hose
     
    Surge tank-to-cylinder head hose
     
    Radiator lower hose
     
    Inlet and outlet heater hoses
     

  14.  
  15. Disconnect the following electrical connections:

    Intake Air Control (IAC)
     
    Throttle Position Sensor (TPS)
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft Position (CKP) sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module
     
    Oxygen Sensor (O 2 S)
     
    Vehicle Speed Sensor (VSS)
     
    Engine temperature sensor
     
    Back-up lamp switch
     

  16.  
  17. Remove or disconnect the following:

    Drive belt
     
    A/C compressor bolts and set the compressor aside without disconnecting the lines
     
    Starter and alternator wiring
     
    Front exhaust pipe from the manifold
     
    Transmission harness connectors
     
    Transmission shift cable
     

  18.  
  19. Use suitable blocks of wood to support the powertrain assembly between the assembly and the frame.
  20.  
  21. Support the engine with a jack using a piece of wood between the jack and the engine to avoid damage.

    Engine mount, nuts and bolts.
     

  22.  
  23. Remove the side transmission mount on models with a manual transmission as follows:
    1. Remove the under hood electrical tray.
    2.  
    3. Disconnect the wiring harness from the tray bracket.
    4.  
    5. Lift the electrical center up and swing it back out of the way.
    6.  
    7. Remove the mount-to-transmission bolts and mount-to-rail bolts.
    8.  
    9. Remove the mount.
    10.  

  24.  
  25. Remove the side transmission mount on models with a automatic 5-speed transmission as follows:
    1. Support the transmission with a jack.
    2.  
    3. Remove the front and rear transmission mount through bolts.
    4.  
    5. Remove the under hood electrical center cover.
    6.  
    7. Disconnect the engine control module harness connector.
    8.  
    9. Disconnect the positive battery cable from the under hood electrical center.
    10.  
    11. Make sure the surge tank hose is disconnected.
    12.  
    13. Remove the electrical center tray.
    14.  
    15. Disconnect the harness from the tray bracket.
    16.  
    17. Lift the electrical center up and swing it back out of the way.
    18.  
    19. Remove the mount-to-transmission bolts and mount-to-rail bolts.
    20.  
    21. Remove the mount.
    22.  

  26.  
  27. Remove the side transmission mount on models with a automatic 5-speed continuously variable transmission as follows:
    1. Remove the engine cradle.
    2.  
    3. Remove the under hood electrical center cover.
    4.  
    5. Disconnect the engine control module harness connector.
    6.  
    7. Disconnect the positive battery cable from the under hood electrical center.
    8.  
    9. Make sure the surge tank hose is disconnected.
    10.  
    11. Remove the electrical center tray.
    12.  
    13. Disconnect the harness from the tray bracket.
    14.  
    15. Lift the electrical center up and swing it back out of the way.
    16.  
    17. Install an engine support fixture. If not already removed, remove the engine mount.
    18.  
    19. Disconnect the upper transmission cooler line from the radiator.
    20.  
    21. Remove the mount-to-transmission bolts
      NOTE
      Make sure the A/C clutch does not contact the inner metal rail of the vehicle.

    22.  
    23. Lower and tilt the powertrain assembly down approximately 4 inches.
    24.  
    25. Remove the mount-to-rail bolts.
    26.  
    27. Remove the mount.
    28.  

  28.  
  29. Remove or disconnect the following:
    CAUTION
    To prevent air bag system deployment, do not attempt to rotate the steering shaft.



    Stabilizer link from the stabilizer bar
     
    Outer tie rod ends from knuckles
     



    Intermediate shaft from the steering gear
     
    Lower control arms from the knuckles
     
    Half shafts from the knuckles
     

  30.  
  31. Remove the front frame as follows:
    1. Mark the frame-to-body position.
    2.  
    3. Lower the vehicle until it is 3 feet off the ground so that a lift table may be placed in position. As necessary, use blocks of wood between the frame and table to support the assembly.
    4.  
    5. Slowly remove the front frame bolts, the partially unscrew the bolts until 1 1 / 2 inch of the bolt shank is exposed.
    6.  
    7. Slowly lower the table to the floor
    8.  

  32.  
  33. Attach the engine hooks to a hoist.
  34.  
  35. Remove or disconnect the following:

    Starter
     
    Torque converter-to-flywheel bolts, if equipped
     
    Engine-to-transmission bolts and the engine from the transmission.
     

  36.  

To install:

  1. Install or connect the following:

    Engine to the transmission and tighten the bolts to 55 ft. lbs. (75 Nm)
     
    Torque converter-to-flywheel bolts, if equipped and tighten the bolts to 46 ft. lbs. (62 Nm)
     
    Starter
     

  2.  
  3. Install the front frame as follows:
    1. Slowly raise the table to the into position and align the frame to the marks made during removal.
    2.  
    3. Hand tighten the frame bolts
    4.  
    5. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus an additional torque of 180 degrees using a torque angle meter.
    6.  
    7. Remove the lift table.
    8.  

  4.  
  5. Install or connect the following:
    CAUTION
    To prevent air bag system deployment, do not attempt to rotate the steering shaft.



    Half shafts to the knuckles
     
    Lower control arms to the knuckles
     



    Intermediate shaft to the steering gear
     
    Outer tie rod ends to knuckles
     
    Stabilizer link to the stabilizer bar
     

  6.  
  7. Install the side transmission mount on models with a manual transmission as follows:
    1. Place the mount in position and tighten the mount-to-rail bolts to 25 ft. lbs. (34 Nm).
    2.  

  8.  
  9. Use a jack to align the mount when it is in position.
    1. Install and hand tighten the mount-to-transmission bolts. Do not pry the transmission or mount to align the holes. Hand start the bolts in the following sequence; rear bolt, middle and then front bolt. Using the same sequence, tighten the bolts to 33 ft. lbs. (45 Nm).
    2.  
    3. Place the electrical center in position.
    4.  
    5. Connect the wiring harness to the tray bracket.
    6.  
    7. Install the under hood electrical tray.
    8.  

  10.  
  11. Install the side transmission mount on models with a automatic 5-speed transmission as follows:
    1. Place the mount in position and tighten the mount-to-rail bolts to 25 ft. lbs. (34 Nm).
    2.  

  12.  
  13. Use a jack to align the mount when it is in position.
    1. Install and hand tighten the mount-to-transmission bolts. Do not pry the transmission or mount to align the holes. Hand start the bolts in the following sequence; rear bolt, middle and then front bolt. Using the same sequence, tighten the bolts to 33 ft. lbs. (45 Nm).
    2.  
    3. Place the electrical center in position.
    4.  
    5. Connect the wiring harness to the tray bracket.
    6.  
    7. Install the under hood electrical tray.
    8.  
    9. Connect the positive battery cable to the under hood electrical center.
    10.  
    11. Connect the engine control module harness connector.
    12.  
    13. Install the under hood electrical center cover.
    14.  
    15. Install the front and rear transmission mount through bolts. Tighten to 74 ft. lbs. (100 Nm).
    16.  

  14.  
  15. Install the side transmission mount on models with a automatic 5-speed continuously variable transmission as follows:
    1. Place the mount in position and tighten the mount-to-rail bolts to 25 ft. lbs. (34 Nm).
    2.  

  16.  
  17. Use a jack raise the engine back into position and to align the mount when it is in position.
    1. Install and hand tighten the mount-to-transmission bolts. Do not pry the transmission or mount to align the holes. Hand start the bolts in the following sequence; rear bolt, middle and then front bolt. Using the same sequence, tighten the bolts to 33 ft. lbs. (45 Nm).
    2.  
    3. If installed, install the engine mount and remove the engine support fixture.
    4.  
    5. Connect the upper transmission cooler line to the radiator.
    6.  
    7. Place the electrical center in position.
    8.  
    9. Connect the wiring harness to the tray bracket.
    10.  
    11. Install the under hood electrical tray.
    12.  
    13. Connect the positive battery cable to the under hood electrical center.
    14.  
    15. Connect the engine control module harness connector.
    16.  
    17. Install the under hood electrical center cover.
    18.  
    19. Install the front and rear transmission mount through bolts. Tighten to 74 ft. lbs. (100 Nm).
      NOTE
      The engine mount bolts must be hand started. Do not pry on the engine mount to align the holes.

    20.  

  18.  
  19. Install or connect the following:

    Engine mount nuts and bolts. Tighten the nuts to 74 ft. lbs. (100 Nm) and the bolts to 37 ft. lbs. (50 Nm).
     

  20.  
  21. Remove the blocks of wood used to support the powertrain assembly between the assembly and the frame.

    Transmission shift cable
     
    Transmission harness connectors
     
    Front exhaust pipe to the manifold
     
    Starter and alternator wiring
     
    A/C compressor
     
    Drive belt
     

  22.  
  23. Connect the following electrical connections:

    Back-up lamp switch
     
    Engine temperature sensor
     
    VSS
     
    O 2 S
     
    Ignition coil and module
     
    Purge solenoid
     
    Oil pressure sensor
     
    CKP
     
    MAP sensor
     
    TPS
     
    IAC
     

  24.  
  25. Install or connect the following:

    Inlet and outlet heater hoses
     
    Radiator lower hose
     
    Surge tank-to-cylinder head hose
     
    Radiator upper hose
     
    Fuel feed and return lines to the rail
     
    Throttle cable
     
    Cooling module
     
    Air cleaner and intake duct assembly
     
    Negative battery cable
     

  26.  
  27. Fill the engine with coolant.
  28.  
  29. Fill the engine with new oil.
  30.  
  31. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine.
  32.  
  33. Start the engine, check for leaks, and repair if necessary.
  34.  

2.4L Engine
  1. Ensure that the tires are in the straight forward position, remove the key from the ignition.
  2.  
  3. Before servicing the vehicle, refer to the precautions section.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Drain the engine oil.
  10.  
  11. Drain the power steering fluid.
  12.  
  13. Disconnect the negative battery cable.
  14.  
  15. Disconnect the fuel feed line quick connect fitting from the fuel rail.
  16.  
  17. Disconnect the evaporative emission (EVAP) line quick connect fitting from the EVAP purge solenoid.
  18.  
  19. Remove the fuel line clips from the engine brackets.
  20.  
  21. Secure the cooling module to the upper body structure.
  22.  
  23. Remove the engine drive belt.
  24.  
  25. Disconnect the cooling fan electrical connector
  26.  
  27. Reposition the radiator inlet hose clamp at the engine.
  28.  
  29. Remove the radiator inlet hose from the engine
  30.  
  31. If the vehicle is equipped with engine oil cooler perform the following:
    1. Reposition the radiator outlet hose clamp at the water outlet.
    2.  
    3. Reposition the radiator outlet hose clamp at the oil cooler.
    4.  
    5. Remove the radiator outlet hose from the water outlet.
    6.  
    7. Remove the radiator outlet hose from the oil cooler
    8.  

  32.  
  33. If the vehicle is not equipped with an engine oil cooler, reposition the surge tank outlet hose clamp at the surge tank.
  34.  
  35. Remove the surge tank outlet hose from the surge tank
  36.  
  37. Reposition the radiator outlet hose clamp at the thermostat cover.
  38.  
  39. Remove the radiator outlet hose from the thermostat cover
  40.  
  41. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
  42.  
  43. Reposition the brake booster vacuum hose clamp at the intake manifold.
  44.  
  45. Remove the brake booster vacuum hose from the intake manifold. Reposition the hose
  46.  
  47. Remove the heater inlet and outlet hoses from the thermostat housing.
  48.  
  49. Disconnect the Throttle actuator control (TAC), Manifold absolute pressure (MAP) sensor, Fuel injector harness and alternator connectors.
  50.  
  51. Disconnect the engine harness clip from the oil level indicator tube.
  52.  
  53. Disconnect the engine harness clips from the intake manifold.
  54.  
  55. Disconnect the ignition coils electrical connectors.
  56.  
  57. Disconnect the intake and exhaust camshaft position actuator electrical connectors.
  58.  
  59. Remove the engine harness clips from the camshaft cover.
  60.  
  61. Remove the negative battery cable ground nut.
  62.  
  63. Remove the engine harness ground terminal from the stud.
  64.  
  65. Remove the negative battery cable ground terminal from the stud.
  66.  
  67. Remove the stud.
  68.  
  69. Remove the engine harness ground terminals.
  70.  
  71. Disconnect Oil pressure sensor, Crankshaft position (CKP) sensor and Knock sensor (KS) the connectors.
  72.  
  73. Disconnect the EVAP purge solenoid electrical connector.
  74.  
  75. Remove the engine harness clip from the purge solenoid bracket.
  76.  
  77. Remove the engine harness ground bolt.
  78.  
  79. Reposition the engine harness ground terminal.
  80.  
  81. Disconnect the engine harness electrical connector from the air conditioning (A/C) pressure switch.
  82.  
  83. Disconnect the engine harness electrical connector (2) from A/C compressor.
  84.  
  85. Unbolt and reposition the AC compressor aside.
  86.  
  87. Raise and suitably support the vehicle.
  88.  
  89. Remove the transaxle fluid cooler bracket nut.
  90.  
  91. Remove the transaxle fluid cooler lines from the transaxle.
  92.  
  93. Remove the engine harness clip nut from the engine stud.
  94.  
  95. Remove the engine harness clip from the stud.
  96.  
  97. If equipped with an automatic transaxle, disconnect the engine harness electrical connector from the vehicle speed sensor (VSS).
  98.  
  99. Remove the engine harness clip from the speed sensor.
  100.  
  101. Remove the positive battery cable lead nut from the starter solenoid.
  102.  
  103. Remove the positive battery cable terminal from the starter.
  104.  
  105. Remove the engine harness to starter solenoid "S" terminal nut.
  106.  
  107. Remove the engine harness lead terminals from the starter solenoid.
  108.  
  109. Lower the vehicle.
  110.  
  111. Reposition the engine harness boot.
  112.  
  113. Remove the alternator nut.
  114.  
  115. Remove the engine harness lead terminal from the alternator.
  116.  
  117. If equipped with an automatic transaxle, disconnect the engine harness from the transaxle.
  118.  
  119. If equipped with an automatic transaxle, perform the following:
    1. Disconnect the engine harness electrical connector from the engine coolant temperature (ECT) sensor.
    2.  
    3. Remove the heater oxygen sensor (HO2S) connector position assurance (CPA) retainers.
    4.  
    5. Disconnect the engine harness electrical connectors from the heater oxygen sensors (HO2S).
    6.  
    7. Remove the HO2S connector clips from the thermostat housing and engine bracket.
    8.  
    9. Disconnect the engine harness electrical connector from the park neutral position switch.
    10.  

  120.  
  121. If equipped with a manual transaxle, perform the following:
    1. Disconnect the engine harness electrical connector from the VSS.
    2.  
    3. Disconnect the engine harness electrical connector from the back up lamp switch.
    4.  
    5. Remove the HO2S CPA retainers.
    6.  
    7. Disconnect the engine harness electrical connectors from the HO2S.
    8.  
    9. Remove the HO2S clips from the engine brackets.
    10.  
    11. Gather all engine harness branches and reposition the harness off to the side, out of the way.
    12.  

  122.  
  123. If equipped with an automatic transaxle, perform the following:
    1. Disconnect the range selector lever cable from the transaxle lever.
    2.  
    3. Remove the range selector lever cable from the transaxle bracket.
    4.  

  124.  
  125. If equipped with a manual transaxle, perform the following:
    1. Disconnect the range selector and shift lever cables from the transaxle levers.
    2.  
    3. Remove the range selector and shift lever cables from the transaxle bracket.
    4.  
    5. Remove the catalytic converter.
    6.  
    7. Lower the vehicle.
    8.  

  126.  
  127. Insert blocks of wood between the powertrain and the frame, in order to support the powertrain.
  128.  
  129. Remove the engine mount.
  130.  
  131. Remove the transaxle mount to transaxle bolts.
  132.  
  133. Raise the vehicle.
  134.  
  135. Disconnect the stabilizer links from the stabilizer bar.
  136.  
  137. Disconnect the outer tie rod ends from the steering knuckles.
  138.  
  139. Disconnect the intermediate shaft from the steering gear.
  140.  
  141. Disconnect the lower control arms from the steering knuckles.
  142.  
  143. Using a paint pen or magic marker, mark the frame to body position.
  144.  
  145. Lower the vehicle to about 3 feet off the ground.
  146.  
  147. Position an engine lift table under the frame.
  148.  
  149. Place wood blocks on top of the lift table between the table and the frame.
  150.  
  151. Lower the vehicle until the frame is resting on the blocks of wood.
  152.  
  153. Slowly loosen/remove the front then rear frame bolts
  154.  
  155. Slowly raise the vehicle away from the powertrain assembly.
  156.  
  157. Slide the lift table out from under the vehicle.
  158.  
  159. Attach the engine lift hoist to the engine lift hooks.
  160.  

To install:

  1. Remove the engine lift hoist from the engine lift hooks.
  2.  
  3. Slide the lift table under the vehicle.
  4.  
  5. Slowly lower the vehicle until it aligns with the alignment marks made during the removal.
  6.  
  7. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus 180 degrees.
  8.  
  9. Raise the vehicle until the lift table can be removed from under the vehicle.
  10.  
  11. Remove the lift table.
  12.  
  13. Install the transaxle fluid cooler lines to the transaxle and tighten the bracket nut to 62 inch lbs. (7 Nm).
  14.  
  15. Connect the lower control arms to the steering knuckles.
  16.  
  17. Connect the intermediate shaft to the steering gear.
  18.  
  19. Connect the outer tie rod ends to the steering knuckles.
  20.  
  21. Connect the stabilizer links to the stabilizer bar.
  22.  
  23. Lower the vehicle.
  24.  
  25. Install the transaxle mount to transaxle bolts and tighten to 33 ft. lbs. (45 Nm).
  26.  
  27. Install the engine mount. Tighten the bolts to 74 ft. lbs. (100 Nm) in the sequence illustrated and the bracket bolts in the sequence illustrated to 37 ft. lbs. (50 Nm).

    Click image to see an enlarged view

    Fig. Engine mount installation-2.4L engine

  28.  
  29. Remove the blocks of wood from between the powertrain and the frame.
  30.  
  31. Install the catalytic converter.
  32.  
  33. Lower the vehicle.
    NOTE
    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.

  34.  
  35. If equipped with a manual transaxle, install the range selector and shift lever cables to the transaxle bracket and connect the range selector and shift lever cables to the transaxle levers.
  36.  
  37. If equipped with an automatic transaxle, install the range selector lever cable to the transaxle bracket and connect the range selector lever cable to the transaxle lever.
  38.  
  39. Gather all engine harness branches and position the harness over the engine.
  40.  
  41. If equipped with a manual transaxle perform the following:
    1. Install the HO2S clips to the engine brackets.
    2.  
    3. Connect the engine harness electrical connectors to the HO2S.
    4.  
    5. Install the HO2S CPA retainers.
    6.  
    7. Connect the engine harness electrical connector to the back up lamp switch.
    8.  
    9. Connect the engine harness electrical connector to the VSS.
    10.  

  42.  
  43. If equipped with an automatic transaxle perform the following:
    1. Connect the engine harness electrical connector to the park neutral position switch.
    2.  
    3. Install the engine harness clips to the thermostat housing and engine brackets.
    4.  
    5. Connect the engine harness electrical connectors to the HO2S.
    6.  
    7. Install the HO2S CPA retainers.
    8.  
    9. Connect the ECT sensor electrical connector.
    10.  

  44.  
  45. If equipped with an automatic transaxle, connect the engine harness to the transaxle.
  46.  
  47. Install the engine harness lead terminal to the alternator.
  48.  
  49. Install the alternator nut and tighten to 20 ft. lbs. (27 Nm).
  50.  
  51. Position the engine harness boot.
  52.  
  53. Raise the vehicle.
  54.  
  55. Install the engine harness lead terminal to the starter solenoid.
  56.  
  57. Install the engine harness to starter solenoid "S" terminal nut.
  58.  
  59. Install the positive battery cable terminal to the starter.
  60.  
  61. Install the positive/negative battery cable lead nut to the starter solenoid. Tighten the nut to 13 ft. lbs. (13 ft. lbs. (17 Nm).
  62.  
  63. Install the engine harness clip to the speed sensor.
  64.  
  65. Connect the engine harness electrical connector to the VSS.
  66.  
  67. Install the engine harness clip to the stud.
  68.  
  69. Install the engine harness clip nut to the engine stud. Tighten to 37 ft. lbs. (50 Nm).
  70.  
  71. Lower the vehicle.
  72.  
  73. Reposition and install the A/C compressor. Tighten to 37 ft. lbs. (50 Nm).
  74.  
  75. Connect the engine harness electrical connector to the A/C compressor.
  76.  
  77. Connect the engine harness electrical connector to the A/C pressure switch.
  78.  
  79. Position the engine harness ground terminal to the engine block.
  80.  
  81. Install the engine harness ground bolt and tighten to 18 ft. lbs. (25 Nm).
  82.  
  83. Connect the EVAP purge solenoid electrical connector2).
  84.  
  85. Install the engine harness clip to the EVAP purge solenoid bracket. Connect the KS, CKP and oil pressure connectors.
  86.  
  87. Position the engine harness ground terminals. Install the stud and tighten to 18 ft. lbs. (25 Nm).
  88.  
  89. Install the negative battery cable ground terminal to the stud.
  90.  
  91. Install the engine harness ground terminal to the stud.
  92.  
  93. Install the negative battery cable ground nut.
  94.  
  95. Install the engine harness clip to the camshaft cover.
  96.  
  97. Connect the intake and exhaust camshaft position actuator electrical connectors.
  98.  
  99. Connect the ignition coils electrical connectors.
  100.  
  101. Connect the engine harness clips to the intake manifold.
  102.  
  103. Connect the engine harness clip to the oil level indicator tube.
  104.  
  105. Connect all remaining electrical connectors and hoses.
  106.  
  107. If the vehicle is not equipped with engine oil cooler perform the following:
    1. Install the surge tank outlet hose to the surge tank.
    2.  
    3. Position the surge tank outlet hose clamp at the surge tank.
    4.  
    5. Install the radiator outlet hose to the thermostat cover.
    6.  
    7. Position the radiator outlet hose clamp at the thermostat cover.
    8.  

  108.  
  109. If the vehicle is equipped with engine oil cooler perform the following:
    1. Install the radiator outlet hose to the oil cooler.
    2.  
    3. Install the radiator outlet hose to the water outlet.
    4.  
    5. Position the radiator outlet hose clamp at the oil cooler.
    6.  
    7. Position the radiator outlet hose clamp at the water outlet.
    8.  

  110.  
  111. Install the radiator inlet hose to the engine.
  112.  
  113. Position the radiator inlet hose clamp at the engine.
  114.  
  115. Connect the cooling fan electrical connector.
  116.  
  117. Install the engine drive belt.
  118.  
  119. Unfasten the cooling module from the upper body structure.
  120.  
  121. Fill the cooling system.
  122.  
  123. Check and fill the transaxle fluid as needed.
  124.  
  125. Connect the EVAP line quick connect fitting to the EVAP purge solenoid.
  126.  
  127. Connect the fuel feed line quick connect fitting to the fuel rail.
  128.  
  129. Install the fuel line clips to the engine brackets.
  130.  
  131. Fill the engine with oil.
  132.  
  133. Connect the negative battery cable.
  134.  
  135. Road test the vehicle.
  136.  

 
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