Installation — Power Transfer Unit

Install the PTU heat shield.
Torque: 89 lb-in (10 N·m)

If equipped, install the PTU temperature sensor wiring harness bracket.
Torque: 97 lb-in (11 N·m)

Install a new gasket.

Install a new PTU onto the transmission compression seal.

Install the PTU and mounting bolts.
Torque: 76 lb-ft (103 N·m)

At this stage, install the new PTU bolts and hand tighten.
Torque: 76 lb-ft (103 N·m)

Tighten in the sequence shown.
Torque: 81 lb-ft (110 N·m)

Install the PTU support bracket and bolts.
Torque: 35 lb-ft (48 N·m)

Install the catalytic converter to the vehicle.

Install the catalytic converter mounting bracket and hand tighten at this stage.

Install the exhaust manifold nuts.
Torque: 41 lb-ft (55 N·m)

1. Tighten the lower bracket nut.
   Torque: 35 lb-ft (48 N·m)

2. Tighten the PIA nut.
   Torque: 35 lb-ft (48 N·m)

Install the heat shield.
Torque: 93 lb-in (10.5 N·m)

Install the EGR cooler inlet pipe.
Refer to: Exhaust Gas Recirculation (EGR) Cooler Inlet Pipe (303-08C Engine Emission Control System - Removal and Installation).

• Connect the catalyst monitor sensor connector and the wiring harness clips.

• Connect the HO2S sensor connector and the harness clip.

If equipped, position the wiring harness and connect the clip.

If equipped, connect the PTU temperature sensor. Connect the engine connectors and clips.

Install the vent hose retainer.

Connect the PTU vent hose.

Install new PTU flange bolts.
Torque: 26 lb-ft (35 N·m)

Install the intermediate shaft.
Refer to: Intermediate Shaft (205-04 Front Drive Axle Shafts, Removal and Installation).

Fill the PTU.
Refer to: Power Transfer Unit Fluid Drain and Fill (308-07D).

Install the front subframe.
Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).

1. If the engine appearance cover stud is loosened or removed, install/tighten it in the valve cover.
   Torque: 62 lb-in (7 N·m)

2. Position the engine appearance cover on the engine so that the bushings are aligned with the studs.

3. Press down on the engine appearance cover at each bushing location to attach the bushings to the studs.

4. Install the engine appearance cover nut.
   Torque: 44 lb-in (5 N·m)

Check the exhaust system for leaks.