Service Procedure
1. Remove and discard the existing hose from the PCV valve located in the forward valve cover. Install the new [1][2]PCV hose on the PCV valve. Slip the insulator over the hose and PCV valve until the insulator contacts the valve cover. Install the other end of the hose to the intake manifold connector.2. Remove the air cleaner assembly. Remove and discard the crankcase vent to air cleaner hose connected between the air cleaner and the valve cover.
3. Separate the air cleaner assembly into its two halves. Remove the air filter element and the brake booster vacuum hose clip from the lower half and return the lower half of the air cleaner.
4. Check that the small foam filter is in place in the corner of the new air cleaner lower half -- just flush with top of compartment. Insert the air cleaner element and the brake booster vacuum hose clip removed in step 3 into the new air cleaner lower half and reassemble the air cleaner.
5. Install the drain hose onto the lower nipple of the air cleaner.
FIGURE 1:
6. Locate the manifold vacuum connector on the right side of the intake manifold, forward of the fuel pressure regulator (see Figure 1). Detach hoses and replace the connector with the new manifold vacuum connector supplied. Be certain that the two smaller vacuum connections are aligned in a horizontal position.
FIGURE 2:
Service Procedure
7. Remove the MAP sensor from the bracket at its present location (right shock tower on the C-Body and on the right side of the cowl panel, to the rear of the engine on S-Body -- see Figure 2).
FIGURE 3:
8. Detach the electrical connector and vacuum line from the MAP sensor.
^ Remove and discard the MAP sensor bracket on the C-Body.
^ Do not remove the bracket on S-Body--this bracket will be used to secure a wiring harness later in this procedure.
9. Install the new MAP sensor bracket by loosening the bolt located on the front of the alternator bracket and slipping the new MAP sensor bracket behind the bolt head flat washer (see Figure 3). Retighten bolt to 220 in.lbs. (25 N-m.).
10. Install the MAP sensor on the new bracket using the original screws (see Figure 3).
Service Procedure
11. Remove and discard the existing vacuum line assembly serving the old MAP sensor location. Connect the new, supplied vacuum hose between the large vacuum nipple on the intake manifold connector and the nipple on the MAP sensor (see Figure 3).
FIGURE 4:
12. Using the supplied jumper harness, connect the MAP sensor to the wiring harness connector. Route and tie wrap as follows:
^ On the C-Body, the jumper harness should be secured with tie wraps to the underhood wiring harness and the right side engine mount (see Figure 4).
FIGURE 5:
^ On the S-Body, the jumper harness is to be secured with tie wraps to the alternator and to the original MAP sensor bracket on the cowl (see Figure 5).
Service Procedure
13. Inspect the camshaft end seals for evidence of oil leakage. If no oil leak is evident, move to step 14. If an oil leak is found, replace the end seals as follows:
^ Using a small punch and hammer, carefully remove and discard the leaking seal. Clean the area of the cylinder head where the new seal is to be installed.
^ Apply a light coating of RTV sealer to the outer diameter of the new seal. Using a suitable installing tool and hammer, install the new seal to a depth of .02" (0.5 mm) below the surface of the cylinder head.
Note: Engines built after November, 1987 already have the new type seals installed. The new seals are not susceptible to leakage and therefore do not require replacement. For identification purposes:
^ The new seals are thicker and, when installed, are nearly flush with the cylinder head surface.
^ The old seals are thinner and obviously inserted deeper -- about .08" (2 mm) below the cylinder head. These old seals require replacement only if leakage is evident.
14. Install the air cleaner assembly on the engine.
Note: When connecting the convoluted fresh air duct to the air cleaner inlet add a screw as shown below, to ensure duct to air cleaner inlet retention (use screw PN 6032723, or an equivalent sheet metal screw).
15. Install the new crankcase vent to air cleaner hose from the valve cover to the upper nipple on the air cleaner.
16. There is an engine compartment wiring harness routed under the convoluted fresh air duct, between duct and the exhaust system. This harness must be tie wrapped to the duct to maintain maximum clearance between the harness and the exhaust system.