Part 3
Engine
Assembly
80. Install the knock sensor (KS) and the bolt.
^ Tighten to 20 Nm (15 ft. lbs.).
81. Install the coolant pump and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.) then rotate 90 degrees.
82. CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
Install the special tool in the camshaft as shown in the illustration.
^ Adjust the collar on the special tool screw to get the best thread engagement in the rear of the camshaft.
83. CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-485).
Position the coolant pump pulley over the previously installed special tool and on the end of the camshaft. Install the special tools as shown in the illustration.
^ Using the special tools, install a new service coolant pump pulley flush with the end of the camshaft.
84. Install the coolant pump belt on the coolant pump pulley and position it on the coolant pump drive pulley.
85. CAUTION: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or pulley while installing the belt.
Rotate the crankshaft clockwise to seat the coolant pump belt on the coolant pump drive belt pulley.
86. If equipped, install the coolant pump drive pulley cover and the 2 nuts.
^ Tighten to 6 Nm (53 inch lbs.).
87. Connect the coolant pump hose to the cylinder block outlet.
88. NOTE: Lubricate the new O-ring seals with clean engine coolant.
Install new O-ring seals, the bypass tube, bolt and stud bolt.
^ Tighten to 10 Nm (89 inch lbs.).
89. Install the thermostat housing.
90. NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
Position the lower intake manifold and install the 8 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).
91. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
92. Position the oil level indicator and tube and install the stud bolt.
^ Tighten to 9 Nm (80 inch lbs.).
93. Install the LH catalytic convertor bracket and the 2 bolts.
^ Tighten to 35 Nm (26 ft. lbs.).
94. Install 6 new RH catalytic convertor studs.
^ Tighten to 12 Nm (9 ft. lbs.).
95. Install a new gasket, the RH catalytic convertor and 6 new nuts.
^ Tighten to 20 Nm (15 ft. lbs.) in the sequence shown.
96. Position the power steering pump and reservoir assembly onto the engine and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
97. Install the 3 power steering reservoir nuts.
^ Tighten to 9 Nm (80 inch lbs.).
98. Install the A/C compressor bracket and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
99. Install the A/C compressor and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
100. Install the generator and the 3 bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
101. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
102. Attach the wiring harness retainer to the coolant bypass stud bolt.
103. Position the wiring harness onto the engine and connect the engine coolant temperature (ECT) sensor electrical connector.
104. Connect the KS electrical connector.
105. Connect the positive crankcase ventilation (PCV) valve electrical connector.
106. Connect the RH heated oxygen sensor (HO2S) electrical connector.
107. Attach the wiring harness retainer to the power steering stud bolt.
108. Install the radio frequency interference capacitor and the nut.
^ Tighten to 6 Nm (53 inch lbs.).
109. Connect the RH VCT solenoid and LH camshaft position (CMP) sensor electrical connectors.
^ Attach the 2 wiring harness retainers to the valve cover stud bolts.
110. Connect the 3 RH coil-on-plug electrical connectors.
^ Attach the 2 wiring harness pin-type retainers to the valve cover.