B4000 DS Cab Plus 4 2WD V6-4.0L SOHC (2002)
31.
Remove the supports and lower the vehicle.
32.
Connect the fuel vapor hose, and vacuum harness to the left hand valve cover.
33.
Install the heated PCV valve and connect the hose.
34.
Connect the Camshaft Position (CMP) sensor, and the DPFE transducer electrical connectors.
35.
Attach the 42-pin engine electrical connector to the left hand valve cover bracket and connect. Tighten connector bolt to 6 Nm (53 lb-in).
36.
Install the intake manifold:
-
Position the intake manifold, connect the heated PCV fitting, and install the bolts
-
Tighten the intake manifold bolts to 10 Nm (89 lb-in).
37.
Attach the knock sensor electrical connector to the intake manifold.
38.
Position the Powertrain Control Module (PCM) wire harness:
-
Position the wire harness and connect the PCM electrical connector. Tighten to 7 Nm (62 lb-in).
-
Install the retainer(s) attaching the ground wire and wire harness support bracket to the bulk head. Tighten to 10 Nm (89 lb-in).
39.
Install ignition coil and bracket assembly:
-
Tighten top bolts to 8 Nm (71 lb-in).
-
Tighten the bottom bolts to 23 Nm (17 lb-ft).
40.
Connect ignition coil electrical connector.
41.
Connect the radio interference capacitor electrical connector.
42.
Connect the spark plug wires to the ignition coil. Connect the spark plug wires to the separators or attach the routing clip push pin.
43.
Connect the exhaust manifold to EGR valve tube. Tighten the fitting to 34 Nm (25 lb-ft).
44.
Connect the crankcase ventilation hose, brake booster vacuum hose, and the EGR valve vacuum hose.
45.
Connect the EGR vacuum regulator electrical connector and vacuum connector.
46.
Connect the Idle Air Control (IAC) valve and Throttle Position Sensor (TPS) electrical connectors.
47.
Connect both air intake manifold left hand vacuum connections.
48.
Connect the accelerator cable and speed control cable (if equipped).
49.
Install and connect the engine air cleaner cover and outlet pipe.
50.
Install the engine appearance cover.
51.
Fill the engine with clean engine oil.
52.
Connect the battery negative cable.
53.
Fill the radiator and coolant reservoir with the correct 50/50 mix of ethylene glycol (coolant) and water mixture.
54.
Move the interior climate control temperature selector to the full WARM position.
55.
Run the engine until it reaches operating temperature.
56.
Add the correct coolant mixture to the radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks.
57.
Recheck the coolant level and fill as necessary.
