RE-Assembly Instructions

1. Install distributor shaft into distributor. Turn shaft until mark is on top.

2. Install distributor and shaft assembly into engine. Tighten distributor bolts to 11 N-m (8 lb.ft.).


3. Connect four-terminal ECM connector to distributor.

4. Connect spark plug cables to distributor.

5. Install torsional damper to engine. Tighten damper bolts to 81 N-m (60 lb.ft.).

6. Install pump to engine (DO NOT FORCE PUMP ONTO ENGINE):

A. Clean engine block and coolant pump thoroughly.

B. Inspect O-rings on both pump shaft and drive assembly front cover for cracks and replace O-rings if damaged.





C. Apply light coat of grease to seals and splines before assembly of coupling to coolant pump. White band on coupling goes toward engine (refer to Figure 4, page 7).

D. Install new gaskets with tabs up.

E. Tighten coolant pump attaching bolts to 41 N-m (30 lb.ft.).

7. Install belt tensioner to engine. Tighten tensioner attaching bolt to 33 N-m (24 lb.ft.).

8. Install serpentine belt. Use long 5/8 inch box wrench to rotate tensioner.

9. Install coolant sensor wire harness retainer to front of coolant pump and connect ECM coolant sensor connection.

10. Connect upper and lower radiator hose and heater hose to pump.

11. Close radiator drain valve and install engine knock sensors after lightly applying a small amount of sealant to the threads of the knock sensors. DO NOT DIP KNOCK SENSORS IN SEALANT OR PUT SEALANT ON ENDS OF KNOCK SENSORS AS THIS WILL PREVENT THE KNOCK SENSORS FROM FUNCTIONING PROPERLY. Tighten knock sensors to 19 N-m (14 lb.ft.).

12. Open bleed valves on thermostat housing and throttle body.

13. Fill cooling system (using new coolant - 17.8 quarts 50/50 mix) through radiator surge tank until solid stream of coolant comes out bleed valves.

14. Close bleed valves and fill radiator surge tank until level is at the base of surge tank neck.

15. Install pressure cap.

16. Check level of coolant in recovery reservoir.


17. Install air cleaner and intake dust assembly.

18. Connect IAT electronic connection.

19. Clean off excess coolant from engine and compartment.

20. Connect negative battery cable. Tighten battery cable bolt to 15 N-m (11 lb.ft.).

21. Start engine, check for leaks and for proper coolant level.

22. Install Campaign Identification Label.

23. Repackage removed Opti-Spark Distributor in original shipping container and return to parts department.

24. Follow Opti-Spark Distributor Part Return Procedure as instructed in this bulletin.