Honda CRV/Odyssey 1995-2000 Repair Information

Cylinder Head

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REMOVAL & INSTALLATION




WARNING
To avoid damaging the cylinder head, allow the coolant temperature to drop below 100°F (38°C) before removing the head bolts.

Careful thought and a clean work environment should be a priority when removing a cylinder head. Have plenty of cardboard boxes and a good marker handy to label and organize the parts as they are removed.

Be sure to have an ample supply of sealable clear plastic bags that can be labeled for the removed fasteners. Make sure to investigate whether or not certain fasteners can be reused or must be replaced.

Have sealable containers available for the used coolant and engine oil which must be drained during the procedure. Have a pencil and note pad handy to make drawings and make notes of cable routing , wire and bracket locations.

Follow the installation procedures carefully to know whether certain fasteners should be lubricated or not when being installed.

Read the procedures before starting to get a thorough understanding of the Tools and Equipment needed. Many of the components of the cylinder head are precision machined pieces that need to be thoroughly cleaned and inspected before reinstalling. For specific details on the basics of the cylinder head, refer to the ENGINE RECONDITIONING information located further along in this section.

When machined components are removed

NEVER:


Allow two machined pieces to rest or contact one another
 
Lay the component directly on the ground or garage floor
 
Mix up the location from which they were removed
 

Use wood or cardboard to protect a machined component, especially items such as a cylinder head.

CRV See Figure 1

  1. Note the radio security code and station presets.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Remove the air cleaner and the air intake duct.
  8.  
  9. Remove the accessory drive belts.
  10.  
  11. Remove the power steering pump and its bracket.
  12.  
  13. Properly relieve the fuel system pressure, as outlined in Fuel System .
  14.  
  15. Disengage all electrical connectors, fuel lines, throttle linkage and hoses from the engine associated with cylinder head removal. Label the connections as needed to aid installation.
  16.  
  17. Remove the spark plug caps, plug wires, and distributor from the cylinder head.
  18.  
  19. Use a jack with a cushioned pad to support the weight of the engine.
  20.  
  21. Remove the valve cover.
  22.  
  23. Remove the timing belt, camshaft sprocket and back cover.
  24.  
  25. Remove the exhaust header pipe from the manifold.
  26.  
  27. Remove the intake manifold mounting bolts and water bypass hose.
  28.  
  29. Remove the camshafts.
  30.  
  31. Remove the cylinder head bolts. To prevent warpage of the cylinder head, loosen the bolts 1 / 3 of a turn in the reverse sequence of the cylinder head tightening sequence.
  32.  
  33. Remove the cylinder head.
  34.  

To install:
  1. Clean the cylinder head and block surface.
  2.  
  3. Clean the oil control orifice and install on the block. Be sure the dowel pins are properly located in the block.
  4.  
  5. Place the new head gasket on the engine block.
  6.  
  7. Apply clean engine oil to the bolt threads and under the bolt heads.
  8.  
  9. Carefully mate the cylinder head to the engine block.
  10.  
  11. Tighten the cylinder head in two steps following the illustrated sequence:

    Step 1: 22 ft. lbs. (29 Nm)
     
    Step 2: 63 ft. lbs. (85 Nm)
     

  12.  

  1. Tighten the intake manifold bolts to 17 ft. lbs. (24 Nm).
  2.  
  3. Install the exhaust header pipe to the exhaust manifold.
  4.  
  5. Install the camshafts.
  6.  
  7. Install the back cover.
  8.  
  9. Set the camshafts at Top Dead Center (TDC) for No. 1 piston, align the holes in the camshafts with the holes in the No. 1 camshaft holder and insert a 5mm pin punch into the holes.
  10.  
  11. Install the keys into the keyways on the camshafts and install the pulleys, then tighten the retaining bolts to 27 ft. lbs. (37 Nm).
  12.  
  13. Install the timing belt.
  14.  
  15. Adjust the valve clearance, as outlined in General Information and Maintenance .
  16.  
  17. Install the valve cover and tighten the nuts to 86 inch lbs. (9.8 Nm).
  18.  
  19. Install the spark plug caps, plug wires, and distributor.
  20.  
  21. Install the air cleaner and the air intake duct.
  22.  
  23. Verify that all tubes, hoses and connectors are installed properly.
  24.  
  25. Connect and adjust the throttle cable. Connect and adjust the throttle control cable and the cruise control cable, if equipped.
  26.  
  27. Drain the engine oil into a sealable container. Install the drain plug with a new crush washer.
  28.  
  29. Refill the engine with clean oil.
  30.  
  31. Fill and bleed the air from the cooling system.
  32.  
  33. Connect the positive and the negative battery cables. Enter the radio security code.
  34.  
  35. Start the engine, checking carefully for any coolant, fuel, oil, or air leaks.
  36.  
  37. Check the ignition timing and adjust it if necessary, then tighten the distributor bolts to 13 ft. lbs. (18 Nm).
  38.  



Click image to see an enlarged view

Fig. Fig. 1: Cylinder head bolt tightening sequence-all four cylinder engines

Odyssey

4-CYLINDER ENGINES

See Figures 1 and 2

  1. Note the radio security code and station presets.
  2.  
  3. Disconnect the negative and positive battery cables.
  4.  
  5. Remove the valve cover and the upper timing belt cover.
  6.  
  7. Turn the crankshaft to align the Top Dead Center (TDC) marks and set cylinder No. 1 to TDC/compression. The white mark on the crankshaft pulley should align with the pointer on the timing belt cover.
  8.  
  9. Drain the engine coolant into a sealable container.
  10.  
  11. Drain the engine oil into a suitable container.
  12.  
  13. Disconnect the throttle cable and throttle control cable from the throttle body. If equipped with cruise control, remove the cruise control cable.
  14.  

Be careful not to bend the cable when removing it. Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with a new one.

  1. Remove the intake air duct.
  2.  
  3. Disconnect and label the breather hose, positive crankcase ventilation (PCV) hose, and evaporative emissions (EVAP) control canister hose.
  4.  
  5. Relieve the fuel system pressure, as outlined in Fuel System .
  6.  


CAUTION
The fuel injection system remains under pressure after the engine has been turnedOFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Disconnect the fuel feed and return hoses from the fuel rail.
  2.  
  3. Disconnect the vacuum hoses located near the fuel feed and return hoses.
  4.  
  5. Remove the brake booster vacuum hose from the intake manifold. Label and remove the other vacuum hoses from the intake manifold.
  6.  
  7. Remove the clamp holding the power steering hose to the strut tower.
  8.  
  9. Remove the wiring harness clamp and the ground cable from the intake manifold.
  10.  
  11. Remove the connector and the terminal from the alternator. Then, remove the engine wiring harness from the valve cover.
  12.  
  13. Remove the mounting bolts and drive belt from the power steering pump. Pull the pump away from the mounting bracket without disconnecting the hoses. Support the pump out of the way.
  14.  
  15. Loosen the adjusting and mounting bolts for the alternator and remove the drive belt.
  16.  
  17. Unclamp the engine wiring harness and bypass hose from the lower side of the intake manifold.
  18.  
  19. Label and detach the following engine wiring harness connectors:

    Fuel injector connectors
     
    Intake air temperature (IAT) sensor connector
     
    Idle air control (IAC) valve connector
     
    Throttle position sensor (TPS) connector
     
    Manifold absolute pressure (MAP) sensor connector
     
    Heated Oxygen sensor (HO 2 S) connector
     
    Engine coolant temperature (ECT) sensor connector
     
    ECT switch connector
     
    ECT gauge sending unit connector
     
    Exhaust gas recirculation (EGR) valve lift sensor
     
    CKP/TDC/CYP sensor connector
     
    Ignition coil connector
     

  20.  
  21. Label and detach the electrical connectors and ignition wires from the distributor.
  22.  
  23. Mark the position of the distributor and remove it from the cylinder head. Disconnect the ignition coil wire from the distributor.
  24.  
  25. Remove the upper radiator hose and the heater inlet hose from the cylinder head.
  26.  
  27. Remove the lower radiator hose from the thermostat housing.
  28.  
  29. Remove the coolant bypass hoses.
  30.  
  31. Use a jack with a cushioned pad to support the weight of the engine. Remove the through-bolt from the side engine mount and remove the mount.
  32.  
  33. Remove the cylinder head cover. Replace the rubber seals if they're damaged or deteriorated.
  34.  
  35. Remove the timing belt covers and the timing belt.
  36.  
  37. Remove the camshaft sprocket and the back cover. Do not lose the sprocket key.
  38.  
  39. Raise and safely support the vehicle.
  40.  
  41. Remove the splash shield.
  42.  
  43. Disconnect the exhaust pipe from the exhaust manifold.
  44.  
  45. Lower the vehicle.
  46.  
  47. Remove the exhaust manifold and the exhaust manifold heat insulator.
  48.  
  49. Remove the thermostat housing mounting bolts. Remove the thermostat housing from the intake manifold and the connecting pipe by pulling and twisting the housing. Discard the O-rings.
  50.  
  51. Remove the fuel rail and fuel injectors.
  52.  
  53. Remove the intake manifold bracket bolts.
  54.  
  55. Remove the intake manifold chamber with the throttle body attached.
  56.  
  57. Remove the intake manifold.
  58.  
  59. Remove the cylinder head bolts in the proper crisscross sequence starting at the outer edges and working inward. Then, remove the cylinder head.
  60.  

To prevent warpage, loosen the bolts in reverse of the tightening sequence1/3turn at a time. Repeat the sequence until all bolts are loosened.

To install:
  1. Be sure all cylinder head and block gasket surfaces are clean. Check the cylinder head for warpage. If warpage is less than 0.002 in. (0.05mm), cylinder head resurfacing is not required. The maximum resurface limit is 0.008 in. (0.2mm) based on a cylinder head total height of 3.94 in. (100mm).
  2.  
  3. Install a new head gasket.
  4.  
  5. Be sure the No. 1 cylinder is at TDC/compression.
  6.  
  7. Clean the oil control orifice and install a new O-ring. Replace the oil control orifice if necessary.
  8.  
  9. Install the dowel pins to the engine block.
  10.  
  11. Install the bolts that secure the intake manifold to its bracket, but do not tighten them.
  12.  
  13. Position the camshaft so that the UP mark is facing upward.
  14.  
  15. Install the cylinder head and be sure it is properly seated onto its dowel pins.
  16.  

On 1996-97 engines, apply clean engine oil to the threads of the cylinder head bolts and to the underside of their heads. Install all of the head bolts. Following a crisscross pattern, tighten the bolts sequentially in three steps:



Step 1: 29 ft. lbs. (39 Nm)
 
Step 2: 51 ft. lbs. (69 Nm)
 
Step 3: 72.3 ft. lbs. (98.1 Nm)
 

On 1998 engines, apply clean engine oil to the threads of the cylinder head bolts and to the underside of their heads. Install all of the head bolts. Tighten the cylinder head bolts following this procedure:



Step 1: 22 ft. lbs. (29 Nm)
 
Step 2: Mark the bolt head and cylinder head as illustrated
 
Step 3: Tighten the head bolts in sequence 90 degrees
 
Step 4: Tighten the head bolts in sequence another 90 degrees
 
Step 5: If using new head bolts, tighten the head bolts in sequence a final 90 degrees
 



Click image to see an enlarged view

Fig. Fig. 2: Cylinder head bolt tightening marks-1998 Odyssey models

  1. Install the intake manifold, manifold chamber and throttle body.
  2.  
  3. Install new O-rings, cushion rings, and seal rings onto the fuel injectors, fuel rail, and intake orifice. Install the fuel rail to the intake manifold as an assembly with the fuel injectors.
  4.  
  5. Install the exhaust manifold.
  6.  
  7. Lower the vehicle.
  8.  
  9. Install the timing belt back cover to the cylinder head. Tighten the cover bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install the key into the camshaft groove, then install the camshaft sprocket. Tighten the sprocket bolt to 27 ft. lbs. (37 Nm).
  12.  
  13. Be sure the camshaft sprocket and the crankshaft pulleys are aligned to TDC for the compression stroke. The camshaft sprocket UP mark should face up. The camshaft keyway should also face up.
  14.  
  15. Install the timing belt and the balancer shaft belt.
  16.  
  17. Install the lower timing belt cover and tighten the bolts to 106 inch lbs. (12 Nm).
  18.  
  19. Install a new seal around the adjusting nut. Do not loosen the adjusting nut.
  20.  
  21. Install the crankshaft pulley. Coat the threads and seating face of the pulley bolt with engine oil. Install and tighten the bolt to 181 ft. lbs. (245 Nm).
  22.  
  23. Install the side engine mount. Tighten the bolt and nut attaching the mount to the engine to 40 ft. lbs. (55 Nm). Tighten the through-bolt and nut to 47 ft. lbs. (65 Nm). Remove the jack from under the engine.
  24.  
  25. Adjust the valves, as outlined in General Information and Maintenance .
  26.  
  27. Install the upper timing belt cover. Tighten the bolt on the intake side of the head to 106 inch lbs. (12 Nm) and tighten the bolt on the exhaust side of the head to 88 inch lbs. (10 Nm).
  28.  
  29. Tighten the crankshaft pulley bolt to 181 ft. lbs. (245 Nm) if it broke loose while adjusting the valves.
  30.  
  31. Install the splash shield.
  32.  
  33. Thoroughly clean the valve cover gasket mating surfaces . Install the valve cover gasket to the groove of the cylinder head cover. Be sure the gasket is seated securely in the corners of the recesses.
  34.  
  35. Apply sealant to the four corners of the recesses of the valve cover gasket. Do not install the parts if 5 minutes or more have elapsed since applying sealant. After assembly, wait at least 20 minutes before filling the engine with oil.
  36.  
  37. Clean the valve cover contact surface with a shop towel. Install the valve cover. Tighten the valve cover capnuts in a clockwise sequence to 88 inch lbs. (10 Nm).
  38.  
  39. Install a new O-ring to the coolant connecting pipe, and to the thermostat housing. Install the housing to the coolant pipe and the intake manifold. Tighten the mounting bolts to 16 ft. lbs. (22 Nm).
  40.  
  41. Install the coolant bypass hoses.
  42.  
  43. Connect the lower radiator hose to the thermostat housing.
  44.  
  45. Connect the upper radiator hose and the heater inlet hose to the cylinder head.
  46.  
  47. Install the distributor to the cylinder head. Only hand-tighten the mounting bolts at this time.
  48.  
  49. Connect the ignition wires to the spark plugs. Attach the distributor electrical connectors. Install the ignition coil wire to the distributor.
  50.  
  51. Attach the all electrical engine wiring harness connectors, as tagged during removal.
  52.  
  53. Install the engine wiring harness and bypass hose to the lower side of the intake manifold.
  54.  
  55. Install and adjust the alternator drive belt.
  56.  
  57. Install the power steering pump to the power steering pump mounting bracket.
  58.  
  59. Install and adjust the power steering belt.
  60.  
  61. Install the alternator wiring harness to the valve cover. Connect the terminal to the alternator.
  62.  
  63. Connect the ground cable and the wiring harness clamp to the intake manifold.
  64.  
  65. Connect the power steering hose clamp to the engine block.
  66.  
  67. Connect the brake booster vacuum hose to the intake manifold. Connect the other vacuum hoses to the intake manifold.
  68.  
  69. Connect the vacuum hoses located near the fuel feed and return hoses.
  70.  
  71. Connect the fuel return hose and the fuel feed hose to the fuel rail. Install new washers to the fuel feed hose connection. Tighten the fuel feed hose banjo bolt to 16 ft. lbs. (22 Nm). Tighten the service bolt to 106 inch lbs. (12 Nm).
  72.  
  73. Install the breather hose, PCV hose, and the EVAP control canister hose.
  74.  
  75. Install the air intake duct.
  76.  
  77. Connect and adjust the throttle cable. Connect and adjust the throttle control cable and the cruise control cable, if equipped.
  78.  
  79. Drain the engine oil into a sealable container. Install the drain plug with a new crush washer.
  80.  
  81. Refill the engine with clean oil.
  82.  
  83. Fill and bleed the air from the cooling system.
  84.  
  85. Connect the positive and the negative battery cables. Enter the radio security code.
  86.  
  87. Start the engine, checking carefully for any coolant, fuel, oil, or air leaks.
  88.  
  89. Check and adjust the ignition timing if necessary.
  90.  

V6 ENGINE

See Figures 3, 4, 5 and 6


WARNING
To avoid damaging the cylinder head, allow the coolant temperature to drop below 100°F (38°C) before removing the head bolts.

  1. Note the radio security code and station presets.
  2.  
  3. Disconnect the negative and positive battery cables.
  4.  
  5. Drain the engine coolant into a sealable container.
  6.  
  7. Remove the emissions evaporative hose from the throttle body.
  8.  
  9. Remove the vacuum hose and breather pipe from the air intake duct.
  10.  
  11. Remove the intake air duct.
  12.  
  13. Remove the covers for the ignition coils and intake manifold.
  14.  
  15. Remove the throttle cable and cruise control cable.
  16.  


CAUTION
The fuel injection system remains under pressure after the engine has been turnedOFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the residual fuel pressure in the fuel lines before removing. To relieve fuel line pressure remove the fuel filler cap, place a suitable rag or shop towel over the fuel pulsation damper and slowly loosen the fuel pulsation damper one complete turn using a suitable wrench. Always replace the sealing washers whenever the pulsation damper is removed or loosened.
  2.  
  3. Remove the fuel inlet and return hoses.
  4.  
  5. Remove the crankcase ventilation hose.
  6.  
  7. Remove the large and small diameter vacuum hoses from the brake booster.
  8.  
  9. Remove the valve cover breather hose and remove the three water bypass hoses at the throttle body.
  10.  
  11. Move the alternator belt tensioner to relieve tension on the alternator belt and remove the belt.
  12.  
  13. Remove the belt tensioner release arm.
  14.  
  15. Place a wood block on a floor jack and support the engine carefully by lifting on the oil pan.
  16.  
  17. Remove engine side mount bracket.
  18.  
  19. Loosen the power steering adjustment nut, and remove the adjustment locking nut, the pump mounting bolt and the power steering hose guide clamp bolt.
  20.  
  21. Remove the power steering belt and the power steering pump without removing the power steering hoses.
  22.  
  23. Remove the wire harness at the connector from the back of the alternator.
  24.  
  25. Remove the nut securing the large black wire at the back of the alternator and remove the wire.
  26.  
  27. Remove the alternator mounting bolt, the bracket mounting bolt and remove the harness clamp from the alternator bracket.
  28.  
  29. Remove the alternator.
  30.  
  31. Label and detach the wire harness connectors and harness clamps from the following:

    Intake air temperature (IAT) sensor connector
     
    Idle air control (IAC) valve connector
     
    Throttle position sensor (TPS) connector
     
    Manifold absolute pressure (MAP) sensor connector
     
    Heated Oxygen sensor (HO 2 S) connector
     
    Engine coolant temperature (ECT) sensor connector
     
    ECT switch connector
     
    ECT gauge sending unit connector
     
    Exhaust gas recirculation (EGR) valve lift sensor
     
    CKP/TDC/CYP sensor connector
     
    Ignition coil connectors
     
    VTEC solenoid valve terminal
     
    VTEC oil pressure switch terminal
     
    Oil pressure switch connector
     
    Radiator fan switch A terminal
     
    Radiator fan switch B terminal
     

  32.  
  33. Remove the six ignition coils from the cylinder head covers.
  34.  
  35. Remove the intake manifold.
  36.  
  37. Detach the connectors from the six fuel injectors and remove the fuel rails.
  38.  
  39. Remove the two vacuum hoses from the fuel injection air control valve.
  40.  
  41. Remove the timing belt, as outlined in this section.
  42.  
  43. Remove the upper and lower radiator hoses located near the throttle body.
  44.  
  45. Remove both heater hoses.
  46.  
  47. Detach the Oxygen (O 2 S) sensor wire connector.
  48.  
  49. Remove the front exhaust pipe with the O 2 S attached, and move it to a safe place out of the immediate work area.
  50.  
  51. Remove both exhaust manifolds.
  52.  
  53. Remove the thermostat housing water passage assembly.
  54.  
  55. Remove both camshaft sprockets and rear covers.
  56.  
  57. Remove both valve covers.
  58.  
  59. Loosen the cylinder head bolts 1 / 3 a turn in reverse order of the tightening sequence.
  60.  
  61. Continue the loosening sequence until all the bolts are loose.
  62.  
  63. Remove the cylinder head(s).
  64.  

To install:
  1. Be sure all cylinder head and block gasket surfaces are clean. Check the cylinder head for warpage. If warpage is less than 0.002 in. (0.05mm), cylinder head resurfacing is not required. The maximum resurface limit is 0.008 in. (0.2mm) based on a cylinder head total height of 4.76 in. (121mm).
  2.  
  3. Install a new head gasket.
  4.  
  5. Clean the oil control orifice and install new O-rings. Replace the oil control orifice if necessary.
  6.  
  7. Install the dowel pins to the engine block.
  8.  
  9. Check the timing belt drive pulley and clean if necessary.
  10.  
  11. Align the timing Top Dead Center (TDC) mark on the drive belt pulley with the pointer on the oil pump cover.
  12.  
  13. Be sure the No. 1 cylinder is at TDC/compression.
  14.  



Click image to see an enlarged view

Fig. Fig. 3: Crankshaft timing belt sprocket TDC marks. Align sprocket mark (A) with pointer ( B)-V6 Odyssey

  1. Inspect both camshaft cam belt pulleys for cleanliness and clean as necessary.
  2.  
  3. Align the camshaft sprocket TDC marks of both cylinder heads with the pointers located on the back cover.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Camshaft TDC marks. Align sprocket mark (A) with the back cover pointer (B)-Odyssey with V6 engine

  1. Inspect the cylinder head bolts for cleanliness and clean as necessary.
  2.  
  3. Apply a thin layer of clean engine oil to the bolt threads and flange area of the cylinder head bolts.
  4.  
  5. Carefully place the cylinder heads on the engine block.
  6.  
  7. Following the accompanying torque sequence, perform each step twice for each cylinder head. Tighten the head bolts for each cylinder head sequentially in following three steps:

    Step 1: 29 ft. lbs. (39 Nm)
     
    Step 2: 51 ft. lbs. (69 Nm)
     
    Step 3: 72.3 ft. lbs. (98.1 Nm)
     

  8.  



Click image to see an enlarged view

Fig. Fig. 5: Cylinder head torque sequence-Odyssey V6 engines

  1. Install a new exhaust manifold gasket on each cylinder head.
  2.  
  3. Install the exhaust manifolds and tighten the manifold nuts in three stages to a final torque of 23 ft. lbs. (31 Nm), using a crisscross pattern, starting with the inner manifold nut and working outward.
  4.  
  5. Install the exhaust pipe using new gaskets and torque the manifold flange self locking nuts to 40 ft. lbs. (54 Nm).
  6.  
  7. Torque the exhaust pipe flange mounting nuts to 25 ft. lbs. (33 Nm)
  8.  
  9. Install the exhaust pipe mounting bracket bolts and torque to 28 ft. lbs. (38 Nm).
  10.  
  11. Connect the O 2 S wire harness plug.
  12.  
  13. Install the manifold heat shields and tighten the heat shield bolts to 16 ft. lbs. (22 Nm).
  14.  
  15. Install the timing belt, as outlined in this section.
  16.  
  17. Check and adjust the valve clearances as necessary.
  18.  
  19. Inspect the valve cover gaskets and bolt sealing grommets for damage or deterioration and replace as necessary.
  20.  
  21. Install the valve covers and torque the bolts from the inside out in a crisscross pattern to 104 inch lbs. (12 Nm).
  22.  
  23. Install the thermostat housing water passage assembly using a new O-ring and new gaskets and torque the mounting bolts to 16 ft. lbs. (22 Nm).
  24.  
  25. Install the intake manifold using a new gasket and torque the bolts from the inside out in a crisscross pattern to 16 ft. lbs. (22 Nm).
  26.  



Click image to see an enlarged view

Fig. Fig. 6: Intake manifold torque sequence-Odyssey 3.5L V6 engines

  1. Install the ignition coils and torque the bolts to 104 inch lbs. (12 Nm).
  2.  
  3. Attach the wire harness connectors and harness clamps to the engine electrical components, as tagged during removal.
  4.  
  5. Install the alternator, mounting bolt, the bracket mounting bolt, and install the harness clamp to the alternator bracket.
  6.  
  7. Install the nut securing the large black wire at the back of the alternator and install the wire.
  8.  
  9. Install the wire harness at the connector to the back of the alternator.
  10.  
  11. Install the power steering pump, the hose guide clamp bolt, and the power steering belt.
  12.  
  13. Tension the power steering belt such that a 22 pound pull on the belt halfway between the two drive pulleys will allow the belt to move 0.51-0.65 in. (13.0-16.5mm).
  14.  
  15. Tighten the power steering pump mounting bolt and adjustment lock nut.
  16.  

If a new belt is used, set the tension such that a 22 pound pull on the belt halfway between the two drive pulleys will allow the belt to move 0.33-0.43 in. (8.5-11mm). After the engine has run for five minutes readjust the new belt to the used belt specification.

  1. Place a wood block on a floor jack and support the engine carefully by lifting on the oil pan.
  2.  
  3. Install engine side mount bracket.
  4.  
  5. Install the alternator belt tensioner arm.
  6.  
  7. Move the alternator belt tensioner to relieve tension on the alternator belt and install the belt.
  8.  
  9. Attach the valve cover breather hose and the three water bypass hoses to the throttle body.
  10.  
  11. Connect the large and small diameter vacuum hoses to the brake booster.
  12.  
  13. Install the crankcase ventilation hose.
  14.  
  15. Connect the fuel inlet and return hoses.
  16.  
  17. Attach the throttle cable and cruise control cable.
  18.  
  19. Install the covers for the ignition coils and intake manifold.
  20.  
  21. Install the intake air duct.
  22.  
  23. Connect the vacuum hose and breather pipe to the air intake duct.
  24.  
  25. Install the emissions evaporative hoses onto the throttle body.
  26.  
  27. Drain the engine oil into a sealable container and replace the engine oil filter.
  28.  
  29. Fill the engine oil to the specified amount using fresh engine oil that meets the standards of the vehicle manufacturer.
  30.  
  31. Open the heater control valve, fill the cooling system with the recommended coolant mix, and bleed all air from the cooling system.
  32.  
  33. Install the negative and positive battery cables.
  34.  
  35. Start the engine and allow it to reach normal operating temperature.
  36.  
  37. Check for proper adjustment of the cruise control and throttle cables once the engine has been started, reaches normal operating temperature, and is idling at the normal idle speed. The correct cable free play for the cruise control cable should be 0.13-0.17 in. (3.25-4.25mm). The throttle cable should have enough free play that the cable can be moved side to side 3 / 8 - 1 / 2 inch (10-12mm) at the throttle linkage.
  38.  
  39. Check all fluid levels and top off if necessary. Check for signs of fluid or fuel leaks.
  40.  
  41. Check the operation of the heater and air conditioner and verify proper adjustment of all belts and cables.
  42.  
  43. Enter the radio security code and radio presets.
  44.  
  45. Road test the vehicle and check for proper operation of all accessories.
  46.  

 
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