Engine- 2.3L: Other Ford Focus I рестайлинг

Valve Clearance Check

1. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-234427-S11704634312006060900000) .
2. Use a feeler gauge to measure each valve's clearance and record its location.
3. intake: 0.22-0.28 mm (0.008-0.011 inch) exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location.
4. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to «VALVE TAPPETS»(ref-234427-S28466906932006060900000) .

Scheme 1380

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1. Remove the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-207748) .
2. Remove the lower intake manifold bolt.
3. Remove the accelerator control snow shield.
4. Remove the air cleaner outlet tube. Loosen the retaining clamps. Remove the emissions breather tube. Remove the air cleaner outlet tube.
5. Disconnect the throttle position (TP) sensor electrical connector and position the wiring harness aside.
6. Disconnect the idle air control (IAC) valve electrical connector and position the wiring harness aside.
7. Disconnect the throttle cables from the intake manifold. Disconnect the accelerator cable and speed control cable (if so equipped) from the throttle linkage. Remove the bolts from the accelerator cable bracket and position aside.
8. Remove the evaporative emissions hoses.
9. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
10. Disconnect the electrical connectors and position the wiring harness aside.
11. Disconnect the outward intake manifold runner control (IMRC) actuator electrical connector.
12. Disconnect the vacuum hose from the fuel pressure regulator.
13. Loosen the fuel injection supply manifold retainers.
14. Disconnect the power brake booster vacuum tube. Disconnect the quick release coupling and pull out the line.
15. Remove the two oil level indicator tube bolts.
16. Remove the seven intake manifold bolts.
17. Raise the intake manifold enough to gain clearance to disconnect the knock sensor (KS) wiring harness.
18. Disconnect the positive crankcase ventilation (PCV) hose.
19. Remove the exhaust gas recirculation (EGR) tube.
20. Remove the intake manifold.

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1. Inspect and install new intake manifold gaskets, if necessary.
2. Install the EGR tube.
3. Install the PCV hose.
4. Connect the KS wiring harness.
5. Install the intake manifold and the seven mounting bolts.
6. Install the two oil level indicator tube bolts.
7. Reconnect the brake booster tube.
8. Tighten the fuel injection supply manifold retainers.
9. Install the fuel pressure regulator vacuum hose.
10. Connect the outward intake manifold runner control (IMRC) actuator electrical connector.
11. Connect the wiring harness and connectors.
12. Connect the TMAP sensor electrical connector.
13. Connect the evaporative emissions hoses.
14. Install the accelerator cable bracket. Install the accelerator cable bracket. Install the accelerator cable and speed control cable (if equipped).
15. Connect the IAC wiring harness and connector.
16. Connect the TP sensor electrical wiring harness and connector.
17. Install the air cleaner outlet tube.
18. Install the accelerator control snow shield.
19. Install the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-207748) .
20. Install the lower intake bolt.

Material

MATERIAL SPECIFICATIONS

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
2. Disconnect the camshaft position (CMP) sensor electrical connector.
3. Position aside the cylinder head temperature (CHT) sensor boot.
4. Disconnect the CHT sensor electrical connector.
5. Disconnect the coil-on-plug electrical connectors.
6. Remove the ignition coils. Remove the ignition coil bolts. While rotating, pull the ignition coils straight up.
7. Disconnect the breather tube from the valve cover.
8. Disconnect the wiring harness retainers from the valve cover studs and position aside.
9. Detach the fuel injection supply manifold wiring harness from the valve cover.
10. Disconnect the fuel injector electrical connectors.
11. Disconnect the fuel pressure regulator electrical connector and the vacuum hose.
12. Disconnect the upper HO2S electrical connector.
13. Disconnect the wiring connector. Remove the two wire connectors from the bracket. Remove the bracket bolt and position it aside.
14. Remove the bolts and the valve cover.
15. Clean and inspect the sealing surfaces.

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1. Inspect the valve cover gaskets for damage. Install new gaskets if necessary.
2. Install the valve cover and bolts. Tighten the bolts in the sequence shown.
3. Reposition the fuel injection supply wiring harness.
4. Install the bracket and bolt. Install the two wire connectors on the bracket.
5. Connect the upper HO2S electrical connector.
6. Connect the fuel injector electrical connectors.
7. Connect the fuel pressure regulator electrical connector and the vacuum hose.
8. Install the wiring harness retainers on the valve cover studs.
9. Install the breather tube on the valve cover.
10. Install the coil-on-plug assemblies. NOTE: Push the coil assemblies down firmly until the boot seal has sealed the access hole. Install the coil assemblies. Install the coil assembly bolts.
11. Connect the ignition coil electrical connectors.
12. Connect the cylinder head temperature (CHT) sensor electrical connector.
13. Position the CHT boot.
14. Connect the camshaft position (CMP) sensor electrical connector.
15. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 1442

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1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
2. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
3. Disconnect the dual electric cooling fan electrical connectors.
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207748) .
5. Lift and remove the cooling fan motors and shroud from the retainer brackets and lower from the vehicle.
6. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
7. Remove the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-139409) .
8. Remove the fuel injection supply manifold. For additional information, refer to «FUEL CHARGING & CONTROLS - 2.3L»(ref-207752) .
9. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-234427-S41087853422006060900000) .
10. Therefore the engine must be retimed each time the damper is removed. Otherwise severe damage can occur. Remove the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-234427-S28466906932006060900000) .
11. Remove the fuel injection supply manifold spacers.
12. Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector.
13. Remove the hoses from the air control valve.
14. Disconnect the EGR valve electrical connector.
15. Remove the coolant hoses from the coolant bypass.
16. Remove the coolant bypass. Remove the coolant bypass lower hose. Remove the coolant bypass bolts and the coolant bypass.
17. Disconnect the EGR coolant hose.
18. Disconnect the radio interference capacitor.
19. Remove the bolts and the cylinder head. Discard the bolts.
20. Remove and discard the head gasket.
21. Inspect the cylinder head mating surfaces. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .

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1. Clean the cylinder head gasket surfaces with metal surface cleaner.
2. Apply silicone gasket and sealant to the locations shown.
3. Install a new head gasket.
4. Install the cylinder head and new bolts. Tighten the bolts in the sequence shown in five stages. Stage 1: Tighten the bolts to 5 Nm (44 lb-in). Stage 2: Tighten the bolts to 15 Nm (11 lb-ft). Stage 3: Tighten the bolts to 45 Nm (33 lb-ft). Stage 4: Turn the bolts 90 degrees. Stage 5: Turn the bolts an additional 90 degrees.
5. Connect the radio interference capacitor electrical connector.
6. Install the EGR coolant hose.
7. Install the coolant bypass. Install the coolant bypass and the bolts. Install the coolant bypass lower hose.
8. Install the coolant hoses onto the coolant bypass.
9. Connect the EGR valve electrical connector.
10. Install the air control valve hoses.
11. Connect the EGR vacuum regulator electrical connector.
12. Install the fuel injector supply manifold spacers.
13. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-234427-S28466906932006060900000) .
14. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-234427-S41087853422006060900000) .
15. Install the fuel injector supply manifold. For additional information, refer to «FUEL CHARGING & CONTROLS - 2.3L»(ref-207752) .
16. Install the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-139409) .
17. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
18. Drain the engine oil and change the filter. Tighten the plug to 28 Nm (21 lb-ft).
19. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
20. Fill the engine with clean oil.
21. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207748) .
22. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-207742) .

MATERIAL SPECIFICATIONS

Scheme 1464

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Scheme 1466

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
2. Disconnect the oil pressure sender electrical connector.
3. Remove the oil filter.
4. Remove the four bolts and the oil filter adapter and gasket.
5. To install, reverse the removal procedure. Install a new oil filter adapter gasket.
6. Top off the engine with clean engine oil.
7. Run the engine and check for leaks.

MATERIAL SPECIFICATIONS

Scheme 1467

Scheme 1468

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
3. Disconnect the electrical connector from the oil pressure sender.
4. Remove the oil pressure sender.
5. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 1469

1. Remove the oil level indicator and tube. Remove the oil level indicator. Remove the two bolts. Remove the oil level indicator tube.
2. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 1470

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Scheme 1473

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
2. Drain the engine oil.
3. Remove the engine oil level indicator assembly. Remove the engine oil level indicator. Remove the bolts. Remove the engine oil level indicator tube.
4. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-234427-S41996954992006060900000) .
5. Remove the bolts.
6. Remove the oil pan-to-bellhousing bolts.
7. Remove the bolts and oil pan.

Scheme 1474

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Scheme 1477

1. Clean and inspect all mating surfaces.
2. Apply a 2.5 mm bead of silicone gasket and sealant to the oil pan. Install the oil pan. Position the oil pan onto the engine and install the two rear oil pan bolts finger-tight.
3. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
4. Install the remaining oil pan bolts and tighten in the sequence shown.
5. Install the oil pan-to-bellhousing bolts.
6. Install the oil pan-to-bellhousing bolts.
7. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-234427-S41996954992006060900000) .
8. Install the engine oil level indicator tube and the bolt. Install the engine oil level indicator tube. Install the bolts. Install the oil level indicator.
9. Fill the engine with clean engine oil.

MATERIAL SPECIFICATIONS

Scheme 1478

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-234427-S21824717752006060900000) .
3. Remove the bolts and the oil pump screen and pickup tube. Discard the gasket.

Scheme 1479

1. Clean and inspect all mating surfaces.
2. Install the oil pump screen and pickup tube with a new mounting gasket.
3. Install the oil pan. For additional information refer to «OIL PAN»(ref-234427-S21824717752006060900000) .

MATERIAL SPECIFICATIONS

Scheme 1480

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Scheme 1484

1. Remove the rear lifting eye and the front bracket.
2. Remove the cylinder head temperature (CHT) sensor.
3. Remove the exhaust gas recirculation (EGR) valve.
4. Remove the spark plugs.
5. Remove the 16 tappets.
6. Using the special tools, compress the valve spring and remove the valve spring retainer keys, the valve spring retainers, and the valve springs. Remove the special tools.
7. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) . Install new parts as necessary.
8. Remove the valves.
9. Using the special tools, remove and discard the valve stem seals.
10. Inspect the valves. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) . Install new parts as necessary.

Scheme 1485

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1. Install the valves.
2. Lubricate the valve and guides with clean engine oil and, using the special tool, install the valve stem seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the special tools, compress the valve spring and install the valve spring retainer keys. Remove the special tools.
5. Install the 16 tappets.
6. Install the CHT sensor.
7. Install the spark plugs.
8. Install the EGR valve and gasket.
9. Install the rear lifting eye and front lifting eye bracket.

SPECIAL TOOL SPECIFICATIONS Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Engine Stand 014-0232 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft 303-507 Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Adapter for 205-126 (205-072-02) Aligner, Clutch Disc 308-006 (T71P-7137-H) Heavy Duty Floor Crane 014-00071 or equivalent Locking Tool, Flywheel 303-103 (T74P-8375-A)

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MATERIAL SPECIFICATIONS

All vehicles

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1. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
2. Remove the engine plug bolt.
3. Install the special tool.
4. Install a new gasket and the oil pump assembly. Tighten the bolts in the sequence shown in two stages. Stage 1: Tighten the bolts to 10 Nm (89 lb-in). Stage 2: Tight the bolts to 23 Nm (17 lb-ft).
5. Install a new oil pump pickup tube gasket and the pickup tube.
6. Using the special tool, install the crankshaft rear main oil seal.
7. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
8. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the oil pan bolts in the sequence shown.
9. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
10. Apply silicone gasket and sealant to the locations shown.
11. Install a new cylinder head gasket.
12. Clean the cylinder head surface with metal surface cleaner.
13. Install the cylinder head and the new bolts. Tighten the bolts in the sequence shown in five stages. Stage 1: Tighten the bolts to 5 Nm (44 lb-in). Stage 2: Tighten the bolts to 15 Nm (11 lb-ft). Stage 3: Tighten the bolts to 45 Nm (33 lb-ft). Stage 4: Tighten the bolts an additional 90 degrees (1/4 turn). Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
14. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages. Stage 1: Tighten the camshaft bearing caps one turn at a time until tight. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
15. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block.
16. Install the oil pump sprocket bolt.
17. Install the oil pump chain guide and the shoulder bolt.
18. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
19. Install the camshaft sprockets and the bolts. Do not tighten the sprocket bolts at this time.
20. Using the edge of a vise, compress the timing chain tensioner plunger.
21. Using a small pick, push back and hold the ratchet mechanism.
22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
23. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
24. Install the timing chain.
25. Install the timing chain guides.
26. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.
27. Install the special tool in the timing slots on the rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
28. Tighten the camshaft sprocket bolts.
29. Clean the front cover gasket surface with metal surface cleaner.
30. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
31. Apply silicone gasket and sealant to the locations shown.
32. Install the front cover. Tighten the bolts in the sequence shown in three stages. Stage 1: Tighten the 8 mm bolts to 10 Nm (89 lb-in). Stage 2: Tighten the 10 mm bolts to 25 Nm (18 lb-ft). Stage 3: Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
33. Install the crankshaft pulley and hand-tighten the bolt.
34. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
35. Using the special tools to hold the crankshaft pulley in place, tighten the pulley bolt in two stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees.
36. Remove the special tools.
37. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
38. Remove the special tool.
39. Remove the special tool.
40. Turn the engine two complete revolutions.
41. Turn the engine until the No. 1 piston is at top dead center (TDC).
42. Install the special tool.
43. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
44. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
45. Remove the special tool.
46. Install a new CKP sensor. Do not tighten the bolts at this time.
47. Adjust the CKP sensor with the alignment tool and tighten the bolts.
48. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
49. Remove the special tool.
50. Install the engine plug bolt.
51. Clean the valve cover gasket surface with metal surface cleaner.
52. Apply silicone gasket and sealant to the locations shown.
53. Install the valve cover. Tighten the bolts in the sequence shown.
54. Install the following: Camshaft position (CMP) sensor. Cylinder head temperature (CHT) sensor. Spark plugs.
55. Install the ignition coils. Tighten the bolts to 10 Nm (89 lb-in).
56. Install the coolant pump.
57. Install the coolant pump pulley.
58. Install the fuel injection supply manifold and the ground strap.
59. Install the engine vent cover and the KS.
60. Install a new gasket and the thermostat housing.
61. Install the bypass hose and the clamp.
62. Connect the ignition coil and the CHT sensor electrical connectors.
63. Reposition the CHT sensor boot.
64. Connect the fuel injector connector and the wiring harness pin-type retainers.
65. Install the intake manifold assembly.
66. Secure the pin-type retainers to the intake manifold.
67. Install the positive crankcase ventilation (PCV) hose.
68. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
69. Connect the CMP sensor electrical connector.
70. Connect the swirl control valve monitor electrical connector and the hose.
71. Connect the idle air control (IAC) motor electrical connector.
72. Connect the throttle position (TP) sensor electrical connector.
73. Install the exhaust gas recirculation (EGR) valve. Install the EGR valve and bolts. Connect the EGR valve electrical connector.
74. Install the block heater, if equipped.
75. Connect the knock sensor (KS) electrical connector.
76. Connect the heater hose to the thermostat housing.
77. Connect the coolant hose to the EGR valve.
78. Install the generator.
79. Install the coolant bypass. Install the bolts. Install the hose.
80. Install the oil level indicator tube. Install the oil level indicator tube. Install the bolts. Install the oil level indicator.
81. Install the accessory drive belt.
82. Using the heavy duty floor crane and the spreader bar, remove the engine from the stand.
83. Install the flywheel or the flexplate and the bolts.
84. Install the special tool.
85. Tighten the bolts in the sequence shown in three stages. Stage 1: Tighten the bolts to 50 Nm (37 lb-ft). Stage 2: Tighten the bolts to 80 Nm (59 lb-ft). Stage 3: Tighten the bolts to 112 Nm (83 lb-ft).
86. Lubricate the transmission input shaft pilot bearing with front axle grease.
87. Adjust the clutch pressure plate. Using a suitable press, press downward on the fingers until the adjusting ring moves freely. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
88. Using the special tool, position the clutch disc on the flywheel.
89. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence. Remove the Clutch Disc Aligner.

SPECIAL TOOL SPECIFICATIONS Powertrain Lift With Tilting Plate 014-00765 or equivalent Universal Adapter Brackets 014-0001 Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A)

Scheme 1547

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MATERIAL SPECIFICATIONS

Vehicles equipped with automatic transmissions

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Scheme 1604

1. Remove the special tool from the torque converter. Install the dowel pins.
2. Check the installation depth of the torque converter. Lay a steel straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
3. Using the engine crane, position the engine and transaxle together and install five of the six top bolts.
4. Install the LH flange bolts.
5. Install the transaxle. Make sure the transaxle is flush to the engine.
6. Install the two bolts at the dowels first. Tighten to specification.
7. Install the remaining transaxle RH flange bolts.
8. Using the special tools, raise the engine and transaxle assembly.
9. Using the special tools, secure the engine and transaxle assembly to the lift table.
10. Connect the output shaft speed (OSS) sensor electrical connector.
11. Connect the solenoid body and the transmission range (TR) sensor electrical connectors.
12. Connect the turbine shaft speed (TSS) sensor electrical connector.
13. Connect the vehicle speed sensor (VSS) electrical connector.
14. Using the lift table, position the engine and transaxle assembly in the vehicle.
15. Install the RH motor mount nuts.
16. Install the LH motor mount nut.
17. Remove the special tools and the lift table.
18. Install the lower motor mount. Install the lower mount. Install the bolts.
19. Install the two lower engine-to-bellhousing bolts.
20. Install the remaining engine-to-bellhousing bolts.
21. Install the four torque converter nuts.
22. Install the starter motor isolator.
23. Install the starter motor and the bolts.
24. Install the generator heat shield and the lower nut.
25. Position the compressor to the manifold and tube assembly and tighten the bolt.
26. Install the A/C compressor and the three bolts and connect the field coil electrical connector.
27. Attach the power steering pressure tube brackets to the stud bolts and install the nuts.
28. Connect the starter motor electrical connections.
29. Install the cooling fan.
30. Connect the transmission cooler hoses.
31. Connect the transmission shifter cable.
32. Position the battery cable and install the cable bracket nut.
33. Install the generator cooling tube.
34. Install the generator heat shield top nut.
35. Install the generator B+ cable and install the cable nut.
36. Install the upper radiator hose.
37. Position the ground cable and install the bolt.
38. Connect the cooling fan electrical connector.
39. Connect the cooling fan electrical connector.
40. Connect the wiring harness retainers to the valve cover studs.
41. Position the power steering pump (PSP) and install the bolts.
42. Connect the PSP tube.
43. Using the special tool, install the power steering pump pulley.
44. Connect the PSP switch electrical connector.
45. Connect the three main engine wiring harness connectors.
46. Install the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-207748) .
47. Connect the heater hose to the "T" fitting.
48. Connect the exhaust gas recirculation (EGR) valve electrical connector.
49. Connect the fuel injection supply manifold wiring harness electrical connector.
50. Reposition the accelerator cable bracket. Position the accelerator cable bracket. Install the speed control cable (if equipped) and the throttle cable.
51. Attach the hose and install the screw and the pin-type retainer. Install the snow shield.
52. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
53. Connect the lower radiator hose, the heater hose and the overflow hose to the coolant bypass.
54. Connect the engine emissions hose and EGR vacuum regulator solenoid electrical connector.
55. Install the vapor tube.
56. Connect the fuel tube. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
57. Install the brake booster vacuum hose.
58. Fill the engine with clean engine oil.
59. Install the LH front drive halfshaft.
60. Install the RH front halfshaft together with the intermediate shaft.
61. Install the mounting bracket for the front drive halfshaft intermediate bearing.
62. Install both of the lower control arms to the knuckles. Connect the suspension arm ball joint. Install the bolt.
63. Install both of the tie-rod ends to the knuckles.
64. Connect the stabilizer bar at the strut.
65. Tighten the LH strut and spring assembly top mount nuts.
66. Install the caliper. Install the bolts. Install the covers.
67. Install the brake hose onto the support bracket.
68. Install the accessory drive belt.
69. Connect the reversing lamp switch electrical connector.
70. Connect the clutch slave cylinder supply line. Insert the clip.
71. Attach the gearshift cables to the bracket. Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders. Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
72. Attach the gearshift cables. Attach the shifter cable to the shift mast. Attach the selector cable to the selector lever.
73. Check the shift cables at the metal holders. Pull outward on the cables. Cables should remain in the metal.
74. Adjust the shift cables. For additional information, refer to «MANUAL TRANSMISSION/TRANSAXLE & CLUTCH - GENERAL INFORMATION»(ref-207765) .
75. Fill and bleed the clutch hydraulic system. For additional information, refer to «CLUTCH CONTROLS - MT285/MTX75 TRANSAXLE»(ref-207770) .
76. Evacuate and recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-207782) .
77. Install the air intake resonator. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-207759) .
78. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
79. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
80. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207748) .
81. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-207742) .