Engine Mechanical - 2.0L: Overhaul Ford Focus II facelift

DISASSEMBLY

Note. If the components are to be reinstalled, mark the location of the components removed, they must be installed in the same location.

1. Remove the 4 bolts and the coolant outlet. Discard the gasket.
2. Remove the 2 bolts and the EGR valve. Discard the gasket.
3. Remove the Cylinder Head Temperature (CHT) sensor.
4. Remove the EGR tube.
5. Remove the spark plugs.
6. Using the Valve Spring Compressors, compress the valve spring and remove the valve spring collets, the valve spring retainers and the valve springs.
7. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article.
8. Remove the valves.
9. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seals.
10. Inspect the valves. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-357133) article. Install new parts, as necessary.

ASSEMBLY

1. Install the valves.
2. Lubricate the valve stems and guides with clean engine oil and, using the Valve Stem Oil Seal Installer, install the valve seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the Valve Spring Compressors, compress the valve spring and install the valve collets.
5. Install the spark plugs. Tighten to 12 Nm (106 lb-in).
6. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
7. Install the CHT sensor. Tighten to 12 Nm (106 lb-in).
8. Using a new gasket, install the EGR valve, and the 2 bolts. Tighten to 20 Nm (177 lb-in).
9. Using a new gasket, install the coolant outlet and the 4 bolts. Tighten to 10 Nm (89 lb-in).

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

Scheme 22

GENERAL EQUIPMENT

MATERIAL

Scheme 23

Scheme 24

Scheme 25

Scheme 26

All engines

1. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
2. Remove the engine plug bolt.
3. Install the Crankshaft TDC Timing Peg.
4. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
5. Using a new oil pump pickup tube gasket, install the pickup tube and bolts. Tighten to 10 Nm (89 lb-in).
6. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear seal.
7. Tighten the 6 crankshaft rear seal with retainer plate bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
8. Clean and inspect all mating surfaces.
9. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
10. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
11. Install the remaining 13 oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration 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 in the following sequence. 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 in illustration.
15. Install a new cylinder head gasket.
16. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (177 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
17. Install the valve tappets.
18. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten one turn at a time until tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
19. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block.
20. Install the oil pump chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
21. Install the oil pump chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
22. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
23. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
24. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
25. Install the LH timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
26. Install the timing chain.
27. Install the RH timing chain guide.
28. Using the edge of a vise, compress the timing chain tensioner plunger.
29. Using a small pick, push back and hold the ratchet mechanism.
30. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
31. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
32. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
33. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts to 72 Nm (53 lb-ft).
34. Clean and inspect the mounting surfaces of the engine and the front cover.
35. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
36. Install the engine front cover. Tighten the 22 bolts in the sequence shown in illustration 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).
37. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.
38. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
39. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
40. Assemble the Drive Pinion Flange Holding Fixture and Adapter using 4 hardened washers in the locations shown in illustration.
41. Install a new crankshaft pulley bolt. Using the Drive Pinion Flange Holding Fixture and Adapter 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 (one-fourth turn).
42. Remove the 6 mm x 18 mm bolt.
43. Remove the Crankshaft TDC Timing Peg.
44. Remove the Camshaft Alignment Plate.
45. Turn the crankshaft clockwise one and three-fourths turn.
46. Install the Crankshaft TDC Timing Peg.
47. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
48. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected.
49. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
50. Remove the Camshaft Alignment Plate.
51. Install the Crankshaft Position (CKP) sensor and the 2 bolts. Do not tighten the bolts at this time.
52. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
53. Remove the 6 mm x 18 mm bolt.
54. Remove the Crankshaft TDC Timing Peg.
55. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
56. Clean the valve cover gasket surface with metal surface prep.
57. Apply silicone gasket and sealant to the locations shown in illustration.
58. Install the valve cover. Tighten the 14 bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
59. Install the Cylinder Head Temperature (CHT) sensor and the spark plugs. Tighten the CHT sensor to 12 Nm (106 lb-in). Tighten the spark plugs to 12 Nm (106 lb-in).
60. Install the 4 ignition coil-on-plugs and the 4 bolts. Tighten to 10 Nm (89 lb-in).
61. If equipped, install the engine block heater. Tighten to 21 Nm (15 lb-ft).
62. Install the crankcase vent oil separator and the 8 bolts. Tighten to 10 Nm (89 lb-in).
63. Install the KS and the bolt. Tighten to 20 Nm (177 lb-in).
64. Install the A/C compressor, 2 bolts and the stud bolt. Tighten to 25 Nm (18 lb-ft).
65. Install the thermostat housing and 3 bolts. Tighten to 10 Nm (89 lb-in).
66. Connect the coolant bypass hose.
67. Using a new gasket, install the coolant outlet and the 4 bolts. Tighten to 10 Nm (89 lb-in).
68. Connect the coolant bypass hose.
69. Connect the EGR valve coolant hose.
70. Install the radio interference capacitor bracket and bolt. Tighten to 10 Nm (89 lb-in).
71. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
72. Inspect and install new intake manifold gaskets if necessary.
73. Position the intake manifold and connect the PCV hose.
74. Install the intake manifold and hand-tighten the 2 intake manifold bolts.
75. Install the 5 intake manifold mounting bolts. Tighten all 7 bolts to 18 Nm (159 lb-in).
76. Install the lower intake manifold bolt. Tighten to 18 Nm (159 lb-in).
77. Using a new O-ring seal, install the oil level indicator tube assembly and the bolt. Tighten to 10 Nm (89 lb-in).
78. Connect the EGR valve electrical connector and if equipped, connect the swirl control valve sensor electrical connector.
79. If equipped, connect the swirl control valve solenoid electrical connector.
80. Connect the Manifold Absolute Pressure (MAP) electrical connector.
81. Connect the KS electrical connector and pin-type retainer.
82. 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.
83. Install the fuel rail with the fuel injectors and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
84. Connect the 4 fuel injector electrical connectors and attach the wiring harness retainers to valve cover stud bolts and intake manifold.
85. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
86. Connect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
87. Using a new gasket, install the oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
88. Connect the Engine Oil Pressure (EOP) switch electrical connector.
89. Connect the heater hose and lower radiator hose to the thermostat housing.
90. Position the coolant pump and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
91. Install the coolant pump pulley and 3 bolts. Tighten to 20 Nm (177 lb-in).
92. Install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
93. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
94. Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in illustration 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).
95. Lubricate the transaxle input shaft pilot bearing with front axle grease.
96. Using the Clutch Disc Aligner, position the clutch disc on the flywheel.
97. Position the clutch pressure plate and install the 7 bolts. Tighten the bolts in a star pattern sequence to 27 Nm (20 lb-ft).

Engine - Automatic Transaxle

SPECIAL TOOLS Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent

Scheme 27

MATERIAL

1. Check the installation depth of the torque converter. Lay a straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 bellhousing-to-engine fasteners. Tighten to 48 Nm (35 lb-ft).
3. Using the Heavy Duty Floor Crane, Engine Lifting Bracket and Spreader Bar, raise the engine and transaxle assembly onto the lift table.
4. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine and transaxle assembly to the lift table.
5. Install the 7 new catalytic converter manifold studs. Tighten to 17 Nm (150 lb-in).
6. Install the 4 torque converter nuts. Tighten to 35 Nm (26 lb-ft).
7. Install the starter motor isolator.
8. Install the starter motor, stud bolt and the bolt. Install the upper bolt and lower stud bolt finger-tight. Tighten the upper bolt to 35 Nm (26 lb-ft). Tighten the lower stud bolt to 35 Nm (26 lb-ft).
9. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.
10. Install the engine ground wire and the bolt. Tighten to 48 Nm (35 lb-ft).
11. Install the power steering tube bracket on the starter motor stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
12. Attach the starter wire harness retainer to the starter motor stud bolt.
13. Connect the starter motor electrical terminals and install the 2 nuts. Tighten the small nut to 5 Nm (44 lb-in). Tighten the large nut to 12 Nm (106 lb-in).
14. Connect the Crankshaft Position (CKP) sensor electrical connector.
15. Attach the 2 CKP sensor wire harness retainers.
16. Connect the Power Steering Pressure (PSP) switch electrical connector.
17. Connect the A/C compressor electrical connector.
18. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
19. Connect the Output Shaft Speed (OSS) sensor electrical connector.
20. Position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket and install the nut. Tighten to 25 Nm (18 lb-ft).
21. Install the nut for the HO2S and CMS wire connector bracket. Tighten to 25 Nm (18 lb-ft).
22. Using the lift table, position the engine and transaxle assembly in the vehicle.
23. Install the transaxle mount plate and the 5 nuts. Tighten the center nut to 150 Nm (111 lb-ft). Tighten the 4 outer nuts to 48 Nm (35 lb-ft).
24. Install the engine mount and the 2 bolts and the stud bolt. Tighten to 48 Nm (35 lb-ft).
25. Install the 2 motor mount nuts. Tighten to 90 Nm (66 lb-ft).
26. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
27. Install the 2 lower bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
28. Install the transaxle roll restrictor and the 2 bolts. Install the transaxle roll restrictor. Install the short bolt. Install the long bolt. Tighten to 70 Nm (52 lb-ft).
29. Position the transaxle fluid indicator tube and install the bolt. Tighten to 8 Nm (71 lb-in).
30. Install the transaxle fluid indicator tube bracket bolt. Tighten to 8 Nm (71 lb-in).
31. Attach the wire harness retainer to the transaxle fluid indicator tube.
32. Install the transaxle fluid indicator.
33. Connect the throttle control electrical connector.
34. Connect the heater hose to the coolant tube.
35. Connect the upper radiator hose, the heater hose to the coolant bypass.
36. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-357172) article.
37. Clean and inspect the catalytic converter flange. Using a straightedge and feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
38. Using a new gasket and 7 new nuts, install the catalytic converter and tighten in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 55 Nm (41 lb-ft). Stage 2: Tighten to 55 Nm (41 lb-ft).
39. Install the heat shield and 6 bolts. Tighten to 11 Nm (97 lb-in).
40. Install the catalytic converter support bracket and the 2 bolts. Tighten to 22 Nm (16 lb-ft).
41. Install the 2 catalytic converter support bracket-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
42. Using a new gasket and 2 new nuts, connect the flexpipe to the muffler and tail pipe assembly. Tighten to 48 Nm (35 lb-ft).
43. Using 2 new O-ring seals, install the power steering tubes to the steering gear and install the bolt. Tighten to 18 Nm (159 lb-in).
44. Install the power steering tube clip and the bolt.
45. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-357140) article.
46. Install a new engine oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
47. Connect the lower radiator hose to the radiator.
48. Install the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
49. Using 2 new O-ring seals, connect the A/C tubes to the compressor.
50. Install the A/C tube bracket to the A/C compressor stud bolt and install the nut. Tighten to 10 Nm (89 lb-in).
51. Install the 2 A/C tube nuts. Tighten to 15 Nm (133 lb-in).
52. Position and attach the 4 B+ battery cable wire harness retainers (2 shown in illustration).
53. Install the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-357135) article.
54. Install the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) article.
55. Install the splash shield and the retainers.
56. Install the 2 front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-357130) article.
57. Install the radio capacitor ground cable and the bolt. Tighten to 10 Nm (89 lb-in).
58. Install the engine oil level indicator.
59. Attach the shift cable to the retainer.
60. Connect the 2 transaxle electrical connectors.
61. Install the transmission fluid cooler tubes on the transaxle and slide the latches to the locked position.
62. Install the secondary latches.
63. Connect the transaxle shift cable to the lever and bracket.
64. Connect the HO2S and CMS electrical connectors and attach the wire harness retainer.
65. Connect the starter wire harness electrical connector.
66. Connect the 3 PCM electrical connectors.
67. Attach the engine harness to the coolant outlet bracket harness retainer.
68. Connect and attach the 2 engine harness electrical connectors.
69. Attach the brake booster vacuum hose retainer.
70. Install the power brake booster vacuum tube into the quick connect fitting.
71. Position and connect the Evaporative Emission (EVAP) tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
72. Connect the fuel tube quick connect coupling to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
73. Install the negative battery cable ground and the bolt. Tighten to 6 Nm (53 lb-in).
74. Attach the 2 positive battery cable wire harness retainer.
75. Connect the positive battery cable nut. Tighten to 10 Nm (89 lb-in).
76. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-357167) article.
77. Connect the crankcase vent tube to the valve cover.
78. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-357190) article.
79. Fill the engine with clean engine oil.
80. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
81. Evacuate and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-357136) article.

Engine - Manual Transaxle

SPECIAL TOOLS Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent

MATERIAL

1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 7 bellhousing-to-engine fasteners. Tighten to 48 Nm (35 lb-ft).
2. Using the Heavy Duty Floor Crane, Engine Lifting Bracket and Spreader Bar, raise the engine and transaxle assembly onto the lift table.
3. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine and transaxle assembly to the lift table.
4. Install the 7 new catalytic converter manifold studs. Tighten to 17 Nm (150 lb-in).
5. Install the starter motor isolator.
6. Install the starter motor, stud bolt and the bolt. Install the upper bolt and lower stud bolt finger-tight. Tighten the upper bolt to 35 Nm (26 lb-ft). Tighten the lower stud bolt to 35 Nm (26 lb-ft).
7. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.
8. Install the engine ground wire and the bolt. Tighten to 48 Nm (35 lb-ft).
9. Install the power steering tube bracket on the starter motor stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
10. Attach the starter wire harness retainer to the starter motor stud bolt.
11. Connect the starter motor electrical terminals and install the 2 nuts. Tighten the small nut to 5 Nm (44 lb-in). Tighten the large nut to 12 Nm (106 lb-in).
12. Connect the Crankshaft Position (CKP) sensor electrical connector.
13. Attach the 2 CKP sensor wire harness retainers.
14. Connect the Power Steering Pressure (PSP) switch electrical connector.
15. Connect the A/C compressor electrical connector.
16. Connect the reversing lamp switch electrical connector.
17. Connect the Vehicle Speed Sensor (VSS) electrical connector.
18. Position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket and install the nut. Tighten to 25 Nm (18 lb-ft).
19. Install the nut for the HO2S and CMS wire connector bracket. Tighten to 25 Nm (18 lb-ft).
20. Using the lift table, position the engine and transaxle assembly in the vehicle.
21. Install the transaxle mount plate and the 5 nuts. Tighten the center nut to 150 Nm (111 lb-ft). Tighten the 4 outer nuts to 48 Nm (35 lb-ft).
22. Install the engine mount and the 2 bolts and the stud bolt. Tighten to 48 Nm (35 lb-ft).
23. Install the 2 motor mount nuts. Tighten to 90 Nm (66 lb-ft).
24. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
25. Install the 2 lower bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
26. Install the transaxle roll restrictor and the 2 bolts. Install the transaxle roll restrictor. Install the short bolt. Install the long bolt. Tighten to 70 Nm (52 lb-ft).
27. Connect the throttle control electrical connector.
28. Connect the heater hose to the coolant tube.
29. Connect the upper radiator hose and the heater hose to the coolant bypass.
30. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-357172) article.
31. Clean and inspect the catalytic converter flange. Using a straightedge and a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
32. Using a new gasket and 7 new nuts, install the catalytic converter and tighten in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 55 Nm (41 lb-ft). Stage 2: Tighten to 55 Nm (41 lb-ft).
33. Install the heat shield and 6 bolts. Tighten to 11 Nm (97 lb-in).
34. Install the catalytic converter support bracket and the 2 bolts. Tighten to 22 Nm (16 lb-ft).
35. Install the 2 catalytic converter support bracket-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
36. Using a new gasket and 2 new nuts, connect the flexpipe to the catalytic converter. Tighten to 48 Nm (35 lb-ft).
37. Install 2 new O-ring seals and install the power steering tubes to the steering gear and install the bolt. Tighten to 18 Nm (159 lb-in).
38. Install the power steering tube clip and the bolt. Tighten to 10 Nm (89 lb-in).
39. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-357140) article.
40. Install a new engine oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
41. Connect the lower radiator hose to the radiator.
42. Install the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
43. Using 2 new O-ring seals, connect the A/C tubes to the A/C compressor.
44. Install the A/C tube bracket to the A/C compressor stud bolt and install the nut. Tighten to 10 Nm (89 lb-in).
45. Install the 2 A/C tube nuts. Tighten to 15 Nm (133 lb-in).
46. Position and attach the 4 B+ battery cable wire harness retainers (2 shown in illustration).
47. Install the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-357135) article.
48. Install the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE»(ref-357139) article.
49. Install the retainers and the splash shield.
50. Install the 2 front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-357130) article.
51. Install the radio capacitor ground cable and the bolt. Tighten to 10 Nm (89 lb-in).
52. Install the engine oil level indicator.
53. Connect the hydraulic clutch line and grommet to the retaining bracket.
54. Connect the clutch slave cylinder supply tube. Install the clip.
55. Attach the transaxle cables to the bracket. Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders. Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
56. Attach the gearshift cables. Attach the shifter cable to the shift mass. Attach the selector cable to the selector lever.
57. Adjust the gearshift cables. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-357197) article.
58. Connect the HO2S and CMS electrical connectors and attach the wire harness retainer.
59. Connect the starter wire harness electrical connector.
60. Connect the 3 PCM electrical connectors.
61. Attach the engine harness to the coolant outlet bracket harness retainer.
62. Connect and attach the 2 engine harness electrical connectors.
63. Attach the brake booster vacuum hose retainer.
64. Install the power brake booster vacuum tube into the quick connect fitting.
65. Position and connect the Evaporative Emission (EVAP) tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
66. Connect the fuel tube quick connect coupling to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-357165) article.
67. Install the negative battery cable ground and the bolt. Tighten to 6 Nm (53 lb-in).
68. Attach the 2 positive battery cable wire harness retainer.
69. Connect the positive battery cable nut. Tighten to 10 Nm (89 lb-in).
70. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-357167) article.
71. Connect the crankcase vent tube to the valve cover.
72. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-357190) article.
73. Fill the engine with clean engine oil.
74. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-357157) article.
75. Bleed the clutch system. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-357197) article.
76. Evacuate and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-357136) article.