Engine - All Wheel Drive (AWD): Installation

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

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1. 2.
   
   Align the transaxle to the engine and install the 5 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).

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1. 3.
   
   Install the 2 engine-to-transaxle bolts.
   • Tighten to 48 Nm (35 lb-ft).

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1. 4.
   
   Install the RH halfshaft support bracket and the 2 bolts.
   • Tighten to 40 Nm (30 lb-ft).

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1. 5.
   
   Install the 2 intermediate shaft bracket studs and nuts.
   • Tighten the studs to 10 Nm (89 lb-in).
   • Tighten the nuts to 25 Nm (18 lb-ft).

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NOTE: LH shown, RH similar.
1. 6.
   Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

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1. 7.
   
   Using the Floor Crane and Spreader Bar, install the powertrain and subframe as an assembly on the powertrain lift table.

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NOTE: LH shown, RH similar.
1. 8.
   Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

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1. 9.
   
   Install the Adjustable Grip Arm.

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1. 10.
   
   Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.

1. 11.
   
   Position the PTU support bracket in place and install the 5 bolts.
   • Tighten to 70 Nm (52 lb-ft).

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1. 12.
   
   Install 6 new RH exhaust manifold studs.
   • Tighten to 12 Nm (106 lb-in).

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NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
1. 13.
   Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
   • Stage 1: Tighten to 20 Nm (177 lb-in).
   • Stage 2: Tighten to 25 Nm (18 lb-ft).

1. 14.
   
   Install the RH catalytic converter heat shield, Catalyst Monitor Sensor (CMS) wiring harness bracket and the 4 bolts.
   • Tighten to 10 Nm (89 lb-in).

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1. 15.
   
   Connect the RH Heated Oxygen Sensor(HO2S) electrical connector.

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1. 16.
   
   Connect the RH CMS electrical connector.

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1. 17.
   
   Attach the transaxle control wire harness retainer to the transaxle stud bolt.

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1. 18.
   
   Connect the transaxle control electrical connector.

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1. 19.
   
   Position the wiring harness and attach the 3 wiring harness retainer to the valve cover stud bolt.

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1. 20.
   
   Connect the generator B+ cable and install the nut.
   • Tighten to 17 Nm (150 lb-in).

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1. 21.
   
   Position back the generator B+ cable cover and connect the generator electrical connector.

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1. 22.
   
   Connect the 2 A/C compressor electrical connectors.
   • Attach the A/C wiring harness retainer.

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1. 23.
   
   Install the ground wire to the RH cylinder head and install the bolt.
   • Tighten to 10 Nm (89 lb-In).

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1. 24.
   
   Install the starter and the stud bolts.
   • Tighten to 27 Nm (20 lb-ft).

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1. 25.
   
   Connect the wiring harness retainer to the starter motor stud bolt.

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1. 26.
   
   Attach the starter wire terminals and install the 2 nuts.
   • Tighten the B+ terminal nut to 12 Nm (106 lb-in).
   • Tighten the S-terminal nut to 5 Nm (44 lb-in).

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1. 27.
   
   Install the starter motor solenoid cover.

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1. 28.
   
   Remove the Heavy Duty Floor Crane and Spreader Bar.

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1. 29.
   
   Remove 303-1245 from the LH cylinder head.

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1. 30.
   
   Raise the subframe and powertrain assembly into the vehicle.

1. 31.
   
   Install the engine mount, the 3 bolts and the 4 engine mount nuts hand tight.
   • Tighten the 3 engine mount bolts to 90 Nm (66 lb-ft).
   • Tighten the 4 engine mount nuts to 63 Nm (46 lb-ft).

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1. 32.
   
   Install the transaxle support insulator assembly the 3 nuts and the bolt.
   • Tighten the nuts to 63 Nm (46 lb-ft).
   • Tighten the bolt to 80 Nm (59 lb-ft).

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1. 33.
   
   Install the 4 transmission support insulator-to-frame rail bolts.
   • Tighten the 2 bottom bolts to 55 Nm (41 lb-ft).
   • Tighten the 2 top bolts to 70 Nm (52 lb-ft).

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NOTE: RH shown, LH similar.
1. 34.
   Align the subframe and install the new front subframe bolts.
   • Tighten to 200 Nm (148 lb-ft).

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NOTE: RH shown, LH similar.
1. 35.
   Install the rear subframe brackets and the new subframe bracket-to-body bolts.
   • Finger tight at this stage.

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NOTE: RH shown, LH similar.
1. 36.
   Install the new subframe bracket bolts.
   • Tighten to 150 Nm (111 lb-ft).

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NOTE: RH shown, LH similar.
1. 37.
   Tighten the subframe bracket-to-body bolts to 55 Nm (41 lb-ft).

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1. 38.
   
   Remove the ratchet strap from the front of the subframe to the rear of the subframe.

1. 39.
   
   Remove the Adjustable Grip Arm and the powertrain lift table.

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NOTE: LH shown, RH similar.
1. 40.
   Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.
   • Tighten to 250 Nm (184 lb-ft).

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NOTE: LH shown, RH similar.
1. 41.
   Install the brake caliper and the guide pin bolts.
   • 432 mm (17 in) brakes: Tighten to 72 Nm (53 lb-ft).
   • 457 mm (18 in) brakes: Tighten to 75 Nm (55 lb-ft).

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NOTE: Apply the brake to keep the halfshaft from rotating.
NOTE: LH shown, RH similar.
NOTE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
1. 42.
   Using the previously removed wheel hub nut, seat the LH and RH halfshafts.
   • Tighten to 350 Nm (258 lb-ft).
   • Remove and discard the wheel hub nuts.

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NOTE: Apply the brake to keep the halfshaft from rotating.
NOTE: LH shown, RH similar.
NOTE: The wheel hub nut contains a one time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.
1. 43.
   Install a new wheel hub nuts.
   • Tighten to 350 Nm (258 lb-ft).

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NOTE: LH shown, RH similar.
1. 44.
   Install the new upper stabilizer link nut.
   • Tighten to 150 Nm (111 lb-ft).

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NOTE: LH shown, RH similar.
1. 45.
   Install the wheel speed sensor and the bolt.
   • Tighten to 15 Nm (133 lb-in).

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1. 46.
   
   Connect the transaxle cooler tubes and install the 2 secondary latches.

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1. 47.
   
   If equipped, install the oil cooler hose retainer to the subframe.

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1. 48.
   
   If equipped, connect the oil cooler coolant hoses.

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1. 49.
   
   If equipped, connect the 2 PTU cooler hoses. For additional information, REFER to Fuel System General Information .

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1. 50.
   
   Install the 4 oil pan-to-transaxle bolts.
   • Tighten to 48 Nm (35 lb-ft).

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1. 51.
   
   Install 3 new torque converter bolts by rotating the crankshaft clockwise.
   • Tighten to 55 Nm (41 lb-ft).

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1. 52.
   
   Install the inspection cover and the 2 fasteners.

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NOTE: Do not lubricate the engine oil filter gasket.
1. 53.
   Install a new engine oil filter.
   • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

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1. 54.
   
   Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.
   • Tighten to 70 Nm (52 lb-ft).

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1. 55.
   
   Install the exhaust Y-pipe. For additional information, REFER to Exhaust System .

NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, REFER to Supplemental Restraint System .
1. 56.
   Align and connect the steering column shaft to the steering gear and install the bolt.
   • Tighten to 20 Nm (177 lb-in).

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1. 57.
   
   Install the underbody air duct and the 3 twist lock retainers.

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1. 58.
   
   If equipped, attach the engine block heater harness to the radiator support.

1. 59.
   
   Connect the transaxle control cable to the shift cable bracket.

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1. 60.
   
   Connect the transaxle control cable to the control lever.

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1. 61.
   
   Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.

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1. 62.
   
   Install the ground wire to the RH shock tower and install the bolt.
   • Tighten to 10 Nm (89 lb-in).

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1. 63.
   
   Install the engine wiring harness retainer to the bulkhead.
   • Slide the wiring harness in the bulkhead.
   • Make sure the wiring harness retainer tab is below the bulkhead lip.

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1. 64.
   
   Connect the engine harness electrical connector.
   • Attach the wiring harness retainer.

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1. 65.
   
   Connect the 2 PCM electrical connectors.

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1. 66.
   
   Connect the EVAP tube and the fuel supply tube quick connect coupling. REFER to Fuel System General Information .

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1. 67.
   
   Connect the brake booster vacuum hose to the upper intake manifold.

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1. 68.
   
   Connect the degas bottle coolant hose to the engine coolant tube.

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1. 69.
   
   Install the degas bottle. REFER to Engine Cooling .

1. 70.
   
   Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
   • Tighten to 15 Nm (133 lb-in).

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1. 71.
   
   Connect the A/C pressure switch electrical connector.

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1. 72.
   
   Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.
   • Tighten to 15 Nm (133 lb-in).

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1. 73.
   
   Install the accessory drive belt. REFER to Accessory Drive .

NOTE: RH shown, LH similar.
1. 74.
   Install the 2 RH and 2 LH lower pin-type retainers for the engine splash shields.

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1. 75.
   
   Install the front wheels and tires. REFER to Wheels and Tires .

1. 76.
   
   Connect the engine wiring harness electrical connector.

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1. 77.
   
   Install the ground wire and install the retainer.
   • Tighten to 10 Nm (89 lb-in).

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1. 78.
   
   Install the ground wire and the retainer.
   • Tighten to 10 Nm (89 lb-in).

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1. 79.
   
   Connect the 2 battery feed cables to the positive battery terminal and install the nut.
   • Tighten to 5 Nm (44 lb-in).

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1. 80.
   
   Install the battery tray. REFER to Battery, Mounting and Cables .

1. 81.
   
   Install the engine ACL and ACL outlet pipe. REFER to Intake Air Distribution and Filtering .

1. 82.
   
   Install the cowl panel. REFER to Front End Body Panels .

1. 83.
   
   Fill the engine with clean engine oil.

1. 84.
   
   Fill and bleed the cooling system. REFER to Engine Cooling .

1. 85.
   
   Recharge the A/C system. REFER to Climate Control DATC .

1. 86.
   
   Perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.