Assembly

NOTE:
Lubricate all parts with clean engine oil prior to installing.

1. Rotate the crankshaft until the cam lobe is in the up position and install the camshaft roller followers using Valve Spring Compressor 303-58i. Repeat this step for all camshaft lobes.

2. Position the accessory bracket and install the bolts. Tighten the bolts to 42 Nm (31 lb-ft).

3. Install the A/C line bracket and bolt. Tighten bolt to 20 Nm (15 lb-ft).

4. Connect the lower heater water hose to the water pump.

5. Connect the Crankshaft Position (CKP) sensor electrical connector, position the wiring and secure the wiring anchors.

6. Install the thermostat housing into the water pump bypass hose, install the bolts, and position the bypass hose clamp. Tighten the bolts to 11 Nm (8 lb-ft).

7. Install the generator mounting bracket. Tighten the bolts to 42 Nm (31 lb-ft).

8. Connect the generator wiring. Tighten the B+ terminal nut to 8 Nm (71 lb-in).

9. Install the accessory drive belt tensioner. Tighten the bolt to 47 Nm (35 lb-ft).

10. Install the accessory drive belt.

11. Position the radiator into the engine compartment and install the bolts. Tighten the bolts to 8 Nm (70 lb-in).

12. All Vehicles: Connect the two (2) transmission cooler lines.

CAUTION:
Use 2-wrenches, one to hold the radiator fitting and one to tighten the cooler line. Tighten to 24 Nm (17 lb-ft).

13. Connect the lower radiator hose to the water pump.

14. Install the fan shroud and the fan blade and clutch assembly together in the vehicle.

15. Install the fan shroud bolts and tighten to 8 Nm (70 lb-in).

16. Tighten the fan clutch nut using Fan Pulley Holding Wrench 303-239 or 49UN01008 and Fan Clutch Nut Wrench 303-240 or 49UN01007. Tighten the fan clutch nut to 55 Nm (41 lb-ft).

17. Connect radiator overflow hose.

18. Install the right hand valve cover. Tighten the bolts to 10 Nm (86 lb-in).

19. Install the fuel injection supply manifold. Tighten to 23 Nm (17 lb-ft).

20. Connect the fuel pulse damper vacuum hose.

21. Position wiring and connect all six (6) fuel injector connectors.

22. Install the left hand valve cover. Tighten the bolts to 10 Nm (89 lb-in).

23. Connect the fuel supply line:

- Connect the fuel supply line to the fuel supply manifold.

- Install the bolts to the fuel supply line and retaining clip on the left hand valve cover.

- Tighten the bolts to 6 Nm (53 lb-in).

24. Connect the heater bypass hose to the thermostat housing.

25. Install the upper radiator hose.

26. Connect the engine coolant temperature sensor electrical connector and the water temperature indicator sender unit connector.

27. Raise and support the vehicle.

28. Connect the lower radiator hose to the radiator.

29. Install the air deflector.

30. Drain the engine oil. Tighten the drain plug to 25 Nm (18 lb-ft).

31. Remove the supports and lower the vehicle.

32. Connect the fuel vapor hose, and vacuum harness to the left hand valve cover.

33. Install the heated PCV valve and connect the hose.

34. Connect the Camshaft Position (CMP) sensor, and the DPFE transducer electrical connectors.

35. Attach the 42-pin engine electrical connector to the left hand valve cover bracket and connect. Tighten connector bolt to 6 Nm (53 lb-in).

36. Install the intake manifold:

- Position the intake manifold, connect the heated PCV fitting, and install the bolts

- Tighten the intake manifold bolts to 10 Nm (89 lb-in).

37. Attach the knock sensor electrical connector to the intake manifold.

38. Position the Powertrain Control Module (PCM) wire harness:

- Position the wire harness and connect the PCM electrical connector. Tighten to 7 Nm (62 lb-in).

- Install the retainer(s) attaching the ground wire and wire harness support bracket to the bulk head. Tighten to 10 Nm (89 lb-in).

39. Install ignition coil and bracket assembly:

- Tighten top bolts to 8 Nm (71 lb-in).

- Tighten the bottom bolts to 23 Nm (17 lb-ft).

40. Connect ignition coil electrical connector.

41. Connect the radio interference capacitor electrical connector.

42. Connect the spark plug wires to the ignition coil. Connect the spark plug wires to the separators or attach the routing clip push pin.

43. Connect the exhaust manifold to EGR valve tube. Tighten the fitting to 34 Nm (25 lb-ft).

44. Connect the crankcase ventilation hose, brake booster vacuum hose, and the EGR valve vacuum hose.

45. Connect the EGR vacuum regulator electrical connector and vacuum connector.

46. Connect the Idle Air Control (IAC) valve and Throttle Position Sensor (TPS) electrical connectors.

47. Connect both air intake manifold left hand vacuum connections.

48. Connect the accelerator cable and speed control cable (if equipped).

49. Install and connect the engine air cleaner cover and outlet pipe.

50. Install the engine appearance cover.

51. Fill the engine with clean engine oil.

52. Connect the battery negative cable.

53. Fill the radiator and coolant reservoir with the correct 50/50 mix of ethylene glycol (coolant) and water mixture.

54. Move the interior climate control temperature selector to the full WARM position.

55. Run the engine until it reaches operating temperature.

56. Add the correct coolant mixture to the radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks.

57. Recheck the coolant level and fill as necessary.

58. A/T Vehicles: Check the automatic transmission fluid level and fill as needed (if equipped).

59. Turn off the engine and allow the cooling system to cool. Recheck the coolant level and fill the cooling system to the FULL mark on the radiator coolant reservoir.

60. Turn off the engine and allow the cooling system to cool. Recheck the coolant level and fill the cooling system to the FULL mark on the radiator coolant reservoir.

61. Start the engine and check for leaks.

62. Re-enter the customers radio pre-sets.

63. Verify repair.