Steps 36-77

36. Using the special tool, install the Crankshaft Position (CKP) sensor. The tool must engage a tooth of the vibration damper.

37. Remove the special tool.
38. Clean the valve cover gasket surface with metal surface cleaner.

39. Apply silicone gasket and sealant to the locations shown.

40. NOTE: The valve cover must be secured within four minutes of silicone gasket application. If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

Install the valve cover.

41. Install the following:
^ Camshaft Position (CMP) sensor.
^ Cylinder Head Temperature (CHT) sensor.
^ spark plugs.

42. NOTE:
^ Clean the water pump gasket surface with metal surface cleaner.
^ Lubricate the water pump O-ring seal with MERPOL(R) prior to assembly.

Install the water pump.

43. Install the water pump pulley.

44. Install the fuel injection supply manifold and the ground strap.

45. Install the left motor mount.

46. NOTE: The knock sensor must not touch the engine vent cover.

Install the engine vent cover and the Knock Sensor (KS).

47. NOTE: Clean the thermostat housing gasket surface with metal surface cleaner.

Install a new gasket and the thermostat housing.

48. Install the bypass hose and the clamp.

49. Install the ignition coil.

50. NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.

Connect the spark plug wires to the spark plugs.

51. Install the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.

52. Connect the ignition coil and the CHT sensor electrical connectors.

53. Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.

54. Install the intake manifold.

55. Attach the vacuum line to the intake manifold. Secure the fuel line clip to the intake manifold.

56. Install the EGR tube.
^ Install the EGR tube bracket to the intake manifold.
^ Connect the EGR tube to the cylinder head.

57. Connect the EGR tube to the intake manifold.

58. Install the engine wiring harness connector bracket.
59. Attach the engine wiring harness pin-type retainers to the intake manifold.

60. Connect the CMP sensor electrical connector and the PCV hose.

61. Connect the following electrical connectors:
^ swirl control valve.
^ knock sensor.
^ electric thermostat.

62. Connect the CKP sensor and wiring pin-type retainers.

63. Connect the swirl control valve electrical connector.

64. Connect the following electrical connectors:
^ Manifold Absolute Pressure (MAP) sensor.
^ Throttle Position (TP) sensor.
^ Idle Air Control (IAC) valve.

65. Install the power steering pump and reservoir assembly.

66. NOTE: Clean the EGR valve gasket surface with metal surface cleaner.

Install a new gasket and the EGR valve. Connect the EGR electrical connector.

67. NOTE: Clean the water outlet tube gasket surface with metal surface cleaner.

Install a new gasket and the water outlet tube.
1. Tighten the bolts.
2. Connect the coolant hose.
3. Connect the Engine Coolant Temperature (ECT) sender electrical connector.