Engine - 2.3L - (Except Hybrid): Other Mercury Mariner II

MATERIALS

MATERIALS

Valve Clearance Check

1. Remove the valve cover. For additional information, refer to «Valve Cover»(ref-292207-S16433314052008073100000) .
2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Use a feeler gauge to measure the clearance of each valve and record its location.
4. Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
5. 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-292207-S08158408372008073100000) and «Valve Tappets»(ref-292207-S02783269852008073100000) .

Scheme 26

Scheme 27

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number Adapter for 205-126 (205-072-02) Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Timing Peg, Crankshaft 303-507

Scheme 28

Material

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Installer, Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

Scheme 29

Material

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)

Scheme 30

Material

Engine Front Cover

Special Tools Illustration Tool Name Tool Number Installer, Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

Material

Scheme 31

Timing Drive Components

Material

Camshafts

Special Tools Illustration Tool Name Tool Number Timing Peg, Crankshaft 303-507 Alignment Plate, Camshaft 303-465 (T94P-6256-CH)

Material

Valve Springs

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

Scheme 32

Scheme 33

Material

Valve Seals

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Scheme 34

Scheme 35

Material

Valve Tappets

Material

Cylinder Head

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH)

Material

Scheme 36

Engine Oil Pressure (EOP) Switch

Material

Oil Pan

Material

Oil Pump

Material

Oil Level Indicator and Tube

Material

Scheme 37

Engine Mount

Special Tools Illustration Tool Name Tool Number Support Bar, Engine 303-F072

Scheme 38

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Material

Scheme 39

Engine Block

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

Engine (Except Block)

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, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Installer, Front Oil Seal 303-096 (T74P-6150-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft 303-507

Scheme 40

Material

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage may occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

All vehicles

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 special tool.
4. 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).
5. Install a new oil pump pickup tube gasket and the pickup tube. Tighten to 10 Nm (89 lb-in).
6. Using the special tool, install the crankshaft rear main oil seal.
7. Tighten the crankshaft rear oil seal retainer bolts in the sequence shown. To install, 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. Install the oil pan. Install the 2 oil pan bolts finger-tight.
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 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 the cylinder head and 10 new 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 in their original location and orientation. Tighten the bearing caps 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, new 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 tensioner shoulder bolt. 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 72 Nm (53 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. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
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.
39. Assemble the special tools using 4 hardened washers in the locations shown.
40. Install a new crankshaft pulley bolt. 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).
41. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
42. Remove the special tool.
43. Remove the special tool.
44. Turn the crankshaft clockwise 1 and 3/4 turns.
45. Install the special tool.
46. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
47. 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, the engine valve timing must be corrected.
48. Install the special tool to check the position of the camshafts. If it is not possible to install the special tool, the engine valve timing must be corrected.
49. Remove the special tool.
50. Install a new CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
51. Adjust the CKP sensor with the alignment tool. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
52. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
53. Remove the special tool.
54. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
55. Clean the valve cover gasket surface with metal surface cleaner.
56. Apply silicone gasket and sealant to the locations shown.
57. Install the valve cover. Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
58. 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 12 Nm (9 lb-ft).
59. Install the coil-on-plugs, stud bolts and the crankcase vent tube. Tighten to 8 Nm (71 lb-in).
60. If equipped, install the block heater. Tighten to 21 Nm (15 lb-ft).
61. 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).
62. Install the coolant hoses.
63. Install the coolant hose.
64. Install the coolant hose.
65. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
66. Attach the wiring harness retainer.
67. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
68. Connect the exhaust gas recirculation (EGR) valve electrical connectors. Attach the wiring harness retainer.
69. Attach the wiring harness retainer.
70. 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.
71. Install the fuel rail with the fuel injectors and stud bolts. Tighten to 23 Nm (17 lb-ft).
72. Install the radio capacitor and nut. Tighten to 10 Nm (89 lb-in).
73. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
74. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
75. Position the intake manifold and connect the positive crankcase ventilation hose.
76. Install the intake manifold gaskets and intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
77. Connect the throttle position (TP) sensor electrical connector.
78. Connect the radio capacitor electrical connector.
79. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
80. Connect the swirl control valve electrical connector.
81. Connect the idle air control (IAC) motor electrical connector.
82. Connect the manifold absolute pressure (MAP) electrical connector.
83. Connect the KS and attach the 2 wiring harness retainers.
84. Attach the 2 wiring harness retainers.
85. If removed, install the capacitor and bolt. Tighten to 20 Nm (15 lb-ft).
86. Install the oil filter adapter with a new gasket. Tighten to 25 Nm (18 lb-ft).
87. Install a new oil filter. Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
88. Connect the engine oil pressure (EOP) switch electrical connector.
89. Install the oil level indicator and bolt. Tighten to 10 Nm (89 lb-in).
90. Install the thermostat housing and bolts. Tighten to 10 Nm (89 lb-in).
91. Attach the 2 wiring harness retainers.
92. Install the coolant pump and bolts. Tighten to 10 Nm (89 lb-in).
93. Install the 3 coolant pump pulley and bolts. Tighten to 20 Nm (15 lb-ft).
94. Install the accessory drive belt idler pulley and bracket and the 3 bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
95. Install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
96. Install the generator, nut and bolts. Tighten to 47 Nm (35 lb-ft).
97. Install 7 new exhaust manifold studs in the cylinder head. Tighten to 17 Nm (13 lb-ft).
98. Install the new exhaust manifold gasket on the engine.
99. Position the catalytic converter and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages: Stage 1: Tighten to 47 Nm (35 lb-ft). Stage 2: Tighten to 47 Nm (35 lb-ft).
100. Install the heat shield and the 6 bolts. Tighten to 10 Nm (89 lb-in).
101. Install the 2 catalytic converter bracket bolts. Tighten to 25 Nm (18 lb-ft).
102. Connect the generator electrical connections and install the nut. Tighten to 6 Nm (53 lb-in).
103. Connect the CKP sensor electrical connector.
104. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
105. 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 (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
106. 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 (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
107. Install the starter motor isolator.
108. Lubricate the transaxle input shaft pilot bearing with front axle grease.
109. Using the special tool, position the clutch disc on the flywheel.
110. Position the clutch pressure plate and install the bolts. Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.

Engine - Automatic Transaxle

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

Material

All vehicles

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. 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. Install new torque converter nuts. Tighten to 35 Nm (26 lb-ft).
5. Install the power transfer unit (PTU) and the 3 PTU-to-transaxle bolts. Tighten to 70 Nm (52 lb-ft).
6. Install the 1 transaxle-to-PTU bolt. Tighten to 48 Nm (35 lb-ft).
7. Attach the PTU vent hose.
8. Install the PTU bracket and the 2 bolts. Tighten to 45 Nm (33 lb-ft).
9. Install the 3 PTU bracket-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
10. Install 7 new exhaust manifold studs in the cylinder head. Tighten to 17 Nm (13 lb-ft).
11. Install the new exhaust manifold gasket on the engine.
12. Position the catalytic converter and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages: Stage 1: Tighten to 47 Nm (35 lb-ft). Stage 1: Tighten to 47 Nm (35 lb-ft).
13. Install the heat shield and the 6 bolts. Tighten to 10 Nm (89 lb-in).
14. Install the 2 lower catalytic converter bolts. Tighten to 25 Nm (18 lb-ft).
15. Install the starter motor isolator.
16. Install the starter motor. Tighten to 35 Nm (26 lb-ft).
17. Install the starter motor harness connector. Install the starter motor solenoid battery nut. Tighten to 12 Nm (9 lb-ft). Install the starter motor solenoid nut. Tighten to 5 Nm (44 lb-in).
18. Install the wire harness clip retainer and the ground wire and nut to the starter bolts. Tighten to 25 Nm (18 lb-ft).
19. Raise the engine and transaxle into the vehicle.
20. Install the bolt in the LH transaxle mount. Tighten to 103 Nm (76 lb-ft).
21. Install the bolt in the rear transaxle mount. Tighten to 115 Nm (85 lb-ft).
22. Install the engine mount bracket and nuts. Tighten to 115 Nm (85 lb-ft).
23. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
24. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
25. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
26. Install the damper and the 3 bolts. Tighten to 40 Nm (30 lb-ft).
27. Install the engine support crossmember and new nut. Tighten to 175 Nm (129 lb-ft).
28. 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).
29. Install the A/C compressor and connect the A/C compressor electrical connector. Tighten the bolts to 25 Nm (18 lb-ft).
30. Connect the lower radiator hose to the radiator.
31. Connect the PCM electrical connectors. Position the harness and install the nut. Tighten to 6 Nm (53 lb-in).
32. Install the ground wire and bolt. Tighten to 10 Nm (89 lb-in).
33. Attach the electrical connector retainers.
34. Connect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
35. Connect the fuel vapor return tube and retainer.
36. Connect the vacuum supply tube.
37. Position the accelerator control cable and bracket and install the nut. Tighten to 6 Nm (53 lb-in).
38. Install the accelerator control cable and bracket and nut. Tighten to 6 Nm (53 lb-in).
39. 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).
40. Install the accelerator cable snow shield and retainers. Tighten to 4 Nm (35 lb-in).
41. Connect the heater hoses to the heater core.
42. Attach the heater hose support strap to the stud.
43. Connect the upper radiator hose.
44. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
45. Install the output shaft speed (OSS) sensor and bolt. Tighten to 13 Nm (10 lb-ft).
46. Install the fluid cooler tube. Connect the OSS sensor. Connect the turbine shaft speed (TSS) sensor (white connector). Connect the wiring harness retainer to the transaxle case. Position the bracket and install the bolt. Tighten 13 Nm (10 lb-ft). Install the fluid cooler tube fitting. Tighten to 23 Nm (17 lb-ft).
47. Connect the rear transaxle fluid cooler tube. Tighten to 23 Nm (17 lb-ft).
48. Connect the front transaxle fluid cooler tube. Tighten to 23 Nm (17 lb-ft).
49. Connect the transaxle range sensor electrical connector.
50. Install the transaxle control cable, bracket and bolts. Tighten to 19 Nm (14 lb-ft). Attach the wiring harness pin-type retainers.
51. Connect the shift cable to the transaxle manual lever.
52. Install the transaxle wiring harness bracket and nut and connect the transaxle electrical connector. Tighten to 10 Nm (89 lb-in).
53. Attach the transaxle vent tube retaining clip to the engine wiring harness.
54. Attach the wiring harness retainers to the battery tray bracket.
55. Connect the 34-pin electrical connector.
56. Install the ground strap and bolt. Tighten to 10 Nm (89 lb-in).
57. Connect the electrical connector to the power distribution box (PDB).
58. Connect the cable to the PDB and install the nut. Tighten to 12 Nm (9 lb-ft).
59. Install the PDB cover.
60. If equipped, install the ground eyelet and bolt. Tighten to 10 Nm (89 lb-in).
61. Align index mark and position the driveshaft to the PTU and install the 6 bolts. Tighten to 37 Nm (27 lb-ft).
62. Install the intermediate shaft.
63. Install the intermediate shaft retaining nuts. Tighten to 27 Nm (20 lb-ft).
64. Install the LH halfshaft in the transaxle and the RH halfshaft to the intermediate shaft. Install the ball joints in the knuckles.
65. Connect the RH suspension. Install the lower ball joint-to-knuckle bolt. Tighten to 63 Nm (46 lb-ft). Position the tie-rod end and install the retaining nut. Tighten to 55 Nm (41 lb-ft). Connect the stabilizer bar link. Tighten to 63 Nm (46 lb-ft).
66. Install the RH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (11 lb-ft).
67. Connect the LH suspension. Install the lower ball joint-to-knuckle bolt. Tighten to 63 Nm (46 lb-ft). Position the tie-rod end and install the retaining nut. Tighten to 55 Nm (41 lb-ft). Connect the stabilizer bar link. Tighten to 63 Nm (46 lb-ft).
68. Install the LH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (11 lb-ft).
69. Install the lateral support crossmember and bolts. Tighten to 115 Nm (85 lb-ft).
70. Install the generator shield, the nut and the pin-type retainer. Tighten to 20 Nm (15 lb-ft). Attach the wire retainers.
71. Install the lower air duct.
72. Install the accessory drive belt and tensioner. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
73. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
74. Install the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-292156) article.
75. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
76. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-292182) article.
77. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-292215) article.
78. Fill the engine with clean engine oil.
79. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292200) article.

Engine - Manual Transaxle

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

Material

1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 5 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. Install the starter motor. Tighten to 35 Nm (26 lb-ft).
5. Install the starter motor harness connector. Install the starter motor solenoid battery nut. Tighten to 12 Nm (9 lb-ft). Install the starter motor solenoid nut. Tighten to 5 Nm (44 lb-in).
6. Install the wire harness clip retainer and the ground wire and nut to the starter bolts. Tighten to 25 Nm (18 lb-ft).
7. Raise the engine and transaxle into the vehicle.
8. Install the bolt in the LH transaxle mount. Tighten to 103 Nm (76 lb-ft).
9. Install the bolt in the rear transaxle mount. Tighten 115 Nm (85 lb-ft).
10. Install the engine mount bracket and nuts. Tighten 115 Nm (85 lb-ft).
11. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
12. Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
14. Install the engine support crossmember and new nut. Tighten to 175 Nm (129 lb-ft).
15. 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).
16. Position the A/C compressor and install the bolts. Tighten the bolts to 25 Nm (18 lb-ft). Connect the A/C compressor electrical connector.
17. Connect the lower radiator hose to the radiator.
18. Connect the PCM electrical connectors. Position the harness and install the nut. Tighten to 6 Nm (53 lb-in).
19. Install the ground wire and bolt. Tighten to 10 Nm (89 lb-in).
20. Attach the electrical connector retainers.
21. Connect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
22. Connect the fuel vapor return tube and retainer.
23. Connect the vacuum supply tube.
24. Position the accelerator control cable and bracket and install the nut. Tighten to 6 Nm (53 lb-in).
25. Install the accelerator control cable and bracket and nut. Tighten to 6 Nm (53 lb-in).
26. 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).
27. Install the accelerator cable snow shield and retainers. Tighten to 4 Nm (35 lb-in).
28. Connect the heater hoses to the heater core.
29. Attach the heater hose support strap to the stud.
30. Connect the upper radiator hose.
31. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
32. Install the shift cable bracket. Position the shift cable bracket. Install the 3 bolts. Tighten to 22 Nm (16 lb-ft).
33. Connect the shift cables.
34. Connect the reversing lamp indicator switch.
35. Connect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
36. Install the wiring harness bracket nut. Tighten to 12 Nm (9 lb-ft).
37. Connect the clutch hydraulic line. Position the clutch hydraulic line. Connect the clutch hydraulic line to the clutch slave cylinder. Tighten to 25 Nm (18 lb-ft). Install the clutch hydraulic line bracket-to-transaxle bolt. Tighten to 3 Nm (27 lb-in).
38. Attach the wiring harness retainers to the battery tray bracket.
39. Connect the 34-pin electrical connector.
40. Install the ground strap and bolt. Tighten to 10 Nm (89 lb-in).
41. Connect the electrical connector to the power distribution box (PDB).
42. Connect the cable to the PDB and install the nut. Tighten to 12 Nm (9 lb-ft).
43. Install the PDB cover.
44. Install the intermediate shaft.
45. Install the intermediate shaft retaining nuts. Tighten to 27 Nm (20 lb-ft).
46. Install the LH halfshaft in the transaxle and the RH halfshaft to the intermediate shaft. Install the ball joints in the knuckles.
47. Connect the RH suspension. Install the lower ball joint-to-knuckle bolt. Tighten to 63 Nm (46 lb-ft). Position the tie-rod end and install the retaining nut. Tighten to 55 Nm (41 lb-ft). Connect the stabilizer bar link. Tighten to 63 Nm (46 lb-ft).
48. Install the RH brake hose retainer and the anti-lock brake system (ABS) sensor bolt. Tighten to 15 Nm (11 lb-ft).
49. Connect the LH suspension. Install the lower ball joint-to-knuckle bolt. Tighten to 63 Nm (46 lb-ft). Position the tie-rod end and install the retaining nut. Tighten to 55 Nm (41 lb-ft). Connect the stabilizer bar link. Tighten to 63 Nm (46 lb-ft).
50. Install the LH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (11 lb-ft).
51. Install the lateral support crossmember and bolts. Tighten to 115 Nm (85 lb-ft).
52. Install the generator shield, the nut and the pin-type retainer. Tighten to 20 Nm (15 lb-ft). Attach the wire retainers.
53. Install the lower air duct.
54. Install the accessory drive belt tensioner. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-292197) article.
55. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
56. Install the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-292156) article.
57. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
58. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-292182) article.
59. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-292215) article.
60. Fill the engine with clean engine oil.
61. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292200) article.
62. Bleed the clutch system. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-292154) article.