Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

Or, hide this message: temporarily or permanently

Part 2

36. Install the camshaft synchronizer; refer to Computers and Control Systems.





37. Apply four beads of silicone as shown.





38. Install the intake manifold gaskets.
39. Install the lower intake manifold.

Intake Torque Sequence:





1) Tighten the bolts in the sequence shown.

Rocker Arm:





40. Install the push rods and the rocker arms.
1) Install the push rods.
2) Install the rocker arms.





41. Apply a bead of silicone to the four intake-to-cylinder head seams.





42. Install the valve cover gaskets.
43. Install the valve covers

Valve Cover Torque Sequence:





1) Tighten the bolts in the sequence shown.





44. Position the engine control sensor wiring and connect:
- the camshaft synchronizer.
-the fuel injectors.
- the water temperature indicator sender unit.
- the engine control sensor wiring.





45. Install the intake manifold upper gasket.
46. Install the PCV valve.
47. Install the upper intake manifold.
1) Install the six upper bolts.

Upper Intake Torque Sequence:





2) Tighten in the sequence shown.





48. Connect the engine control sensor wiring to:
- the idle air control valve.
- the throttle position sensor.
- the DPFE sensor.





49. Using the Damper Installer, install the crankshaft damper.





50. Install the bolt.

Vibration Dampner:





51. Install the crankshaft vibration damper and the bolts.

Water Pump Pulley:





52. Install the water pump pulley and the bolts.

A/C Bracket:





53. Install the A/C compressor mounting bracket and the five bolts.

Alternator Bracket:





54. Install the generator mounting bracket and the bolts.





55. Install the nuts.





56. Connect the engine control sensor wiring to:
- the ignition coil.
- the radio ignition interference capacitor.
- the EGR solenoid.
- the vacuum line from the EGR solenoid.





57. Connect the vacuum line.
58. Connect the spark plug wires.