Final Assembly Procedure

1. Position LH coil bracket on studs and install retaining nuts and bolt.

2. Torque coil bracket nuts and bolt to 15-22 lb-ft (20-30 N-m).

3. Position RH coil bracket and install retaining bolts.

4. Torque coil bracket nuts and bolt to 15-22 lb-ft (20-30 N-m).

5. Connect camshaft position sensor.

6. Connect ignition wires to spark plugs.

7. Install RH and LH ignition wire covers and retaining nuts onto the cam cover studs.

8. Torque the ignition wire cover nuts to 18-35 lb-in (2-4 N-m).

9. Install two (2) nuts retaining the main harness to the lower portion of the cylinder front cover.

10. Torque the main harness retaining nuts to 6-9 lb-ft (8-12 N-m).

11. Install accessory drive belt idler pulley.

12. Tighten idler pulley bolt to 15-22 lb-ft (20-30 N-m).

13. Install accessory drive belt tensioner.

14. Tighten bolts to 15-22 lb-ft (20-30 N-m).





15. Install accessory drive belt (Figure 13).

16. Install radiator cooling fan and shroud.

17. Install power distribution box and bracket.

18. Install LH strut appearance cover onto LH fender apron.

19. Install brake master cylinder to brake vacuum booster.

20. Torque brake master cylinder nuts to 15-22 lb-ft (20-30 N-m).

21. Connect vacuum hose to brake booster.

22. Install PCV valve into cam cover grommet.

23. Connect fuel injector wiring harness at the 42-pin connector.

24. Install main harness bracket-to-front cover bolt.

25. Torque main harness bracket bolt to 15-22 lb-ft (20-30 N-m).

26. Install radiator hoses.

NOTE:
HOSE CLAMPS MUST BE INSTALLED IN THE ORIGINAL POSITION.

27. Install air cleaner outlet tube and resonator.

28. Torque air cleaner outlet tube clamp to 25-45 lb-in (3-5 N-m).

29. Torque throttle body attaching bolt to 45-65 lb-in (5-7 N-m).

30. Install battery.

31. Fill the cooling system:

CAUTION:
IT IS IMPERATIVE THAT THE FOLLOWING PROCEDURE FOR FILLING THE COOLING SYSTEM IS ADHERED TO. FAILURE TO PROPERLY FILL THE COOLING SYSTEM WILL DAMAGE THE ENGINE.

a. Remove coolant recovery reservoir pressure cap.

b. Remove the coolant outlet cap (on the coolant crossover tube).

c. Add a 50/50 mixture of recommended coolant to engine through the coolant outlet (on the coolant crossover tube) fill neck, until the coolant reservoir is full.

NOTE:
AVOID SPILLING COOLANT ON THE ACCESSORY DRIVE BELT. THIS WILL RESULT IN BELT SLIPPAGE AND NOISE.

CAUTION:
DO NOT FILL THE COOLING SYSTEM THROUGH THE COOLANT RESERVOIR ON INITIAL FILL. COOLANT WILL NOT ENTER THE ENGINE. THIS MAY LEAD TO ENGINE OVERHEATING AND POSSIBLE ENGINE DAMAGE.

d. Reinstall the pressure cap on the coolant reservoir.

e. Continue filling at the coolant crossover tube slowly, allowing air to escape from the cooling system.

f. When the coolant system is full, reinstall the coolant outlet cap.

g. Set the climate control system to maximum heater temperature.

h. Set airflow through the panel vents.

I. Set fan speed to maximum.

j. Start engine.

k. Allow engine to idle (while engine is idling, check for warm air at the panel vents).

CAUTION:
IF AIR DISCHARGED FROM THE PANEL VENTS REMAINS COOL AND THE ENGINE TEMPERATURE GAUGE DOES NOT MOVE, SHUT OFF ENGINE IMMEDIATELY. THIS IS AN INDICATION OF LOW COOLANT LEVEL AND/OR AIR IN THE COOLING SYSTEM. ALLOW THE ENGINE TO COOL AND THEN REPEAT THE COOLANT FILL PROCEDURE FROM THE START.

l. Allow engine to idle until normal operating temperature is reached (hot air should be discharged from the panel vents, the temperature gauge should maintain a stabilized reading in the middle of the normal" range and the lower radiator hose should be hot).

m. Turn engine off.

n. Allow engine to cool.

o. Check the coolant level in the coolant reservoir.

p. Fill to the "cold" level, if required.

q. Inspect for leaks at the radiator hoses, radiator draincock, and coolant outlet plug.

32. Install engine appearance cover.

33. Torque appearance cover fasteners to 45-60 lb-in (5-7 N-m).

34. Install wiper motor module assembly.

a. Disconnect negative terminal of battery.

b. Place module support bracket on the dash panel mounting stud.

c. Reconnect the two (2) wiring connectors to the motor.

d. Install five (5) retaining bolt/washer assemblies and one (1) nut to the wiper module (Figure 2).

e. Install seven (7) retaining screws and washers and cowl top extension (Figure 1).

f. Install LH and RH cowl vent screens.

g. Install cowl top-to-hood seal.

h. Install LH and RH wiper arms.

i. Reconnect battery cable(s).

35. Turn air ride system switch (in trunk compartment) to "on".





Parts Block