Part 2
38. Using the special tool, install a new O-ring seal onto the steering gear to power steering pump.
1 Push the new O-ring seal onto the special tool.
2 Locate the special tool onto the union and install the O-ring seal.
39. Connect the PSP tube.
40. Connect the PSP switch electrical connector.
41. Using the special tool, install the power steering pump pulley.
42. Install the coolant expansion tank and the bolt.
43. Connect the coolant hoses.
44. Connect the heater hose to the "T" fitting.
Vehicles equipped with a 2.0L engine and automatic transmission
45. Connect the transmission cooler hoses.
46. Connect the transmission shifter cable.
Vehicles equipped with a manual transmission
47. Connect the reversing lamp switch electrical connector.
48. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.
CAUTION: If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.
Connect the clutch slave cylinder supply tube.
- Install the clip.
49. NOTE: The shift cable abutment sleeve is colored white.
NOTE: The selector cable abutment sleeve is colored black.
Attach the transaxle cables to the bracket.
1 Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
2 Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
50. Attach the gearshift cables.
1 Attach the shifter cable to the shift mass.
2 Attach the selector cable to the selector lever.
51. Adjust the gearshift cables and bleed the clutch system.
All vehicles
52. Connect the three main engine wiring harness connectors and attach the connectors to the bracket.
53. Connect the power distribution harness eyelet and install the nut.
54. Attach the wiring harness retainers.
55. Connect the power distribution wiring harness electrical connector.
56. Connect the fuel charging wiring harness electrical connector.
57. Connect the fuel charging wiring harness electrical connector and harness retainer.
58. Install the ground eyelet and bolt.
59. Connect the upper radiator hose, the heater hose and the coolant vent hose to the coolant bypass.
60. Connect the Exhaust Gas Recirculation (EGR) valve electrical connector.
61. Install the power brake booster vacuum tube into the quick release fitting.
62. If equipped, connect the Secondary Air Injection (AIR) vacuum regulator electrical connector.
63. If equipped, connect the AIR hose.
64. Connect the evaporative emissions tube.
65. Connect the fuel tube quick release coupling onto the fuel rail.
66. Connect the accelerator cable and speed control cable (if equipped).
1 Install the accelerator cable bracket and bolts.
2 Connect the accelerator and speed control cable (if equipped) to the throttle body.
67. Install the accelerator control snow shield.
- Position the snow shield and install the screw and pin-type retainer.
- Attach the evaporative emissions hose pin-type retainer.
68. Install the air cleaner outlet pipe and air intake resonator into the grommets and install the bolt.
69. Tighten the air cleaner outlet pipe and connect the vent tube.
70. Clean and inspect the catalytic converter flange.
- Using a straightedge and a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
71. Using a new gasket and nuts, install the catalytic converter.
72. If equipped, connect the AIR hose.
73. If equipped, connect the upper exhaust sensor electrical connector and retainer.
74. Connect the exhaust sensor electrical connectors.
75. If removed, install the heat shield and bolts.
76. Install the catalytic converter support bracket and bolts.
77. NOTE: Clean the mating surfaces of the muffler assembly and catalytic converter.
Using a new gasket and nuts, connect the catalytic converter and muffler assembly.
78. Install the accessory drive belt.
1 Rotate the tensioner clockwise.
2 Install the accessory drive belt.
79. Install the accessory drive belt splash shield.
80. Install the battery tray.
81. Fill the engine with clean engine oil.
82. Fill and bleed the power steering system.
83. Fill and bleed the cooling system.
Vehicles equipped with air conditioning
84. Evacuate and charge the A/C system.