Assembly - Passenger Side

1. Assemble the passenger side of the engine by completing the following steps:

A. Install the water hose under the air regulator.

B. Install the air regulator and its connector. Ensure the 0-ring is in its proper location and tighten the bolts.

C. Install the PCV hose.

D. Install the brake booster hose.

E. Install the EGR solenoid valve connector, pressure regulator control valve connector and vacuum hose.

F. Install the EGR valve upper and lower tube nuts and tighten to 24 - 32 ft-lbs (34 - 44 N.m).

G. Install the EGR temperature sensor connector (if equipped).

2. Install the plenum ornament cover. Clean all the plenum ornament cover bolt threads with a wire brush. Apply a small amount of Loctite(R) # 222 (purple) to the screw threads and torque each screw to 53 - 69 in-lbs (6 - 8 N.m).

NOTE:
After the plenum is installed, make sure the ECI harness is installed in the original clamps. If clamps are missing or broken, replace them using the following part numbers:

Driver's side: 24228-89964 and 24220-35F01

Passenger side: 24220-05100

3. Perform an electrical circuit test using the following procedure.

NOTE:
The negative battery cable must not be connected prior to performing this test. If the terminal is corroded, clean with a wire brush.

A. Turn the dome light switch off and close all doors and trunk lid.

B. Check the resistance between the negative battery cable and the positive battery terminal with a volt/ohm meter. Make sure the contact points are clean and free of corrosion. (Negative test lead to the negative battery cable; positive test lead to the positive battery terminal). Record this value on the repair order.





C. Reverse the tester leads and check the resistance. (Negative test lead to the positive battery terminal; positive test lead to the negative battery cable). Record this value on the repair order.

If the resistance value is more than 100 ohms in either step B or C, the circuit is normal.

If the resistance reading is less than 100 ohms in both steps B and C, the circuit may be shorted. Check the injector harness to see if it is shorted to ground or damaged. Repair as necessary and recheck.

4. Reconnect the ground lead to the battery and recheck your work.

5. Start engine and inspect for leaks.

6. Perform the Engine Performance Assessment Test found in this bulletin. Erase any codes stored in ECCS memory and reset the clock and radio presets.

7. Perform the "Final Inspection Checklist" in this bulletin. Make a copy of this checklist for each vehicle that receives this campaign and attach the completed checklist to the vehicle repair order.