For 1990-2009 cars

### Removal Procedure

1. Disconnect the negative battery cable.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Remove the intake air resonator. Refer to Intake Air Resonator Replacement in Engine Controls.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the splash shield bolts.
5. Remove the splash shield.
6. Counterhold the generator bolt on the back side of the generator to remove the AIR injection crossover pipe bracket nut (6) from the generator bolt.
7. Remove the AIR injection crossover pipe bushing nut (1), located on the left side of the engine, from the bracket.
8. Remove the AIR injection crossover pipe clamps from the rubber hose connections.
9. Remove the AIR injection crossover pipe from the rubber hose connections (2).
10. Lower the vehicle.
11. Remove the AIR injection diverter (8) hose clamp.
12. Remove the AIR injection diverter hose connection.
13. Remove the AIR injection crossover pipe (4).
14. Loosen the water pump pulley bolts. The serpentine drive belt tension provides the resistance to enable the loosening of the bolts. Do not remove the fastening bolts at this time.
15. Loosen the power steering pump pulley bolts. The serpentine drive belt tension provides the resistance to enable the loosening of the bolts. Do not remove the fastening bolts at this time.
16. Remove the A/C compressor hose support strap bolt from the AIR injection crossover bracket.
17. Remove the serpentine drive belt. Refer to Drive Belt Replacement.
18. Release the plastic retaining tabs on the wiring harness channel extension from the right lower side of the wiring harness channel and pull forward to remove.

Important: Use caution when releasing the retaining tabs to reduce the risk of breakage when removing the wiring harness channel cover.

19. Remove the wiring harness channel cover.
20. Note the wiring harness routing.
21. Remove the wiring harness from the channel.
22. Remove the water pump pulley bolts.
23. Remove the water pump pulley.
24. Remove the power steering pump pulley bolts.
25. Remove the power steering pump pulley.
26. Remove the serpentine drive belt tensioner bolts.
27. Remove the serpentine drive belt tensioner.
28. Remove the front timing belt cover bolts.
29. Remove the front timing belt cover.
30. Remove the transfer wiring harness channel.
31. Inspect the sealing strip on the outer edge of the front timing belt cover for cracks and/or tears.

### Installation Procedure

1. Install the front timing belt cover.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the front timing belt cover bolts.

Tighten
Tighten the front timing belt cover bolts to 8 N·m (71 lb in).

3. Install the serpentine drive belt tensioner.
4. Install the serpentine drive belt tensioner bolts.

Tighten
Tighten the serpentine drive belt tensioner bolts to 40 N·m (30 lb ft).

5. Install the power steering pump pulley.
6. Install the power steering pump pulley bolts.
7. Snug the power steering pump pulley bolts. The bolts will be tightened to proper specification when the serpentine drive belt is installed.
8. Install the water pump pulley.
9. Install the water pump pulley bolts. Snug the water pump pulley bolts. The bolts will be tightened to proper specification when the serpentine drive belt is installed.
10. Install the water pump pulley screws.
11. Route the wiring harness into the wiring harness channel.
12. Install the wiring harness channel cover.
13. Install the wiring harness channel extension to the right lower side of the wiring harness channel.
14. Install the serpentine drive belt. Refer to Drive Belt Replacement.
15. Install the A/C compressor hose support strap bolt to the AIR injection crossover bracket.

Tighten

• | Tighten the A/C compressor hose support strap bolt to 8 N·m (71 lb in).

• | Tighten the water pump pulley bolts to 8 N·m (71 lb in).

• | Tighten the power steering pump pulley bolts to 20 N·m (15 lb ft).

16. Install the AIR injection diverter (8) hose connections.
17. Install the AIR injection diverter hose clamps.
18. Install the AIR injection crossover pipe bushing nut (1), located on the left side of the engine, from the bracket.

Tighten
Tighten the AIR injection crossover pipe bushing nut to 12 N·m (108 lb in).

19. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
20. Install the AIR injection crossover pipe (4) to the rubber hose connections (2).
21. Install the AIR injection crossover pipe clamps to the rubber hose connections.
22. Install the AIR injection crossover pipe bracket (6) nut to the generator bolt.
23. Counterhold the generator bolt with a wrench on the back side of the generator to install the AIR injection crossover pipe support bracket nut to the generator bolt.

Tighten
Tighten the generator bolt to 40 N·m (30 lb ft).

24. Install the splash shield.
25. Install the splash shield bolts.

Tighten
Tighten the splash shield bolts until fully seated. Do not strip the splash shield bolts.

26. Lower the vehicle.
27. Install the intake air resonator. Refer to Intake Air Resonator Replacement in Engine Controls.
28. Reconnect the negative battery cable.
29. Reprogram the applicable accessories.