Mazda Tribute 2001-06

Engine

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Removal & Installation



2.0L Engine
Manual Transaxle
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly recover the air conditioning system refrigerant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove or disconnect the following:

    Hood
     
    Battery and battery tray
     
    Air cleaner housing
     
    Fuel lines
     
    Throttle cable and speed control cable, if equipped
     
    Exhaust Gas Recirculation (EGR) vacuum valve regulator
     
    EGR electrical connectors and vacuum hoses
     
    Brake booster vacuum hose
     
    Powertrain Control Module (PCM) wire harness and ground
     
    Wire harness connector
     
    Power distribution board electrical connectors
     
    Evaporative emissions (EVAP) canister vacuum lines
     
    Upper radiator hose
     
    Power steering line bracket
     
    Upper power steering pump bolts
     
    Coolant hose
     
    Heater hoses
     
    Speed control unit, if equipped
     
    Catalytic converter
     
    A/C compressor
     
    Both halfshafts
     
    Shifter linkages
     
    Block heater electrical connector, if equipped
     
    Front transaxle through bolt
     
    Engine-to-transaxle bolts
     
    Lower radiator hose
     
    Power steering pump
     
    Clutch slave cylinder line from the bracket and move it aside
     
    Rear transaxle mount
     
    Left side transaxle mount
     
    Lower ground cable
     
    Engine mount upper bracket
     
    Engine and transaxle as an assembly by using a proper lifting device
     
    Alternator electrical connectors
     
    Knock Sensor (KS) electrical connector
     
    Oil pressure sender electrical connector
     
    Starter electrical connector
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Park Neutral Position (PNP) electrical connector
     
    Fuel charging wire harness electrical connector
     
    PCM wire harness from the bracket
     
    PCM ground wire
     
    Back up lamp switch electrical connector
     
    Wire harness
     
    Differential Pressure Feedback (DPFEE) EGR sensor
     

  12.  
  13. Separate the engine from the transaxle.
  14.  
  15. Lock the flywheel to the engine.
  16.  
  17. Clutch pressure plate and disc.
  18.  
  19. Flywheel and rear cover plates.
  20.  

To install:

Click image to see an enlarged view

Fig. Pressure plate bolt torque sequence-2.0L engine

  1. Install or connect the following:

    Flywheel. Torque the bolts to 83 ft. lbs. (112 Nm).
     
    Clutch disc to the flywheel
     
    Pressure plate to the flywheel. Torque the bolts in the proper sequence to 18 ft. lbs. (25 Nm).
     
    Transaxle to the engine. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Starter. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Wire harness and attach it to the powertrain assembly
     
    DPFEE sensor electrical connector
     
    Reverse lamp switch electrical connector
     
    Ground wire. Torque the bolt to 80 inch lbs. (9 Nm).
     
    PCM wire harness to the bracket
     
    Fuel charging wire harness electrical connector
     
    PNP switch electrical connector
     
    VSS electrical connector
     
    KS, Oil pressure sender and starter electrical connector. Torque the fasteners to 9 ft. lbs. (12 Nm).
     
    Alternator electrical connectors. Torque the fasteners to 71 inch lbs. (8 Nm).
     
    Powertrain assembly in the vehicle
     
    Left side transaxle mount. Torque the side bolts to 41 ft. lbs. (55 Nm) and the center bolt to 66 ft. lbs. (90 Nm).
     
    Engine mount upper bracket. Torque the side bolts to 72 ft. lbs. (98 Nm) and the center bolt to 57 ft. lbs. (77 Nm).
     
    Ground wire. Torque the bolt to 25 ft. lbs. (34 Nm).
     
    Rear transaxle mount. Torque the bolts to 41 ft. lbs. (55 Nm).
     
    Speed control unit, if equipped. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Power steering pump and hand tighten the bolts
     
    Lower power steering line bracket. Torque the bolt to 89 inch lbs. (10 Nm).
     
    Upper power steering line bolt. Torque the bolt to 15 ft. lbs. (20 Nm).
     
    Slave cylinder line and clip. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    Power steering lines. Torque the retaining bolts to 89 inch lbs. (10 Nm). Torque the power steering pump bolts to 18 ft. lbs. (25 Nm).
     
    Lower radiator hose
     
    Engine-to-transaxle bolts. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Front transaxle through bolt. Torque the bolt to 66 ft. lbs. (90 Nm).
     
    Block heater electrical connector
     
    Shifter linkages. Torque the upper bolt to 33 ft. lbs. (45 Nm) and the lower bolt to 15 ft. lbs. (20 Nm).
     
    Coolant hose
     
    Catalytic converter
     
    Heater hoses
     
    Upper radiator hose
     
    EVAP canister vacuum lines
     
    Power distribution box electrical connector. Torque the fastener to 9 ft. lbs. (12 Nm).
     
    Wire harness electrical connector
     
    Ground wires
     
    PCM wire harness and ground
     
    Brake booster vacuum supply hose to the intake manifold
     
    EGR vacuum regulator valve hoses and electrical connector
     
    Throttle cable and speed control cable, if equipped
     
    Fuel lines
     
    Battery tray and battery
     
    Air cleaner
     
    Hood
     

  2.  
  3. Fill the engine with clean oil.
  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Recharge the A/C system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

Manual Transmission
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly recover the air conditioning system refrigerant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove or disconnect the following:

    Hood
     
    Battery and battery tray
     
    Air cleaner housing
     
    Fuel lines
     
    Throttle cable and speed control cable, if equipped
     
    Exhaust Gas Recirculation (EGR) vacuum valve regulator
     
    EGR electrical connectors and vacuum hoses
     
    Brake booster vacuum hose
     
    Powertrain Control Module (PCM) wire harness and ground
     
    Wire harness connector
     
    Power distribution board electrical connectors
     
    Evaporative emissions (EVAP) canister vacuum lines
     
    Upper radiator hose
     
    Power steering line bracket
     
    Upper power steering pump bolts
     
    Coolant hose
     
    Heater hoses
     
    Speed control unit, if equipped
     
    Catalytic converter
     
    A/C compressor
     
    Both halfshafts
     
    Shifter linkages
     
    Block heater electrical connector, if equipped
     
    Front transmission through bolt
     
    Engine-to-transmission bolts
     
    Lower radiator hose
     
    Power steering pump
     
    Clutch slave cylinder line from the bracket and move it aside
     
    Rear transmission mount
     
    Left side transmission mount
     
    Lower ground cable
     
    Engine mount upper bracket
     
    Engine and transmission as an assembly by using a proper lifting device
     
    Alternator electrical connectors
     
    Knock Sensor (KS) electrical connector
     
    Oil pressure sender electrical connector
     
    Starter electrical connector
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Park Neutral Position (PNP) electrical connector
     
    Fuel charging wire harness electrical connector
     
    PCM wire harness from the bracket
     
    PCM ground wire
     
    Back up lamp switch electrical connector
     
    Wire harness
     
    Differential Pressure Feedback (DPFEE) EGR sensor
     

  12.  
  13. Separate the engine from the transmission.
  14.  
  15. Lock the flywheel to the engine.
  16.  
  17. Clutch pressure plate and disc.
  18.  
  19. Flywheel and rear cover plates.
  20.  

To install:



Click image to see an enlarged view

Fig. Tighten the pressure plate bolts in the proper sequence-2.0L engine

  1. Install or connect the following:

    Flywheel. Torque the bolts to 83 ft. lbs. (112 Nm).
     
    Clutch disc to the flywheel
     
    Pressure plate to the flywheel. Torque the bolts in the proper sequence to 18 ft. lbs. (25 Nm).
     
    Transmission to the engine. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Starter. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Wire harness and attach it to the powertrain assembly
     
    DPFEE sensor electrical connector
     
    Reverse lamp switch electrical connector
     
    Ground wire. Torque the bolt to 80 inch lbs. (9 Nm).
     
    PCM wire harness to the bracket
     
    Fuel charging wire harness electrical connector
     
    PNP switch electrical connector
     
    VSS electrical connector
     
    KS, Oil pressure sender and starter electrical connector. Torque the fasteners to 9 ft. lbs. (12 Nm).
     
    Alternator electrical connectors. Torque the fasteners to 71 inch lbs. (8 Nm).
     
    Powertrain assembly in the vehicle
     
    Left side transmission mount. Torque the side bolts to 41 ft. lbs. (55 Nm) and the center bolt to 66 ft. lbs. (90 Nm).
     
    Engine mount upper bracket. Torque the side bolts to 72 ft. lbs. (98 Nm) and the center bolt to 57 ft. lbs. (77 Nm).
     
    Ground wire. Torque the bolt to 25 ft. lbs. (34 Nm).
     
    Rear transmission mount. Torque the bolts to 41 ft. lbs. (55 Nm).
     
    Speed control unit, if equipped. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Power steering pump and hand tighten the bolts
     
    Lower power steering line bracket. Torque the bolt to 89 inch lbs. (10 Nm).
     
    Upper power steering line bolt. Torque the bolt to 15 ft. lbs. (20 Nm).
     
    Slave cylinder line and clip. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    Power steering lines. Torque the retaining bolts to 89 inch lbs. (10 Nm). Torque the power steering pump bolts to 18 ft. lbs. (25 Nm).
     
    Lower radiator hose
     
    Engine-to-transmission bolts. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Front transmission through bolt. Torque the bolt to 66 ft. lbs. (90 Nm).
     
    Block heater electrical connector
     
    Shifter linkages. Torque the upper bolt to 33 ft. lbs. (45 Nm) and the lower bolt to 15 ft. lbs. (20 Nm).
     
    Coolant hose
     
    Catalytic converter
     
    Heater hoses
     
    Upper radiator hose
     
    EVAP canister vacuum lines
     
    Power distribution box electrical connector. Torque the fastener to 9 ft. lbs. (12 Nm).
     
    Wire harness electrical connector
     
    Ground wires
     
    PCM wire harness and ground
     
    Brake booster vacuum supply hose to the intake manifold
     
    EGR vacuum regulator valve hoses and electrical connector
     
    Throttle cable and speed control cable, if equipped
     
    Fuel lines
     
    Battery tray and battery
     
    Air cleaner
     
    Hood
     

  2.  
  3. Fill the engine with clean oil.
  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Recharge the A/C system.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

2.3L Engine
Automatic Transaxle

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove the engine air cleaner and air cleaner outlet pipe
  6.  
  7. Remove the battery tray.
  8.  
  9. Drain the engine oil.
  10.  
  11. Drain the cooling system.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the catalytic converter.
  16.  
  17. Remove the accessory drive belt.
  18.  
  19. Remove the left front drive halfshafts.
  20.  

4wd vehicles

  1. Remove the transfer case.
  2.  

2wd vehicles

  1. Remove the bolts and the lateral support crossmember.
  2.  
  3. Remove the front drive intermediate halfshaft.
  4.  

All vehicles

  1. If equipped, remove the bolt and ground eyelet.
  2.  
  3. Remove the power distribution box cover.
  4.  
  5. Remove the nuts and disconnect the cables.
  6.  
  7. Disconnect the electrical connector from the power distribution box.
  8.  
  9. Remove the bolt and disconnect the ground strap. Loosen the bolt and disconnect the 42-pin electrical connector.
  10.  
  11. Detach the wiring harness retainers from the battery tray bracket and position the wiring harness out of the way.
  12.  
  13. Disconnect the transaxle electrical connector.
  14.  
  15. Disconnect the shift cable from the transaxle manual lever.
  16.  
  17. Position the transaxle control cable and bracket aside.
  18.  
  19. Disconnect the transmission range (TR) sensor electrical connector.
  20.  
  21. Detach the transaxle control harness from the brackets.
  22.  
  23. Disconnect the fluid cooler tube.
  24.  
  25. Disconnect the output shaft speed (OSS) sensor electrical connector (black).
  26.  
  27. Disconnect the turbine shaft speed (TSS) sensor electrical connector (white connector).
  28.  
  29. Remove the transmission fluid cooler retaining bracket bolt.
  30.  
  31. Position the fluid cooler tube aside.
  32.  
  33. Remove the bolt and the OSS sensor.
  34.  
  35. Detach the transaxle control harness from the retaining clip.
  36.  
  37. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
  38.  
  39. Disconnect the upper radiator and coolant vent hoses.
  40.  
  41. Remove the nuts and the coolant vent hose brackets. Position the coolant vent hose aside.
  42.  
  43. Detach the heater hose support strap from the stud.
  44.  
  45. Disconnect the heater hoses from the heater core.
  46.  
  47. Remove the retainers and the accelerator cable snow shield.
  48.  
  49. Disconnect the accelerator cable and speed control cable (if equipped).
  50.  
  51. Remove the nut from the accelerator control cable bracket.
  52.  
  53. Remove the nut from the accelerator control cable bracket and position the accelerator control cable and bracket assembly aside.
  54.  
  55. Remove the nut and position the power steering tube and bracket aside.
  56.  
  57. Disconnect the vacuum supply tube and position aside.
  58.  
  59. Disconnect the fuel vapor return tube and retainer and position aside.
  60.  
  61. Disconnect the vacuum reservoir tube and position aside.
  62.  
  63. Disconnect the fuel supply tube and position aside.
  64.  
  65. Detach the electrical connector retainers.
  66.  
  67. Disconnect the powertrain control module (PCM) electrical connectors. Remove the nut and position the harness aside.
  68.  
  69. Remove the bolt and detach the ground wire.
  70.  
  71. Remove the two power steering pump bolts.
  72.  
  73. Disconnect the lower radiator hose from the radiator.
  74.  
  75. Disconnect the A/C compressor electrical connector and remove the four bolts. Position the A/C compressor aside and support the compressor with a length of mechanics wire.
  76.  
  77. Disconnect the power steering pressure (PSP) sensor electrical connector.
  78.  


NOTE
The bolt under the power steering pressure tube will remain with the power steering pump.

  1. Remove the bolts and position the power steering pump aside.
  2.  
  3. Remove the front roll restrictor bolt and the two bolts for the engine support crossmember.
  4.  
  5. Remove the rear nut and the engine support crossmember.
  6.  


NOTE
The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

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


NOTE
The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  1. Remove the two transaxle-to-engine bolts
  2.  
  3. Using the special tools, secure the engine to the lift table.
  4.  
  5. Remove the engine mount bracket bolt.
  6.  
  7. Remove the nuts and the engine mount bracket.
  8.  
  9. Remove the bolt from the transaxle rear mount.
  10.  
  11. Remove the bolt from the left transaxle mount.
  12.  
  13. Lower the engine and transaxle from the vehicle.
  14.  
  15. Using the engine crane and spreader bar remove the engine and transaxle from the lift table.
  16.  
  17. Remove the starter motor isolator.
  18.  
  19. Remove and discard the four torque converter nuts.
  20.  


NOTE
The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  1. Remove the remaining six engine-to-transaxle bolts and separate the engine and transaxle.
  2.  

To install:

All vehicles

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the six upper transaxle-to-engine bolts. Torque to 35 ft. lbs. (48 Nm).
  2.  
  3. Install new torque converter nuts. Torque to 26 ft. lbs. (35 Nm).
  4.  
  5. Install the starter motor isolator.
  6.  
  7. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
  8.  
  9. Using the special tools, secure the engine to the lift table.
  10.  
  11. Raise the engine and transaxle into the vehicle.
  12.  
  13. Install the bolt in the left transaxle mount. Torque to 76 ft. lbs. (103 Nm).
  14.  
  15. Install the bolt in the rear transaxle mount. Torque to 85 ft. lbs. (115 Nm).
  16.  
  17. Install the engine mount bracket. Torque to 66 ft. lbs. (90 Nm).
  18.  
  19. Install the engine mount bracket bolt. Torque to 66 ft. lbs. (90 Nm).
  20.  
  21. Install the 4 transaxle-to-engine bolts. Torque to 35 ft. lbs. (48 Nm).
  22.  
  23. Install the engine support crossmember and nut. Torque to 66 ft. lbs. (90 Nm).
  24.  
  25. Install the two bolts for the engine support crossmember. Torque to 66 ft. lbs. (90 Nm).
  26.  
  27. Install the front roll restrictor bolt . Torque to 85 ft. lbs. (115 Nm).
  28.  
  29. Position the power steering pump and install the upper bolts. Torque to 18 ft. lbs. (25 Nm).
  30.  
  31. Connect the power steering pressure (PSP) sensor electrical connector.
  32.  
  33. Install the A/C compressor and connect the A/C compressor electrical connector. Torque to 18 ft. lbs. (25 Nm).
  34.  
  35. Connect the lower radiator hose to the radiator.
  36.  
  37. Install the two lower power steering pump bolts. Torque to 18 ft. lbs. (25 Nm).
  38.  
  39. Install the ground wire and bolt.
  40.  
  41. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut.
  42.  
  43. Attach the electrical connector retainers.
  44.  
  45. Connect the fuel supply tube.
  46.  
  47. Connect the vacuum reservoir tube.
  48.  
  49. Connect the fuel vapor return tube and retainer.
  50.  
  51. Connect the vacuum supply tube.
  52.  
  53. Position the power steering tube and bracket and install the nut.
  54.  
  55. Position the accelerator control cable and bracket and install the nut.
  56.  
  57. Install the accelerator control cable and bracket and nut.
  58.  
  59. Install the accelerator cable and speed control cable (if equipped).
  60.  
  61. Install the accelerator cable snow shield and the retainers.
  62.  
  63. Connect the heater hoses to the heater core.
  64.  
  65. Attach the heater hose support strap to the stud.
  66.  
  67. Position the coolant vent hose and install the coolant vent hose brackets and nuts.
  68.  
  69. Connect the upper radiator and coolant vent hoses.
  70.  
  71. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
  72.  
  73. Attach the transaxle control harness to the retaining clip.
  74.  
  75. Install the output shaft speed (OSS) sensor and bolt.
  76.  
  77. Install the fluid cooler tube.
  78.  
  79. Connect the transmission fluid cooler tube.
  80.  
  81. Attach the transaxle control harness to the brackets.
  82.  
  83. Connect the transmission range (TR) sensor electrical connector.
  84.  
  85. Install the transaxle control cable and bracket.
  86.  
  87. Connect the shift cable to the transaxle manual lever.
  88.  
  89. Connect the transaxle electrical connector.
  90.  
  91. Attach the wiring harness retainers to the battery tray bracket.
  92.  
  93. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt.
  94.  
  95. Connect the electrical connector to the power distribution box.
  96.  
  97. Connect the cables and install the nuts.
  98.  
  99. Install the power distribution box cover.
  100.  
  101. If equipped, install the ground eyelet and bolt.
  102.  

2wd vehicles

  1. Install the front drive intermediate halfshaft.
  2.  
  3. Install the lateral support crossmember. Torque to 85 ft. lbs. (115 Nm).
  4.  

4wd vehicles

  1. Install the transfer case.
  2.  

All vehicles

  1. Install the left front drive halfshaft.
  2.  
  3. Install the accessory drive belt.
  4.  
  5. Install the catalytic converter.
  6.  
  7. Install the starter.
  8.  
  9. Install the battery tray and battery.
  10.  
  11. Install the engine air cleaner and air cleaner outlet pipe.
  12.  
  13. Fill the engine with clean engine oil.
  14.  
  15. Fill and bleed the cooling system.
  16.  

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove the engine air cleaner and air cleaner outlet pipe
  6.  
  7. Remove the battery tray.
  8.  
  9. Drain the engine oil.
  10.  
  11. Drain the cooling system.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the catalytic converter.
  16.  
  17. Remove the accessory drive belt.
  18.  
  19. Remove the left front drive halfshafts.
  20.  

4wd vehicles

  1. Remove the transfer case.
  2.  

2wd vehicles

  1. Remove the bolts and the lateral support crossmember.
  2.  
  3. Remove the front drive intermediate halfshaft.
  4.  

All vehicles

  1. If equipped, remove the bolt and ground eyelet.
  2.  
  3. Remove the power distribution box cover.
  4.  
  5. Remove the nuts and disconnect the cables.
  6.  
  7. Disconnect the electrical connector from the power distribution box.
  8.  
  9. Remove the bolt and disconnect the ground strap. Loosen the bolt and disconnect the 42-pin electrical connector.
  10.  
  11. Detach the wiring harness retainers from the battery tray bracket and position the wiring harness out of the way.
  12.  
  13. Disconnect the transaxle electrical connector.
  14.  
  15. Disconnect the shift cable from the transaxle manual lever.
  16.  
  17. Position the transaxle control cable and bracket aside.
  18.  
  19. Disconnect the transaxle range (TR) sensor electrical connector.
  20.  
  21. Detach the transaxle control harness from the brackets.
  22.  
  23. Disconnect the fluid cooler tube.
  24.  
  25. Disconnect the output shaft speed (OSS) sensor electrical connector (black).
  26.  
  27. Disconnect the turbine shaft speed (TSS) sensor electrical connector (white connector).
  28.  
  29. Remove the transaxle fluid cooler retaining bracket bolt.
  30.  
  31. Position the fluid cooler tube aside.
  32.  
  33. Remove the bolt and the OSS sensor.
  34.  
  35. Detach the transaxle control harness from the retaining clip.
  36.  
  37. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
  38.  
  39. Disconnect the upper radiator and coolant vent hoses.
  40.  
  41. Remove the nuts and the coolant vent hose brackets. Position the coolant vent hose aside.
  42.  
  43. Detach the heater hose support strap from the stud.
  44.  
  45. Disconnect the heater hoses from the heater core.
  46.  
  47. Remove the retainers and the accelerator cable snow shield.
  48.  
  49. Disconnect the accelerator cable and speed control cable (if equipped).
  50.  
  51. Remove the nut from the accelerator control cable bracket.
  52.  
  53. Remove the nut from the accelerator control cable bracket and position the accelerator control cable and bracket assembly aside.
  54.  
  55. Remove the nut and position the power steering tube and bracket aside.
  56.  
  57. Disconnect the vacuum supply tube and position aside.
  58.  
  59. Disconnect the fuel vapor return tube and retainer and position aside.
  60.  
  61. Disconnect the vacuum reservoir tube and position aside.
  62.  
  63. Disconnect the fuel supply tube and position aside.
  64.  
  65. Detach the electrical connector retainers.
  66.  
  67. Disconnect the powertrain control module (PCM) electrical connectors. Remove the nut and position the harness aside.
  68.  
  69. Remove the bolt and detach the ground wire.
  70.  
  71. Remove the two power steering pump bolts.
  72.  
  73. Disconnect the lower radiator hose from the radiator.
  74.  
  75. Disconnect the A/C compressor electrical connector and remove the four bolts. Position the A/C compressor aside and support the compressor with a length of mechanics wire.
  76.  
  77. Disconnect the power steering pressure (PSP) sensor electrical connector.
    NOTE
    The bolt under the power steering pressure tube will remain with the power steering pump.

  78.  
  79. Remove the bolts and position the power steering pump aside.
  80.  
  81. Remove the front roll restrictor bolt and the two bolts for the engine support crossmember.
  82.  
  83. Remove the rear nut and the engine support crossmember.
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  84.  
  85. Remove the two transaxle-to-engine bolts
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  86.  
  87. Remove the two transaxle-to-engine bolts
  88.  
  89. Using the special tools, secure the engine to the lift table.
  90.  
  91. Remove the engine mount bracket bolt.
  92.  
  93. Remove the nuts and the engine mount bracket.
  94.  
  95. Remove the bolt from the transaxle rear mount.
  96.  
  97. Remove the bolt from the left transaxle mount.
  98.  
  99. Lower the engine and transaxle from the vehicle.
  100.  
  101. Using the engine crane and spreader bar remove the engine and transaxle from the lift table.
  102.  
  103. Remove the starter motor isolator.
  104.  
  105. Remove and discard the four torque converter nuts.
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  106.  
  107. Remove the remaining six engine-to-transaxle bolts and separate the engine and transaxle.
  108.  

To install:

All vehicles

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the six upper transaxle-to-engine bolts. Torque to 35 ft. lbs. (48 Nm).
  2.  
  3. Install new torque converter nuts. Torque to 26 ft. lbs. (35 Nm).
  4.  
  5. Install the starter motor isolator.
  6.  
  7. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
  8.  
  9. Using the special tools, secure the engine to the lift table.
  10.  
  11. Raise the engine and transaxle into the vehicle.
  12.  
  13. Install the bolt in the left transaxle mount. Torque to 76 ft. lbs. (103 Nm).
  14.  
  15. Install the bolt in the rear transaxle mount. Torque to 85 ft. lbs. (115 Nm).
  16.  
  17. Install the engine mount bracket. Torque to 66 ft. lbs. (90 Nm).
  18.  
  19. Install the engine mount bracket bolt. Torque to 66 ft. lbs. (90 Nm).
  20.  
  21. Install the 4 transaxle-to-engine bolts. Torque to 35 ft. lbs. (48 Nm).
  22.  
  23. Install the engine support crossmember and nut. Torque to 66 ft. lbs. (90 Nm).
  24.  
  25. Install the two bolts for the engine support crossmember. Torque to 66 ft. lbs. (90 Nm).
  26.  
  27. Install the front roll restrictor bolt . Torque to 85 ft. lbs. (115 Nm).
  28.  
  29. Position the power steering pump and install the upper bolts. Torque to 18 ft. lbs. (25 Nm).
  30.  
  31. Connect the power steering pressure (PSP) sensor electrical connector.
  32.  
  33. Install the A/C compressor and connect the A/C compressor electrical connector. Torque to 18 ft. lbs. (25 Nm).
  34.  
  35. Connect the lower radiator hose to the radiator.
  36.  
  37. Install the two lower power steering pump bolts. Torque to 18 ft. lbs. (25 Nm).
  38.  
  39. Install the ground wire and bolt.
  40.  
  41. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut.
  42.  
  43. Attach the electrical connector retainers.
  44.  
  45. Connect the fuel supply tube.
  46.  
  47. Connect the vacuum reservoir tube.
  48.  
  49. Connect the fuel vapor return tube and retainer.
  50.  
  51. Connect the vacuum supply tube.
  52.  
  53. Position the power steering tube and bracket and install the nut.
  54.  
  55. Position the accelerator control cable and bracket and install the nut.
  56.  
  57. Install the accelerator control cable and bracket and nut.
  58.  
  59. Install the accelerator cable and speed control cable (if equipped).
  60.  
  61. Install the accelerator cable snow shield and the retainers.
  62.  
  63. Connect the heater hoses to the heater core.
  64.  
  65. Attach the heater hose support strap to the stud.
  66.  
  67. Position the coolant vent hose and install the coolant vent hose brackets and nuts.
  68.  
  69. Connect the upper radiator and coolant vent hoses.
  70.  
  71. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
  72.  
  73. Attach the transaxle control harness to the retaining clip.
  74.  
  75. Install the output shaft speed (OSS) sensor and bolt.
  76.  
  77. Install the fluid cooler tube.
  78.  
  79. Connect the transaxle fluid cooler tube.
  80.  
  81. Attach the transaxle control harness to the brackets.
  82.  
  83. Connect the transaxle range (TR) sensor electrical connector.
  84.  
  85. Install the transaxle control cable and bracket.
  86.  
  87. Connect the shift cable to the transaxle manual lever.
  88.  
  89. Connect the transaxle electrical connector.
  90.  
  91. Attach the wiring harness retainers to the battery tray bracket.
  92.  
  93. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt.
  94.  
  95. Connect the electrical connector to the power distribution box.
  96.  
  97. Connect the cables and install the nuts.
  98.  
  99. Install the power distribution box cover.
  100.  
  101. If equipped, install the ground eyelet and bolt.
  102.  

2wd vehicles

  1. Install the front drive intermediate halfshaft.
  2.  
  3. Install the lateral support crossmember. Torque to 85 ft. lbs. (115 Nm).
  4.  

4wd vehicles

  1. Install the transfer case.
  2.  

All vehicles

  1. Install the left front drive halfshaft.
  2.  
  3. Install the accessory drive belt.
  4.  
  5. Install the catalytic converter.
  6.  
  7. Install the starter.
  8.  
  9. Install the battery tray and battery.
  10.  
  11. Install the engine air cleaner and air cleaner outlet pipe.
  12.  
  13. Fill the engine with clean engine oil.
  14.  
  15. Fill and bleed the cooling system.
  16.  

Manual Transaxle

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove the engine air cleaner and air cleaner outlet pipe.
  6.  
  7. Remove the battery tray.
  8.  
  9. Drain the engine oil.
  10.  
  11. Drain the cooling system.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the catalytic converter.
  16.  
  17. Remove the accessory drive belt.
  18.  
  19. Remove the bolts and the lateral support crossmember.
  20.  
  21. Remove the LH front drive halfshaft.
  22.  
  23. Remove the front drive intermediate halfshaft
  24.  

4x4 vehicles

  1. Remove the six bolts holding the driveshaft to the transfer case.
  2.  
  3. Position the driveshaft aside.
  4.  


    Click image to see an enlarged view

    Fig. Engine secured to lift table-2.3L engine w/manual transaxle


All vehicles

  1. If equipped, remove the bolt and ground eyelet.
  2.  
  3. Remove the power distribution box cover.
  4.  
  5. Remove the nuts and disconnect the cables.
  6.  
  7. Disconnect the electrical connector from the power distribution box.
  8.  
  9. Remove the bolt and disconnect the ground strap. Loosen the bolt and disconnect the 42-pin electrical connector.
  10.  
  11. Detach the wiring harness retainers from the battery tray bracket and position the wiring harness out of the way.
  12.  
  13. Disconnect the clutch hydraulic tube fitting. Detach the tube from the spring clip and position aside.
  14.  
  15. Remove the retaining clips and disconnect the transaxle control cable.
  16.  
  17. Remove the retaining clips and disconnect the transaxle control cable.
  18.  
  19. Disconnect the vehicle speed sensor electrical connector and pin-type retainer.
  20.  
  21. Disconnect the reversing lamp indicator switch and detach the wiring harness retainers.
  22.  
  23. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
  24.  
  25. Disconnect the upper radiator and coolant vent hoses.
  26.  
  27. Remove the nuts and the coolant vent hose brackets. Position the coolant vent hose aside.
  28.  
  29. Detach the heater hose support strap from the stud.
  30.  
  31. Disconnect the heater hoses from the heater core.
  32.  
  33. Remove the retainers and the accelerator cable snow shield.
  34.  
  35. Disconnect the accelerator cable and speed control cable (if equipped).
  36.  
  37. Remove the nut from the accelerator control cable bracket.
  38.  
  39. Remove the nut from the accelerator control cable bracket and position the accelerator control cable and bracket assembly aside.
  40.  
  41. Remove the nut and position the power steering tube and bracket aside.
  42.  
  43. Disconnect the vacuum supply tube and position aside.
  44.  
  45. Disconnect the fuel vapor return tube and position aside.
  46.  
  47. Disconnect the vacuum reservoir tube and position aside.
  48.  
  49. Disconnect the fuel supply tube and retainer and position aside.
  50.  
  51. Detach the electrical connector retainers.
  52.  
  53. Disconnect the powertrain control module (PCM) electrical connectors. Remove the nut and position the harness aside.
  54.  
  55. Remove the bolt and detach the ground wire.
  56.  
  57. Remove the two power steering pump bolts.
  58.  
  59. Disconnect the lower radiator hose from the radiator.
  60.  
  61. Disconnect the A/C compressor electrical connector and remove the four bolts. Position the A/C compressor aside and support the compressor with a length of mechanics wire.
  62.  
  63. Disconnect the power steering pressure (PSP) sensor electrical connector.
  64.  


NOTE
The bolt under the power steering pressure tube will remain with the power steering pump.

  1. Remove the bolts and position the power steering pump aside.
  2.  
  3. Remove the front roll restrictor bolt and the two bolts for the engine support crossmember.
  4.  
  5. Remove the rear nut and the engine support crossmember.
  6.  


NOTE
The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

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


NOTE
The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  1. Remove the two transaxle-to-engine bolts.
  2.  
  3. Using the special tools, secure the engine to the lift table.
  4.  
  5. Remove the engine mount bracket bolt.
  6.  
  7. Remove the nuts and the engine mount bracket.
  8.  
  9. Remove the bolt from the transaxle rear mount.
  10.  
  11. Remove bolt from the LH transaxle mount.
  12.  
  13. Lower the engine and transaxle from the vehicle.
  14.  
  15. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
  16.  


NOTE
The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  1. Remove the remaining six engine-to-transaxle bolts and separate the engine and transaxle.
  2.  

To install:

All vehicles

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the six upper transaxle-to-engine bolts. Torque to 35 ft. lbs. (48 Nm).
  2.  
  3. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
  4.  
  5. Using the special tools, secure the engine to the lift table.
  6.  
  7. Raise the engine and transaxle into the vehicle.
  8.  
  9. Install the bolt in the LH transaxle mount. Torque to 76 ft. lbs. (103 Nm).
  10.  
  11. Install the bolt in the rear transaxle mount. Torque to 85 ft. lbs. (115 Nm).
  12.  
  13. Install the engine mount bracket. Torque to 66 ft. lbs. (90 Nm).
  14.  
  15. Install the engine mount bracket bolt. Torque to 66 ft. lbs. (90 Nm).
  16.  
  17. Install the 4 lower transaxle-to-engine bolts. Torque to 35 ft. lbs. (48 Nm).
  18.  
  19. Install the engine support crossmember and nut. Torque to 66 ft. lbs. (90 Nm).
  20.  
  21. Install the two bolts for the engine support crossmember. Torque to 66 ft. lbs. (90 Nm).
  22.  
  23. Install the front roll restrictor bolt. Torque to 85 ft. lbs. (115 Nm).
  24.  


NOTE
The bolt under the power steering pressure tube will remain with the power steering pump.

  1. Position the power steering pump and install the bolts. Torque to 18 ft. lbs. (25 Nm).
  2.  
  3. Connect the power steering pressure (PSP) sensor electrical connector.
  4.  
  5. Install the A/C compressor and connect the A/C compressor electrical connector. Torque to 18 ft. lbs. (25 Nm).
  6.  
  7. Connect the lower radiator hose to the radiator.
  8.  
  9. Install the two lower power steering pump bolts. Torque to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the ground wire and bolt.
  12.  
  13. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut.
  14.  
  15. Attach the electrical connector retainers.
  16.  
  17. Connect the fuel supply tube.
  18.  
  19. Connect the vacuum reservoir tube.
  20.  
  21. Connect the fuel vapor return tube and retainer.
  22.  
  23. Connect the vacuum supply tube.
  24.  
  25. Install the power steering tube and bracket.
  26.  
  27. Position the accelerator control cable and bracket and install the nut.
  28.  
  29. Install the accelerator control cable and bracket and nut.
  30.  
  31. Install the accelerator cable and speed control cable (if equipped).
  32.  
  33. Install the accelerator cable snow shield and retainers.
  34.  
  35. Connect the heater hoses to the heater core.
  36.  
  37. Attach the heater hose support strap to the stud.
  38.  
  39. Position the coolant vent hose and install the coolant vent hose brackets and nuts.
  40.  
  41. Connect the upper radiator and coolant vent hoses.
  42.  
  43. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
  44.  
  45. Connect the reversing lamp indicator switch and attach the wiring harness retainers.
  46.  
  47. Connect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
  48.  
  49. Connect the transaxle control cable and install the retaining clips.
  50.  
  51. Connect the transaxle control cable and install the retaining clips.
  52.  
  53. Connect the clutch hydraulic tube fitting. Attach the tube to the spring clip.
  54.  
  55. Attach the wiring harness retainers to the battery tray bracket.
  56.  
  57. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt.
  58.  
  59. Connect the electrical connector to the power distribution box.
  60.  
  61. Connect the cables and install the nuts.
  62.  
  63. Install the power distribution box cover.
  64.  
  65. If equipped, install the ground eyelet and bolt.
  66.  

4x4 vehicles

  1. Install the driveshaft. Torque to 15 ft. lbs. (20 Nm).
  2.  

All vehicles

  1. Install the front drive intermediate halfshaft.
  2.  
  3. Install the LH front drive halfshaft.
  4.  
  5. Install the lateral support crossmember. Torque to 85 ft. lbs. (115 Nm).
  6.  
  7. Install the accessory drive belt.
  8.  
  9. Install the catalytic converter.
  10.  
  11. Install the starter.
  12.  
  13. Install the battery tray and battery.
  14.  
  15. Install the engine air cleaner and air cleaner outlet pipe.
  16.  
  17. Fill the engine with clean engine oil.
  18.  
  19. Fill and bleed the cooling system.
  20.  
  21. Bleed the clutch system.
  22.  

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove the engine air cleaner and air cleaner outlet pipe.
  6.  
  7. Remove the battery tray.
  8.  
  9. Drain the engine oil.
  10.  
  11. Drain the cooling system.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the catalytic converter.
  16.  
  17. Remove the accessory drive belt.
  18.  
  19. Remove the bolts and the lateral support crossmember.
  20.  
  21. Remove the LH front drive halfshaft.
  22.  
  23. Remove the front drive intermediate halfshaft
  24.  

4x4 vehicles

  1. Remove the six bolts holding the driveshaft to the transfer case.
  2.  
  3. Position the driveshaft aside.

    Click image to see an enlarged view

    Fig. Engine secured to lift table-2.3L engine w/manual transaxle

  4.  

All vehicles

  1. If equipped, remove the bolt and ground eyelet.
  2.  
  3. Remove the power distribution box cover.
  4.  
  5. Remove the nuts and disconnect the cables.
  6.  
  7. Disconnect the electrical connector from the power distribution box.
  8.  
  9. Remove the bolt and disconnect the ground strap. Loosen the bolt and disconnect the 42-pin electrical connector.
  10.  
  11. Detach the wiring harness retainers from the battery tray bracket and position the wiring harness out of the way.
  12.  
  13. Disconnect the clutch hydraulic tube fitting. Detach the tube from the spring clip and position aside.
  14.  
  15. Remove the retaining clips and disconnect the transaxle control cable.
  16.  
  17. Remove the retaining clips and disconnect the transaxle control cable.
  18.  
  19. Disconnect the vehicle speed sensor electrical connector and pin-type retainer.
  20.  
  21. Disconnect the reversing lamp indicator switch and detach the wiring harness retainers.
  22.  
  23. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
  24.  
  25. Disconnect the upper radiator and coolant vent hoses.
  26.  
  27. Remove the nuts and the coolant vent hose brackets. Position the coolant vent hose aside.
  28.  
  29. Detach the heater hose support strap from the stud.
  30.  
  31. Disconnect the heater hoses from the heater core.
  32.  
  33. Remove the retainers and the accelerator cable snow shield.
  34.  
  35. Disconnect the accelerator cable and speed control cable (if equipped).
  36.  
  37. Remove the nut from the accelerator control cable bracket.
  38.  
  39. Remove the nut from the accelerator control cable bracket and position the accelerator control cable and bracket assembly aside.
  40.  
  41. Remove the nut and position the power steering tube and bracket aside.
  42.  
  43. Disconnect the vacuum supply tube and position aside.
  44.  
  45. Disconnect the fuel vapor return tube and position aside.
  46.  
  47. Disconnect the vacuum reservoir tube and position aside.
  48.  
  49. Disconnect the fuel supply tube and retainer and position aside.
  50.  
  51. Detach the electrical connector retainers.
  52.  
  53. Disconnect the powertrain control module (PCM) electrical connectors. Remove the nut and position the harness aside.
  54.  
  55. Remove the bolt and detach the ground wire.
  56.  
  57. Remove the two power steering pump bolts.
  58.  
  59. Disconnect the lower radiator hose from the radiator.
  60.  
  61. Disconnect the A/C compressor electrical connector and remove the four bolts. Position the A/C compressor aside and support the compressor with a length of mechanics wire.
  62.  
  63. Disconnect the power steering pressure (PSP) sensor electrical connector.
    NOTE
    The bolt under the power steering pressure tube will remain with the power steering pump.

  64.  
  65. Remove the bolts and position the power steering pump aside.
  66.  
  67. Remove the front roll restrictor bolt and the two bolts for the engine support crossmember.
  68.  
  69. Remove the rear nut and the engine support crossmember.
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  70.  
  71. Remove the two transaxle-to-engine bolts.
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  72.  
  73. Remove the two transaxle-to-engine bolts.
  74.  
  75. Using the special tools, secure the engine to the lift table.
  76.  
  77. Remove the engine mount bracket bolt.
  78.  
  79. Remove the nuts and the engine mount bracket.
  80.  
  81. Remove the bolt from the transaxle rear mount.
  82.  
  83. Remove bolt from the LH transaxle mount.
  84.  
  85. Lower the engine and transaxle from the vehicle.
  86.  
  87. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  88.  
  89. Remove the remaining six engine-to-transaxle bolts and separate the engine and transaxle.
  90.  

To install:

All vehicles

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the six upper transaxle-to-engine bolts. Torque to 35 ft. lbs. (48 Nm).
  2.  
  3. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
  4.  
  5. Using the special tools, secure the engine to the lift table.
  6.  
  7. Raise the engine and transaxle into the vehicle.
  8.  
  9. Install the bolt in the LH transaxle mount. Torque to 76 ft. lbs. (103 Nm).
  10.  
  11. Install the bolt in the rear transaxle mount. Torque to 85 ft. lbs. (115 Nm).
  12.  
  13. Install the engine mount bracket. Torque to 66 ft. lbs. (90 Nm).
  14.  
  15. Install the engine mount bracket bolt. Torque to 66 ft. lbs. (90 Nm).
  16.  
  17. Install the 4 lower transaxle-to-engine bolts. Torque to 35 ft. lbs. (48 Nm).
  18.  
  19. Install the engine support crossmember and nut. Torque to 66 ft. lbs. (90 Nm).
  20.  
  21. Install the two bolts for the engine support crossmember. Torque to 66 ft. lbs. (90 Nm).
  22.  
  23. Install the front roll restrictor bolt. Torque to 85 ft. lbs. (115 Nm).
    NOTE
    The bolt under the power steering pressure tube will remain with the power steering pump.

  24.  
  25. Position the power steering pump and install the bolts. Torque to 18 ft. lbs. (25 Nm).
  26.  
  27. Connect the power steering pressure (PSP) sensor electrical connector.
  28.  
  29. Install the A/C compressor and connect the A/C compressor electrical connector. Torque to 18 ft. lbs. (25 Nm).
  30.  
  31. Connect the lower radiator hose to the radiator.
  32.  
  33. Install the two lower power steering pump bolts. Torque to 18 ft. lbs. (25 Nm).
  34.  
  35. Install the ground wire and bolt.
  36.  
  37. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut.
  38.  
  39. Attach the electrical connector retainers.
  40.  
  41. Connect the fuel supply tube.
  42.  
  43. Connect the vacuum reservoir tube.
  44.  
  45. Connect the fuel vapor return tube and retainer.
  46.  
  47. Connect the vacuum supply tube.
  48.  
  49. Install the power steering tube and bracket.
  50.  
  51. Position the accelerator control cable and bracket and install the nut.
  52.  
  53. Install the accelerator control cable and bracket and nut.
  54.  
  55. Install the accelerator cable and speed control cable (if equipped).
  56.  
  57. Install the accelerator cable snow shield and retainers.
  58.  
  59. Connect the heater hoses to the heater core.
  60.  
  61. Attach the heater hose support strap to the stud.
  62.  
  63. Position the coolant vent hose and install the coolant vent hose brackets and nuts.
  64.  
  65. Connect the upper radiator and coolant vent hoses.
  66.  
  67. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
  68.  
  69. Connect the reversing lamp indicator switch and attach the wiring harness retainers.
  70.  
  71. Connect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
  72.  
  73. Connect the transaxle control cable and install the retaining clips.
  74.  
  75. Connect the transaxle control cable and install the retaining clips.
  76.  
  77. Connect the clutch hydraulic tube fitting. Attach the tube to the spring clip.
  78.  
  79. Attach the wiring harness retainers to the battery tray bracket.
  80.  
  81. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt.
  82.  
  83. Connect the electrical connector to the power distribution box.
  84.  
  85. Connect the cables and install the nuts.
  86.  
  87. Install the power distribution box cover.
  88.  
  89. If equipped, install the ground eyelet and bolt.
  90.  

4x4 vehicles

  1. Install the driveshaft. Torque to 15 ft. lbs. (20 Nm).
  2.  

All vehicles

  1. Install the front drive intermediate halfshaft.
  2.  
  3. Install the LH front drive halfshaft.
  4.  
  5. Install the lateral support crossmember. Torque to 85 ft. lbs. (115 Nm).
  6.  
  7. Install the accessory drive belt.
  8.  
  9. Install the catalytic converter.
  10.  
  11. Install the starter.
  12.  
  13. Install the battery tray and battery.
  14.  
  15. Install the engine air cleaner and air cleaner outlet pipe.
  16.  
  17. Fill the engine with clean engine oil.
  18.  
  19. Fill and bleed the cooling system.
  20.  
  21. Bleed the clutch system.
  22.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly recover the air conditioning system refrigerant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove or disconnect the following:

    Hood
     
    Battery and battery tray
     
    Air cleaner outlet tube and housing
     
    Lower radiator air deflectors
     
    Fuel lines
     
    Water pump drive belt
     
    Accelerator cable and speed control cable, if equipped
     
    Vapor Management Valve (VMV)
     
    Powertrain Control Module (PCM)
     
    PCM ground wire
     
    Thermostat housing and hose assembly and move them aside
     
    Power distribution box electrical connector
     
    Power distribution box cover
     
    Nuts and cables from inside the power distribution box
     
    Transmission linkage
     
    Brake booster vacuum hose
     
    Heater hoses
     
    Power steering return line
     
    Power Steering Pressure (PSP) switch electrical connector
     
    Power steering supply line
     
    Oil level indicator
     
    Catalytic converter
     
    A/C compressor
     
    Both front wheels
     
    Intermediate drive shaft, if equipped
     

  12.  
  13. Separate both side ball joints.
  14.  
  15. Separate both side tie rod ends from the steering knuckles.
  16.  
  17. Separate both sway bar links from the strut mounts.
  18.  
  19. Separate the struts from the steering knuckles.
  20.  
  21. Remove or disconnect the following:

    Both wheel speed sensors, if equipped
     
    Brake calipers from the steering knuckles and properly support the struts
     
    Steering shaft from the rack
     
    Transmission line bracket bolt
     
    Transmission cooler lines
     
    Torque converter inspection cover
     
    Torque converter nuts
     
    Block heater wiring, if equipped
     

  22.  
  23. Install a powertrain lifting devise and raise the vehicle.

    Engine support bracket
     
    Transmission support
     
    2 rear subframe bolts
     
    2 subframe side bolts
     
    Motor mount support bolts
     
    Engine and transmission as an assembly
     
    Heated Oxygen (HO2S) sensor
     
    Transmission Range (TR) sensor
     
    Transmission harness electronic control switch
     
    Transmission control harness from the bracket
     
    Starter and wire harness
     
    Knock Sensor (KS) electrical connector
     
    Output Shaft Speed (OSS) sensor electrical connector
     
    HO2S sensor and Exhaust Gas Recirculation (EGR) tube from the exhaust manifold
     
    Alternator and electrical connectors
     
    Right side exhaust manifold and gasket
     
    Halfshaft support bracket and move it aside
     

  24.  
  25. Separate the engine from the transmission assembly
  26.  

To install:

  1. Install or connect the following:

    Powertrain assembly on the subframe
     
    Transmission-to-engine bolts. Torque the bolts to 30 ft. lbs. (40 Nm).
     
    Halfshaft bracket. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Right side exhaust manifold and new gasket. Torque the bolts to 15 ft. lbs. (25 Nm).
     
    Alternator. Torque the larger bolts to 18 ft. lbs. (25 Nm) and smaller bolt to 89 inch lbs. (10 Nm).
     
    EGR tube and HO2S sensor electrical connectors
     
    OSS sensor electrical connector
     
    KS jumper electrical connector
     
    Starter. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Transmission control harness to the bracket. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    Transmission harness
     
    Transmission range sensor
     
    Powertrain assembly
     
    Motor mount support. Torque the bolts to 66 ft. lbs. (90 Nm).
     
    Subframe side nuts. Torque the nuts to 76 ft. lbs. (103 Nm). Raise the vehicle and support the powertrain assembly with a lifting device.
     
    Transmission mount. Torque the bolts to side bolts to 66 ft. lbs. (90 Nm) and the other bolts to 76 ft. lbs. (103 Nm).
     
    Motor mount. Torque the bolts to side bolts to 66 ft. lbs. (90 Nm) and the other bolts to 76 ft. lbs. (103 Nm). Remove the powertrain lift.
     
    Block heater electrical connector, if equipped
     
    Torque converter. Torque the nuts to 27 ft. lbs. (37 Nm).
     
    Transmission cover plate and plug
     
    Transmission cooler lines
     
    Transmission cooler line bracket. Torque the bolt to 15 ft. lbs. (20 Nm).
     
    Steering shaft to the rack. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    Struts to the steering knuckles. Torque the bolts to 75 ft. lbs. (102 Nm).
     
    Brake calipers to the steering knuckles
     
    Wheel speed sensors, if equipped. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Sway bar links to the strut mount. Torque the bolts to 41 ft. lbs. (55 Nm).
     
    Tie rods to the steering knuckles. Torque the bolts to 41 ft. lbs. (55 Nm).
     
    Ball joints. Torque the bolts to 52 ft. lbs. (70 Nm).
     
    Intermediate drive shaft, if equipped
     
    Both front wheels
     
    A/C compressor
     
    Lower radiator air deflectors
     
    Catalytic converter
     
    Oil level indicator dipstick tube
     
    Power steering line and bracket. Torque the bolt to 13 ft. lbs. (17 Nm).
     
    PSP switch electrical connector
     
    Power steering return line
     
    Heater hoses
     
    Vacuum lines
     
    Transmission linkage
     
    Wire harness cables and nuts to the power distribution box. Torque the nuts to 89 inch lbs. (10 Nm).
     
    Power distribution box wire harness
     
    Thermostat housing and connect the hoses
     
    Ground wire. Torque the bolt to 89 inch lbs. (10 Nm).
     
    PCM electrical connector
     
    VMV electrical connector
     
    Accelerator cable and speed control cable, if equipped
     
    Air cleaner assembly
     
    Water pump drive belt
     
    Battery and tray
     

  2.  
  3. Fill and bleed the cooling system.
  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Recharge the A/C system.
  8.  
  9. Inspect and top off the power steering fluid.
  10.  
  11. Start the vehicle, check for leaks and repair if necessary.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly recover the air conditioning system refrigerant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove or disconnect the following:

    Hood
     
    Battery and battery tray
     
    Air cleaner outlet tube and housing
     
    Lower radiator air deflectors
     
    Fuel lines
     
    Water pump drive belt
     
    Accelerator cable and speed control cable, if equipped
     
    Vapor Management Valve (VMV)
     
    Powertrain Control Module (PCM)
     
    PCM ground wire
     
    Thermostat housing and hose assembly and move them aside
     
    Power distribution box electrical connector
     
    Power distribution box cover
     
    Nuts and cables from inside the power distribution box
     
    Transaxle linkage
     
    Brake booster vacuum hose
     
    Heater hoses
     
    Power steering return line
     
    Power Steering Pressure (PSP) switch electrical connector
     
    Power steering supply line
     
    Oil level indicator
     
    Catalytic converter
     
    A/C compressor
     
    Both front wheels
     
    Intermediate drive shaft, if equipped
     

  12.  
  13. Separate both side ball joints.
  14.  
  15. Separate both side tie rod ends from the steering knuckles.
  16.  
  17. Separate both sway bar links from the strut mounts.
  18.  
  19. Separate the struts from the steering knuckles.
  20.  
  21. Remove or disconnect the following:

    Both wheel speed sensors, if equipped
     
    Brake calipers from the steering knuckles and properly support the struts
     
    Steering shaft from the rack
     
    Transaxle line bracket bolt
     
    Transaxle cooler lines
     
    Torque converter inspection cover
     
    Torque converter nuts
     
    Block heater wiring, if equipped
     

  22.  
  23. Install a powertrain lifting devise and raise the vehicle.

    Engine support bracket
     
    Transaxle support
     
    2 rear subframe bolts
     
    2 subframe side bolts
     
    Motor mount support bolts
     
    Engine and transaxle as an assembly
     
    Heated Oxygen (HO 2 S) sensor
     
    Transaxle Range (TR) sensor
     
    Transaxle harness electronic control switch
     
    Transaxle control harness from the bracket
     
    Starter and wire harness
     
    Knock Sensor (KS) electrical connector
     
    Output Shaft Speed (OSS) sensor electrical connector
     
    HO 2 S sensor and Exhaust Gas Recirculation (EGR) tube from the exhaust manifold
     
    Alternator and electrical connectors
     
    Right side exhaust manifold and gasket
     
    Halfshaft support bracket and move it aside
     

  24.  
  25. Separate the engine from the transaxle assembly
  26.  

To install:

  1. Install or connect the following:

    Powertrain assembly on the subframe
     
    Transaxle-to-engine bolts. Torque the bolts to 30 ft. lbs. (40 Nm).
     
    Halfshaft bracket. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Right side exhaust manifold and new gasket. Torque the bolts to 15 ft. lbs. (25 Nm).
     
    Alternator. Torque the larger bolts to 18 ft. lbs. (25 Nm) and smaller bolt to 89 inch lbs. (10 Nm).
     
    EGR tube and HO 2 S sensor electrical connectors
     
    OSS sensor electrical connector
     
    KS jumper electrical connector
     
    Starter. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Transaxle control harness to the bracket. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    Transaxle harness
     
    Transaxle range sensor
     
    Powertrain assembly
     
    Motor mount support. Torque the bolts to 66 ft. lbs. (90 Nm).
     
    Subframe side nuts. Torque the nuts to 76 ft. lbs. (103 Nm). Raise the vehicle and support the powertrain assembly with a lifting device.
     
    Transaxle mount. Torque the bolts to side bolts to 66 ft. lbs. (90 Nm) and the other bolts to 76 ft. lbs. (103 Nm).
     
    Motor mount. Torque the bolts to side bolts to 66 ft. lbs. (90 Nm) and the other bolts to 76 ft. lbs. (103 Nm). Remove the powertrain lift.
     
    Block heater electrical connector, if equipped
     
    Torque converter. Torque the nuts to 27 ft. lbs. (37 Nm).
     
    Transaxle cover plate and plug
     
    Transaxle cooler lines
     
    Transaxle cooler line bracket. Torque the bolt to 15 ft. lbs. (20 Nm).
     
    Steering shaft to the rack. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    Struts to the steering knuckles. Torque the bolts to 75 ft. lbs. (102 Nm).
     
    Brake calipers to the steering knuckles
     
    Wheel speed sensors, if equipped. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Sway bar links to the strut mount. Torque the bolts to 41 ft. lbs. (55 Nm).
     
    Tie rods to the steering knuckles. Torque the bolts to 41 ft. lbs. (55 Nm).
     
    Ball joints. Torque the bolts to 52 ft. lbs. (70 Nm).
     
    Intermediate drive shaft, if equipped
     
    Both front wheels
     
    A/C compressor
     
    Lower radiator air deflectors
     
    Catalytic converter
     
    Oil level indicator dipstick tube
     
    Power steering line and bracket. Torque the bolt to 13 ft. lbs. (17 Nm).
     
    PSP switch electrical connector
     
    Power steering return line
     
    Heater hoses
     
    Vacuum lines
     
    Transaxle linkage
     
    Wire harness cables and nuts to the power distribution box. Torque the nuts to 89 inch lbs. (10 Nm).
     
    Power distribution box wire harness
     
    Thermostat housing and connect the hoses
     
    Ground wire. Torque the bolt to 89 inch lbs. (10 Nm).
     
    PCM electrical connector
     
    VMV electrical connector
     
    Accelerator cable and speed control cable, if equipped
     
    Air cleaner assembly
     
    Water pump drive belt
     
    Battery and tray
     

  2.  
  3. Fill and bleed the cooling system.
  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Recharge the A/C system.
  8.  
  9. Inspect and top off the power steering fluid.
  10.  
  11. Start the engine, check for leaks and repair if necessary.
  12.  

 
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