Engine - 2.3L - (Except Hybrid): Other Ford Escape I рестайлинг

Valve Clearance Check

1. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-232194-S28667222292006051600000) .
2. Use a feeler gauge to measure the clearance of each valve and record its location.
3. Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location.
4. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(ref-232194-S34962498422006051600000) and «VALVE TAPPETS»(ref-232194-S07656012862006051600000) .

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1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-232221) .
3. Remove the throttle body. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.3L»(ref-232221) .
4. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(ref-232194-S37696991442006051600000) .
5. Disconnect the intake manifold vacuum hose and pin-type retainer. Position the vacuum hose aside.
6. Disconnect the power brake booster vacuum tube. Depress the quick release locking ring. Pull the vacuum tube out of the quick release fitting.
7. Disconnect the fuel vapor return hose from the intake manifold.
8. Remove the 3 bolts and position the accelerator cable bracket aside. To install, tighten to 10 Nm (89 lb-in).
9. Disconnect the idle air control (IAC) motor electrical connector.
10. Disconnect the swirl control valve electrical connector.
11. Disconnect the knock sensor (KS) electrical connector. Detach the electrical connector pin-type retainer.
12. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
13. Disconnect the oil pressure sender electrical connector. Detach the wiring harness pin-type retainer and position the wiring harness aside.
14. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube. To install, tighten to 18 Nm (13 lb-ft).
15. Release the clamp and disconnect the crankcase vent hose.
16. Remove the exhaust gas recirculation (EGR) tube. To install, tighten to 55 Nm (41 lb-ft).
17. Remove the intake manifold and gaskets.
18. To install, reverse the removal procedure. Inspect and install new intake manifold gaskets if necessary.

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Engine Block

For engine block, crankshaft and piston assembly installation procedures, refer to ENGINE BLOCK - 2.3L .

Engine (Except Block)

SPECIAL TOOL DESCRIPTION Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Alignment Plate, Camshaft 303 - 465 (T94P-6256-CH) Timing Peg, Crankshaft 303 - 507 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Adapter for 205-126 (205-072-02) Installer, Front Oil Seal 303-096 (T74P-6150-A) Installer, Crankshaft Rear Main Oil Seal 303 - 328 (T88P-6701-B1) Aligner, Clutch Disc 308-006 (T71P-7137-H)

Scheme 182

MATERIAL SPECIFICATIONS

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1. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
2. Remove the engine plug bolt.
3. Install the special tool.
4. If removed, install the halfshaft support bracket and bolts. Tighten to 40 Nm (30 lb-ft).
5. Install the oil pump assembly. Tighten the bolts in the sequence shown in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft).
6. Install a new oil pump pickup tube gasket and the pickup tube. Tighten to 10 Nm (89 lb-in).
7. Using the special tool, install the crankshaft rear main oil seal.
8. Tighten the crankshaft rear main oil seal bolts in the sequence shown. To install, tighten to 10 Nm (89 lb-in).
9. Clean and inspect all mating surfaces.
10. Apply a 2.5-mm (0.09-in.) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
11. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
12. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
13. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
14. Apply silicone gasket and sealant to the locations shown.
15. Install a new head gasket.
16. Install new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (11 lb-ft). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
17. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (12 lb-ft).
18. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block.
19. Install the oil pump chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
20. Install the oil pump chain guide and the shoulder bolts. Tighten to 10 Nm (89 lb-in).
21. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
22. Install the special tool in the slots on the rear of both camshafts.
23. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
24. Install the LH timing chain guide and the bolts. Tighten to 10 Nm (89 lb-in).
25. Install the timing chain.
26. Install the RH timing chain guide.
27. Using the edge of a vise, compress the timing chain tensioner plunger.
28. Using a small pick, push back and hold the ratchet mechanism.
29. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
30. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
31. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
32. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. To install, tighten to 65 Nm (48 lb-ft).
33. Clean and inspect the mounting surfaces of the engine and the front cover.
34. Apply a 2.5-mm (0.09-in.) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5-mm (0.09-in.) bead of silicone gasket and sealant to the front cover.
35. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
36. Using the special tool, install a new crankshaft front oil seal.
37. Install the crankshaft pulley and hand-tighten the bolt.
38. Install a standard 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
39. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
40. Remove the 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt.
41. Remove the special tool.
42. Remove the special tool.
43. Turn the engine 2 complete revolutions.
44. Turn the crankshaft until the No. 1 piston is at top dead center (TDC).
45. Install the special tool.
46. Using the 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
47. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
48. Install a new CKP sensor. Do not tighten the bolts at this time.
49. Adjust the CKP sensor alignment jig and tighten the bolts. Tighten to 7 Nm (62 lb-in).
50. Remove the 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt.
51. Install the engine plug bolt.
52. Clean the valve cover gasket surface with metal surface cleaner.
53. Apply silicone gasket and sealant to the locations shown.
54. Install the valve cover. Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
55. Install a new cylinder head temperature (CHT) sensor and the spark plugs. Tighten the CHT sensor to 12 Nm (9 lb-ft). Tighten the spark plugs to 15 Nm (11 lb-ft).
56. Install the coil-on-plugs, bolts and the crankcase vent tube. Tighten to 10 Nm (89 lb-in).
57. If equipped, install the block heater. Tighten to 21 Nm (15 lb-ft).
58. Install the crankcase vent oil separator and the KS. Tighten the oil separator bolts to 10 Nm (89 lb-in). Tighten the KS to 20 Nm (15 lb-ft).
59. Install the coolant hoses.
60. Install the coolant hose.
61. Install the coolant hose.
62. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
63. Attach the wiring harness retainer.
64. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
65. Connect the exhaust gas recirculation (EGR) valve and radio interference capacitor electrical connectors. Attach the wiring harness retainer.
66. Attach the wiring harness retainer.
67. Install new fuel injector O-rings. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
68. Position the fuel rail spacers.
69. Install the fuel rail with the fuel injectors and bolts. Tighten to 25 Nm (18 lb-ft).
70. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
71. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
72. Position the intake manifold and connect the positive crankcase ventilation hose.
73. Install the intake manifold gaskets and intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
74. Connect the throttle position (TP) sensor electrical connector.
75. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
76. Connect the swirl control valve electrical connector.
77. Connect the idle air control (IAC) motor electrical connector.
78. Connect the temperature manifold absolute pressure (TMAP) electrical connector.
79. Connect the KS and attach the 2 wiring harness retainers.
80. Attach the 2 wiring harness retainers.
81. If removed, install the capacitor and bolt. Tighten to 20 Nm (15 lb-ft).
82. Position the oil filter adapter in a vise and install the oil filter, new oil cooler and oil cooler bolt. Tighten the oil cooler bolt to 34 Nm (25 lb-ft). Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
83. Install the oil filter adapter with a new gasket and bolts. Tighten to 25 Nm (18 lb-ft).
84. Connect the oil pressure sensor electrical connector.
85. Install the oil level indicator and bolts. Tighten to 10 Nm (89 lb-in).
86. Install the thermostat housing and bolts. Tighten to 10 Nm (89 lb-in).
87. Connect the oil cooler hoses.
88. Attach the 2 wiring harness retainers.
89. Install the engine vacuum tube. Connect the engine vacuum tube. Attach the 2 engine vacuum tube retainers.
90. Install the coolant pump and bolts. Tighten to 10 Nm (89 lb-in).
91. Install the coolant pump pulley and bolts. Tighten to 25 Nm (18 lb-ft).
92. If equipped, install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
93. Install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
94. Install the generator and bolts. Tighten to 47 Nm (35 lb-ft).
95. Position a new exhaust manifold gasket on the engine.
96. Position the catalytic converter and tighten the 7 exhaust manifold nuts in the sequence shown. Stage 1: Tighten to 47 Nm (35 lb-ft). Stage 2: Tighten to 47 Nm (35 lb-ft).
97. Install the heat shield and the 6 bolts. Tighten to 10 Nm (89 lb-in).
98. Install the 2 catalytic converter bracket bolts. Tighten to 25 Nm (18 lb-ft).
99. Connect the generator electrical connections and install the nut. Tighten to 6 Nm (53 lb-in).
100. Connect the CKP sensor electrical connector.
101. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
102. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
103. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
104. Install the starter motor isolator.
105. Lubricate the transaxle input shaft pilot bearing with front axle grease.
106. Using the special tool, position the clutch disc on the flywheel.
107. Position the clutch pressure plate and install the bolts. Tighten to 27 Nm (20 lb-ft) in a star pattern sequence.

Engine - Automatic Transaxle

SPECIAL TOOL DESCRIPTION Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Powertrain Lift 014-00765 Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

MATERIAL SPECIFICATIONS

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1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
2. Install new torque converter nuts. Tighten to 35 Nm (26 lb-ft).
3. Install the starter motor isolator.
4. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
5. Using the special tools, secure the engine to the lift table.
6. Raise the engine and transaxle into the vehicle.
7. Install the bolt in the LH transaxle mount. Tighten to 103 Nm (76 lb-ft).
8. Install the bolt in the rear transaxle mount. Tighten to 115 Nm (85 lb-ft).
9. Install the engine mount bracket. Tighten to 90 Nm (66 lb-ft).
10. Install the engine mount bracket bolt. Tighten to 90 Nm (66 lb-ft).
11. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the engine support crossmember and nut. Tighten to 175 Nm (129 lb-ft).
14. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt. Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft). Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
15. Position the power steering pump and install the bolts. Tighten to 25 Nm (18 lb-ft).
16. Connect the power steering pressure (PSP) sensor electrical connector.
17. Install the A/C compressor and connect the A/C compressor electrical connector. Tighten the bolts to 25 Nm (18 lb-ft).
18. Connect the lower radiator hose to the radiator.
19. Install the 2 power steering pump bolts. Tighten to 25 Nm (18 lb-ft).
20. Install the ground wire and bolt. Tighten to 10 Nm (89 lb-in).
21. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut. Tighten to 8 Nm (71 lb-in).
22. Attach the electrical connector retainers.
23. Connect the fuel supply tube.
24. Connect the vacuum reservoir tube.
25. Connect the fuel vapor return tube and retainer.
26. Connect the vacuum supply tube.
27. Install the power steering tube, bracket and nut. Tighten to 6 Nm (53 lb-in).
28. Position the accelerator control cable and bracket and install the nut. Tighten to 6 Nm (53 lb-in).
29. Install the accelerator control cable and bracket and nut. Tighten to 6 Nm (53 lb-in).
30. Install the accelerator cable and speed control cable (if equipped). Connect the accelerator and speed control cable (if equipped) to the throttle body. Install the accelerator cable bracket and bolts. Tighten to 10 Nm (89 lb-in).
31. Install the accelerator cable snow shield and retainers. Tighten to 10 Nm (89 lb-in).
32. Connect the heater hoses to the heater core.
33. Attach the heater hose support strap to the stud.
34. Position the coolant vent hose and install the coolant vent hose brackets and nuts. Tighten to 10 Nm (89 lb-in).
35. Connect the upper radiator and coolant vent hoses.
36. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
37. Attach the transaxle control harness to the retaining clip.
38. Install the output shaft speed (OSS) sensor and bolt. Tighten to 13 Nm (10 lb-ft).
39. Install the fluid cooler tube. Connect the OSS sensor. Connect the turbine shaft speed (TSS) sensor (white connector). Position the bracket and install the bolt. Tighten 13 Nm (10 lb-ft). Position the fluid cooler tube. Tighten to 23 Nm (17 lb-ft).
40. Connect the rear transmission fluid cooler tube.
41. Connect the front transmission fluid cooler tube. Tighten to 23 Nm (17 lb-ft).
42. Attach the transaxle control harness to the brackets.
43. Connect the transmission range (TR) sensor electrical connector.
44. Install the transaxle control cable, bracket and bolts. Tighten to 19 Nm (14 lb-ft). Attach the wiring harness pin-type retainers.
45. Connect the shift cable to the transaxle manual lever.
46. Connect the transaxle electrical connector.
47. Attach the wiring harness retainers to the battery tray bracket.
48. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt. Tighten to 10 Nm (89 lb-in).
49. Connect the electrical connector to the power distribution box.
50. Connect the cables and install the nuts. Tighten to 12 Nm (9 lb-ft).
51. Install the power distribution box cover.
52. If equipped, install the ground eyelet and bolt. Tighten to 10 Nm (89 lb-in).
53. Install the front drive intermediate halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
54. Install the lateral support crossmember and bolts. Tighten to 115 Nm (85 lb-ft).
55. Install the transfer case. For additional information, refer to «TRANSFER CASE-POWER TRANSFER UNIT (PTU)»(ref-232190) .
56. Install the LH front drive halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
57. Install the generator shield and the nut and the pin-type retainer and attach the wire retainers. Tighten to 20 Nm (15 lb-ft).
58. Install the lower air duct and install the bolt. Tighten to 4 Nm (35 lb-in).
59. Install the accessory drive belt tensioner. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-232224) .
60. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
61. Install the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-232210) .
62. Install the starter. For additional information, refer to «STARTING SYSTEM»(ref-232203) .
63. Install the battery tray and battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-232248) .
64. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-232204) .
65. Fill the engine with clean engine oil.
66. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207) .

Engine - Manual Transaxle

SPECIAL TOOL DESCRIPTION Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Powertrain Lift 014-00765 Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

MATERIAL SPECIFICATIONS

1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
3. Using the special tools, secure the engine to the lift table.
4. Raise the engine and transaxle into the vehicle.
5. Install the bolt in the LH transaxle mount. Tighten to 103 Nm (76 lb-ft).
6. Install the bolt in the rear transaxle mount. Tighten 115 Nm (85 lb-ft).
7. Install the engine mount bracket and nuts. Tighten 90 Nm (66 lb-ft).
8. Install the engine mount bracket bolt. Tighten to 90 Nm (66 lb-ft).
9. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
10. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
11. Install the engine support crossmember and nut. Tighten to 175 Nm (129 lb-ft).
12. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt. Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft) Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
13. Position the power steering pump and install the bolts. Tighten to 25 Nm (18 lb-ft).
14. Connect the power steering pressure (PSP) sensor electrical connector.
15. Install the A/C compressor and connect the A/C compressor electrical connector. Tighten the bolts to 25 Nm (18 lb-ft).
16. Connect the lower radiator hose to the radiator.
17. Install the 2 power steering pump bolts. Tighten to 25 Nm (18 lb-ft).
18. Install the ground wire and bolt. Tighten to 10 Nm (89 lb-in).
19. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut. Tighten to 8 Nm (71 lb-in).
20. Attach the electrical connector retainers.
21. Connect the fuel supply tube.
22. Connect the vacuum reservoir tube.
23. Connect the fuel vapor return tube and retainer.
24. Connect the vacuum supply tube.
25. Install the power steering tube, bracket and nut. Tighten to 6 Nm (53 lb-in).
26. Position the accelerator control cable and bracket and install the nut. Tighten to 6 Nm (53 lb-in).
27. Install the accelerator control cable and bracket and nut. Tighten to 6 Nm (53 lb-in).
28. Install the accelerator cable and speed control cable (if equipped). Connect the accelerator and speed control cable (if equipped) to the throttle body. Install the accelerator cable bracket and bolts. Tighten to 10 Nm (89 lb-in).
29. Install the accelerator cable snow shield and retainers. Tighten to 10 Nm (89 lb-in).
30. Connect the heater hoses to the heater core.
31. Attach the heater hose support strap to the stud.
32. Position the coolant vent hose and install the coolant vent hose brackets and nuts. Tighten to 10 Nm (89 lb-in).
33. Connect the upper radiator and coolant vent hoses.
34. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
35. Connect the reversing lamp indicator switch and attach the wiring harness retainers.
36. Connect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
37. Connect the transaxle control cable and install the retaining clips.
38. Connect the transaxle control cable and install the retaining clips.
39. Connect the clutch hydraulic tube fitting. Position the clutch hydraulic tube, attach the spring clip and tighten the mounting bolt to 3 Nm (27 lb-in).
40. Attach the wiring harness retainers to the battery tray bracket.
41. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt. Tighten to 10 Nm (89 lb-in).
42. Connect the electrical connector to the power distribution box.
43. Connect the cables and install the nuts. Tighten to 12 Nm (9 lb-ft).
44. Install the power distribution box cover.
45. If equipped, install the ground eyelet and bolt. Tighten to 10 Nm (89 lb-in).
46. Install the driveshaft and bolts. Tighten to 20 Nm (15 lb-ft).
47. Install the front drive intermediate halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
48. Install the LH front drive halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
49. Install the lateral support crossmember and bolts. Tighten to 115 Nm (85 lb-ft).
50. Install the generator shield and the nut and the pin-type retainer and attach the wire retainers. Tighten to 20 Nm (15 lb-ft).
51. Install the lower air duct and install the bolt. Tighten to 4 Nm (35 lb-in).
52. Install the accessory drive belt tensioner. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-232224) .
53. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
54. Install the exhaust flex pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-232210) .
55. Install the starter. For additional information, refer to «STARTING SYSTEM»(ref-232203) .
56. Install the battery tray and battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-232248) .
57. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-232204) .
58. Fill the engine with clean engine oil.
59. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207) .
60. Bleed the clutch system. For additional information, refer to «MANUAL TRANSAXLE-TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-232252) .