Operation CHARM: Car repair manuals for everyone.

Part 2





48. NOTE: Do not connect the battery cables.

Install the battery.






49. Connect the coolant return hose to the reservoir.






50. Install the wire harness and master cylinder nuts.






51. Connect and install the 42-pin connector.






52. Connect and install the 16-pin connector.

53. Install the throttle and speed control cables.

54. Install the throttle cable bracket.

55. Install and connect the DPFE transducer.






56. NOTE: Inspect and install new O-rings and garters if damaged. Lubricate the O-rings with clean engine oil.

Connect the fuel lines.






57. Connect the heater hoses.






58. Connect the chassis vacuum connector.






59. Connect the evaporative emissions connector.






60. Position the wiper assembly and connect the connector.

61. Connect the wiper linkage.






62. Install the wiper assembly screws.






63. Install the RH lower cowl vent panel.






64. Connect the washer hose.






65. Install the cowl vent screens.






66. Install the hood pad.






67. Install the wiper arms.






68. Connect the fuel line bracket.

69. Install the power steering reservoir.

70. Install the radiator upper sight shield.






71. Install the generator cover.






72. Install the air cleaner as an assembly.

73. Position the power steering shaft.

74. Raise the vehicle on the hoist.






75. Install the steering shaft and new bolt.

76. Connect the lower radiator hose.






77. Connect the power steering reservoir supply hose to the power steering pump.






78. Install the secondary air injection valve assembly.






79. Connect the connector and inlet hose to the secondary air injection valve.






80. Connect the air tube to the secondary air injection valve.

1. Connect the vacuum hose.
2. Connect the air tube.

81. Lower the vehicle.






82. Install the steering shaft on the steering column and install a new bolt.






83. Connect the steering column connectors.






84. Install the steering column.






85. Install the A/C duct and reinforcement.






86. Install the steering column cover.






87. Connect the lamp and install the LH instrument panel insulator.

88. Install the hood.

89. Connect the battery cables.

90. Fill the engine with super premium SAE 5W30 engine oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

91. Fill and bleed the cooling system.

92. Fill the power steering system.

93. Charge the A/C system.

94. Fill the transmission.