Final Assembly

1. Install knock sensor, if equipped, and oil pressure switch.
2. Install oil cooler, if equipped. Tighten attaching bolts to specification, then install oil filter.
3. Install intake manifold assembly with new gasket, tighten attaching nuts to specification in two or three steps.
4. Install intake manifold bracket, tighten attaching bolts to specification.
5. Install thermostat in cylinder head and position a new gasket with printed side facing cylinder head, then install thermostat cover, tighten to specification.
6. Apply anti-seize compound to spark plug threads and install plugs, tighten to specification.
7. Install distributor as follows:
a. Apply engine oil to O-ring and position it on distributor.
b. Apply engine oil to blade.
c. Install distributor into the rear housing.
d. Loosely tighten distributor hold down bolt.
8. Connect spark plug wires.
9. Install engine mount bracket, tighten attaching bolt to specification.
10. Install alternator strap and bracket, tighten to specification.
11. Install alternator and drive belt. Adjust belt tension and tighten alternator through- and adjusting bolts to specification.
12. On 1989 models, install coolant inlet pipe.
13. Apply vegetable oil to coolant bypass pipe O-ring, then install coolant bypass pipe.
14. On all models, install front and rear engine hangers. Tighten fasteners 14-22 ft. lbs.
15. Install turbocharger bracket, if equipped. Tighten fasteners 27-38 ft. lbs.
16. Place new exhaust manifold gasket in position with ridge facing cylinder head, then install exhaust manifold assembly. Tighten attaching nuts to specification in two or three steps.
17. Attach turbocharger to bracket, tighten to specification.
18. Install oil pipe and turbocharger hose, if equipped, tighten side bolt and rear bolt and nut to specification.
19. Tighten oil pipe bracket to specification, then connect oil hose and water hoses.
20. Install EGR pipe, tighten to specification.
21. Install exhaust manifold insulator, tighten to specification.
22. Install power steering pump bracket and tighten to specification.