INFORMATION SHEET TURBO TOYS UPGRADE KIT COMPONENTS (1) Switch Bezel (1) Intercooler Sprayer Switch (1) Dial-A-Boost Switch (1) High Octane Mode Switch (1) Pump (1) P-Clamp (1) Screw 1/8 X 3/4 (4) Water Jet Nozzle (2) Water Jet Bracket (1) Water Jet Bracket Strap Tie kit (12ft) 4mm Nylon Tubing (2ft) 6mm Nylon Tubing (1) Check valve (1) Water Filter (1) Connector 6mm-4mm (1) Connector 10mm-6mm (1) Connector 4-way 4mm (1) Washer Bottle Grommet (12) Band Tie (1) Bond All Gel (1) Wiring Harness TURBO TOYS UPGRADE KIT FEATURE DESCRIPTION Intercooler Sprayers The four fine mist water spray nozzles attached to the front mounted intercooler are activated by the 3-position blue rocker switch located on the Turbo Toys bezel. The three intercooler spray system modes are defined as follows: Off Auto No spraying will occur in the off position. This mode uses an algorithm in the PCM to optimize charge air cooling with minimum use of fluid. The PCM monitors vehicle speed, ambient air temperature, charge air temperature, and throttle position to determine when to spray the intercooler. Manual This mode is activated when the switch is fully pressed down. The result is a constant spray of water upon demand. The sprayers will stay on continuously while the switch is held down and will remain on for a short time after the switch is released. The intercooler sprayers increase the efficiency of the intercooler and reduce charge air temperature, resulting in increased engine performance. The blue indicator lamp will illuminate whenever the system is spraying. NOTE: Distilled water is the recommended fluid for the intercooler sprayers. Use of the intercooler spray system is not recommended in driving conditions that warrant use of washer solvent. Dial-A-Boost Manage boost on demand by adjusting the 4-position thumb wheel located on the Turbo Toys bezel. Through boost torque management, engine output can be optimized for the best launch and driveability in conditions varying from the sticky launch pad at the drag strip to snow covered pavement. The thumb wheel can be set to the following four positions: Position 3 This position provides the highest boost level with torque management optimized for traction limit with high grip tires. Position 2 This position provides the highest boost level with torque management optimized for traction limit with the OEM tires. Position 1 This position provides mid-level boost. Position 0 This position provides minimum boost. High Octane Mode Fill the tank with 100 (R+M)/2 octane unleaded fuel, press the red switch located on the Turbo Toys bezel, and discover instant torque and power gains. The PCM will advance the spark, adjust the fueling, and increase the boost to take full advantage of the 100 octane unleaded fuel. The red indicator lamp will illuminate when High Octane Mode is active. During High Octane Mode operation, the PCM prevents damaging detonation via the OEM knock detection system. High Octane Mode will be bypassed if damaging knock is detected. The red indicator lamp will blink when High Octane Mode is bypassed. Spark advance and fueling are returned to standard levels in bypass mode. The blinking indicator light can be turned off by pressing the red High Octane Mode switch. Entering bypass mode is an indication that higher octane fuel is required. NOTE: It is recommended that the level of premium fuel be as low as possible when adding high octane fuel. The tank level should be reduced until the low fuel indicator is blinking and filled completely with 100 (R+M)/2 octane unleaded fuel before the High Octane Mode is engaged. The use of leaded fuels will cause damage to the vehicle s catalytic converter and oxygen sensors. Mopar Performance parts are sold as is, without any warranty whatsoever. Implied warranties, including warranties of merchantability or fitness for a particular purpose, are excluded. The entire risk as to quality and performance of such parts is with the buyer. Should such parts prove defective following their purchase, the buyer and not the manufacturer, distributor or retailer, assumes the entire cost of all necessary servicing or repair. Chrysler, Dodge, and Jeep vehicle and parts warranties are voided if the vehicle or parts are used for competition or if they fail as a result of modification. Not legal for use on pollution-controlled vehicles, or vehicles registered for highway use. For technical assistance regarding Turbo Toys Kit, please call the Mopar Performance Tech Line at (248) 969-1690. K68587010 04/02/04 Page 1 of 1 2004, DaimlerChrysler Motors Company, LLC. Mopar is a registered trademark of DaimlerChrysler Motors Company LLC. All Rights reserved.
INSTRUMENT PANEL CENTER BEZEL REMOVAL (1) Remove HVAC control knobs from control head (Fig. 1). (2) Remove both center A/C outlet louvers (Fig. 1). (3) Remove two screws retaining the top front of the center bezel up inside the center A/C outlet duct (Fig. 2). (4) Remove bezel from vehicle. Fig. 2 Instrument Panel Center Bezel Retaining Screws Fig. 1 A/C Outlet Louvers 1 - INSTRUMENT PANEL CENTER AIR DUCT 2 - OUTSIDE AIR/RECIRC CONTROL KNOB 3 - MODE CONTROL KNOB 4 - BLOWER SPEED KNOB 5 - TEMPERATURE CONTROL KNOB PLEASE DISCONNECT AND REMOVE THE BATTERY FROM THE VEHICLE! WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN. (1) Make sure ignition switch is in OFF position and all accessories are OFF. (2) Open hood. (3) Disconnect and isolate the battery negative cable then thepositive cable (5) Loosen bolt and retainer that holds the battery down to the tray. (6) Lift battery out of battery tray and remove from vehicle ACCESSORY SWITCH BEZEL REMOVAL (1) Disconnect the negative battery terminal. (2) Remove the four screws retaining the accessory switch bezel and pull the bezel forward (Fig. 3). (3) Disconnect the harness connectors to the following: Rear Window Defogger Switch Cigar Lighter/Power Outlet (4) Remove the rear window defroster switch from the accessory switch bezel, install into the bezel included in the kit. (5) Remove the power outlet base from the accessory switch bezel,install into the new bezel included in the kit. (NOT REQUIRED IF THE CAR DOES NOT HAVE CIGAR LIGHTER SINCE THE STANDARD POWER SOCKET IS SUPPLIED WITH BEZEL) Fig. 3 Removed Accessory Switch Bezel K68587010 04/02/04 Page 1 of 11 2004, DaimlerChrysler Motors Company, LLC. Mopar is a registered trademark of DaimlerChrysler Motors Company LLC. All Rights reserved.
Fig. 5 Harness Routing Through Lower Windshield Basin Fig. 4 Cigar Lighter/Power Outlet Base Removal 1 - RETAINING BOSSES ENGAGE PLIERS HERE 2 - PARTIALLY REMOVED 3 - EXTERNAL SNAP-RING PLIERS 4 - PULL BASE OUT THROUGH MOUNTING RING Note: The Turbo Toys replacement bezel is already equipped with a power supply socket (12V power point). If your vehicle does not have a cigar lighter then please go on to Wire Harness Installation POWER OUTLET BASE REMOVAL (1) Look inside and note the position of the retaining bosses. (2) Using external snap ring pliers with 90 degree tips, insert pliers with tips against bosses and squeeze, forcing bosses out of base (Fig. 4). (3) Pull out the base through the mounting ring by gently rocking the pliers. (4) Disconnect the base wires. (5) Set the base aside and remove the base mount ring. POWER OUTLET BASE INSTALLATION (1) Position the mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the indextab at 9 o clock to the key in the instrument panel. Install the ring. (2) Connect wires to base. Orient base alignment rib at 11 o clock to mate the groove in mount ring at the same location. (3) Push base into the bezel till it locks. (4) Install cigar lighter cap and check operation of element. Fig. 6 Black Rubber Wire Boot in Foot Well Fig. 7 Harness Routing Through Door Jam Body Hole K68587010 04/02/04 Page 2 of 11
WIRE HARNESS INSTALLATION (1) Remove the hood weather seal, both wiper arms, and both sides of the lower windshield panel (2) Obtain the wiring harness. Identify the end of the harness with the four indicator lamp wire leads and the nine switch connector wire leads. (3) Using masking tape, wrap the leads together to protect the wires and facilitate routing through the vehicle. (4) Route the harness through the lower windshield basin and upper left side fender (Fig. 5). Exit the left side fender above the level of the upper door hinge. (5) Remove the black rubber body plug located in the upper left side door jam slightly above the upper door hinge. (6) Punch a hole in the center of the body plug large enough to allow the harness conduit to pass through. (7) Insert the harness through the body plug. Slide the plug down the harness approximately four feet. (8) Partially remove the large black rubber wire boot located under the dash in the left side front foot well (Fig. 6). The wire boot is mounted in a hole through the body higher and forward of the hood release lever. (9) Remove lower steering column cover (2 screws) (10) Insert the harness into the exterior body hole and gently route the harness through the door jam and out the interior body hole the foot well (Fig. 7). (11) Route the harness over the knee bolster and secure it underthe dash and away from the controls with the tie straps provided. (12) Route the harness through the back of the center instrument cluster and out accessory switch bezel location. Fig. 9 Detached Interior Fuse Block IGNITION POWER LEAD TERMINATION (1) Remove the interior fuse panel cover located on the left hand side of the upper dash (Fig. 8). (2) Remove the screws that retain the fuse block and pull the fuse block away from the dash (Fig. 9 ). (3) Locate the BLUE/WHITE wire lead in the harness and route from the foot well, over the crash beam to the back of the fuseblock area and secure to the main harness with the tie straps provided. (4) Locate the BLUE/WHITE wire in the fuse block attached to circuit #31. (5) Strip a small portion of the insulation from the BLUE/WHITE fuse box wire. (6) Twist the BLUE/WHITE harness wire around the BLUE/WHITE fuse box wire, solder, and wrap with electrical tape. (7) Reinstall fuse block and cover. (8) Reinstall lower steering column trim panel. Fig. 8 Interior Fuse Panel Cover K68587010 04/02/04 Page 3 of 11
K68587010 04/02/04 Page 4 of 11 Fig. 10 Turbo Toys Wire Harness Electrical Diagram SPRAYER BLUE LED HIGH OCTANE RED LED INTERCOOLER SWITCH PIN DESCRIPTION COLOR GA 1 N/C 2 N/C 3 GROUND BLK 20 4 IGNITION POWER RED/WHT 20 5 SIGNAL FOR NGC BLU 20 DIAL BOOST ILLUMINATION POWER SOURCE PIN DESCRIPTION COLOR GA 1 SIGNAL OUTPUT GRY 20 2 5 VOLTS PPL 20 3 GROUND BLK 20 4 LIGHT ORG 20 HIGH OCTANE SWITCH PIN DESCRIPTION COLOR GA 1 N/C 2 HO SIGNAL WHT 20 3 GROUND BLK 20 4 N/C 3 1 2 4 5 GROUND LEFT FENDER BATTERY + IN PDC 3 1 2 4 5 IGNITION POWER BLU/WHT 18 5 A 15 A INTERCOOLER PUMP PIN DESCRIPTION COLOR GA 1 POWER RED/BLK 18 2 GROUND BLK 18 NEXT GENERATION CONTROLLER (NGC) PIN DESCRIPTION COLOR GA A10 INTERCOOLER SPRAY SWITCH INPUT GRN 20 A16 INTERCOOLER RELAY DRIVER YEL/BLK 20 A27 SENSOR POWER 5 VOLTS PPL 20 B22 DIAL BOOST SELECT INPUT GRY 20 C2 HIGH OCTANE FUEL SWITCH LED YEL/RED 20 C14 HIGH OCTANE FUEL SWITCH INPUT WHT 20 INSTALLATION INSTRUCTIONS
INTERCOOLER SPRAYER SWITCH CONNECTOR TERMINATION (1) Obtain the GRAY connector provided in the kit. This is the connector for the Intercooler Sprayer switch. (2) Locate the harness lead with the BLACK, RED/WHITE, and BLUE wires. (3) Insert the terminal ends into the connector slots as (4) Gently push in the terminals into the connector until they snap into place. (5) Push in the yellow clip on connector to lock the terminals. DIAL-A-BOOST SWITCH CONNECTOR TERMINATION (1) Obtain the BLACK connector provided in the kit. This is the connector for the Dial-A-Boost switch. (2) Locate the harness lead with the GRAY, PURPLE, BLACK and ORANGE wires. (3) Insert the terminal ends into the connector slots as 3 Black 4 Red/White 5 Blue 1 Grey 2 Purple 3 Black 4 Orange (4) Gently push in the terminals into the connector until they snap into place. (5) Push in the yellow clip on connector to lock the terminals. HIGH OCTANE MODE SWITCH CONNECTOR TERMINATION (1) Obtain the WHITE connector provided in the kit. This is the connector for the High Octane Mode switch. (2) Locate the harness lead with the WHITE and BLACK wires. (3) Insert the terminal ends into the connector slots as snap into place. (5) Push in the yellow clip on connector to lock the terminals. INTERCOOLER SPRAYER INDICATOR LAMP CONNECTOR TERMINATION (1) Obtain the MALE two wire connector provided in the kit. This is the connector for the Intercooler Sprayer indicator lamp. The indicator lamp is a blue LED that can be identified by the LED assembly with the blue wire and female connector shell. (2) Locate the harness lead with the RED/WHITE and YELLOW/BLACK wires. (3) Insert the terminal ends into the connector slots as A B (4) Gently push in the terminals into the connector until they snap into place. (5) Push the gray clip into the connector to the lock terminals. HIGH OCTANE MODE INDICATOR LAMP CONNECTOR TER- MINATION (1) Obtain the FEMALE two wire connector provided in the kit. This is the connector for the High Octane Mode indicator lamp. The indicator lamp is a red LED that can be identified by the LED assembly with the red wire and male connector shell. (2) Locate the harness lead with the RED/WHITE and YELLOW/RED wires. (3) Insert the terminal ends into the connector slots as A B Red/White Yellow/Black Red/White Yellow/Red 4) Gently push in the terminals into the connector until they snap into place. (5) Push the gray clip into the connector to the lock terminals. 2 White 3 Black (4) Gently push in the terminals into the connector until they K68587010 04/02/04 Page 5 of 11
DIAL-A-BOOST SWITCH ILLUMINATION POWER LEAD TER- MINATION (1) Remove the instrument panel center air duct by gently working its way through the front of the instrument panel. (2) Locate the ORANGE wire lead in the harness and route it to the HVAC control module area. (3) Locate the ORANGE wire in the HVAC control module connector. (4) Strip a small portion of the insulation from the ORANGE HVAC control module wire. (5) Twist the ORANGE harness wire around the ORANGE HVAC control module wire, solder, and wrap with electrical tape. (6) Reinstall the instrument panel center air duct. ACCESSORY SWITCH BEZEL INSTALLATION (1) Connect the rear window defogger switch, Intercooler Sprayer switch, Dial-A-Boost switch, High Octane Mode switch, and power outlet base. (2) Reinstall the switch bezel back into the center of the dash opening. (3) Install the four retaining screws. INDICATOR LAMP INSTALLATION (1) Identify a desired location in the instrument panel center bezel to mount the Intercooler Sprayer (BLUE) and High Octane Mode (RED) indicator lamps.. (2) Drill a 5/16 hole in the desired location for each indicator lamp. (3) Remove the black plastic bezel from both LEDs (Fig. 11). (4) Insert each LED through its hole from the back side of the instrument panel center bezel. (5) Slide the black plastic bezel over the LED and press the bezel into the hole (Fig. 12). (6) Connect both of the indicator lamp harness connectors. INSTRUMENT PANEL CENTER BEZEL INSTALLATION (1) Snap the center bezel into place. (2) Install the two screws retaining the top front of the center bezel up inside the center A/C outlet duct. (3) Install both center A/C outlet louvers. (4) Install HVAC control knobs onto control head. Fig. 11 LED Black Plastic Bezel Fig. 12 Indicator Lamp Install into Center Bezel Fig. 13 Harness Fuse Block Mounting Location UNDERHOOD WIRE HARNESS INSTALLATION (1) Route the wire harness across the far left side of the lower windshield basin just inboard of the driver s side hood hinge as shown in Figure 5. Be sure to route wire harness away from the windshield wiper mechanism (2) Reinstall the lower windshield panel and the windshield wiper arm. (3) Clip the harness fuse block to the sheet metal edge of lower wind shield basin (Fig. 13). (4) Reinstall the hood weather seal. (5) Route the wire harness around the shock tower. Use the provided tie straps to attach the harness to the vehicle harness in that area. (6) Route the harness between the strut tower and the Power K68587010 04/02/04 Page 6 of 11
Distribution Center (PDC). Align the relays and the positive battery lead with the rear right (vehicle right) corner of the PDC. (7) Route the harness between the fender and the left side (vehicle left) of the PDC. Align the negative battery lead with the body ground screw. (8) Remove the air box assembly. (9) Route the wire harness down to the PCM. Use the provided tie straps to attach the harness to the vehicle harness in that area. Fig. 14 Location of Positive and Negative Lead Contacts RELAY PLACEMENT, POSITIVE LEAD TERMINATION, AND NEGTIVE LEAD TERMINATION (1) Remove cover from PDC. (2) Loosen the positive battery cable nut in the PDC and install the power leg of the harness under the battery cable connector (Fig. 14). Re-tighten the nut. (3) Position the two relays in an open area in the PDC. Use the Velcro provided in the kit to secure them in place (Fig. 15). (4) Reinstall the PDC cover. It may be necessary to notch the cover for the harness. (5) Remove the ground screw located in front of the PDC (Fig. 14). Install the ground lead to the existing ground screw and retighten. PCM CONNECTOR A TERMINATION (1) Unplug all three PCM connectors. (2) Locate PCM connector A. It is the BLACK connector that is plugged into the bottom PCM connector slot. (3) Remove the black plastic cover off the back side of the connector. (4) Locate cavity A10 and A16. (5) Drill through the connector cavities with a 3/32 drill bit by hand. Do not use an electric drill. It is critical to not pierce any other wire or connector terminal. (6) Locate the GREEN and YELLOW/BLACK wires with terminal ends. (7) Insert the terminal ends into the connector slots as A10 A16 Green Yellow/Black (8) Locate the PURPLE wire lead in the harness. (9) Locate the PURPLE/WHITE wire in cavity A27. (10) Strip a small portion of the insulation from the PURPLE/WHITE wire in A27. (11) Twist the PURPLE harness wire around the PURPLE/WHITE wire in A27, solder, and wrap with electrical tape. (12) Install the new black plastic connector cover supplied in the kit. Use electrical tape to protect the new wires added to the connector. Fig. 15 Harness Relay Placement in PDC IMPORTANT NOTES: 1. Drill from the back of the connector just through the black plastic, no further. 2. Push a straight piece of small diameter wire through the K68587010 04/02/04 Page 7 of 11
hole from the back, pushing the stem filler out the front of the connector. 3. The connector lever must be in the unlocked position during the procedure. PCM CONNECTOR B TERMINATION (1) Locate PCM connector B. It is the ORANGE connector that is plugged into the second from the bottom PCM connector slot. (2) Remove the black plastic cover off the back side of the connector. (3) Locate cavity B22. (4) Drill through the connector cavity with a 3/32 drill bit by hand. Do not use an electric drill. It is critical to not pierce any other wire or connector terminal. (5) Locate the GRAY wire with terminal end. (6) Insert the terminal end into the connector slot as (7) Install the new black plastic connector cover supplied in the kit. Use electrical tape to protect the new wire added to the connector. B22 Gray PCM CONNECTOR C TERMINATION (1) Locate PCM connector C. It is the WHITE connector that is plugged into the third from the bottom PCM connector slot. (2) Remove the black plastic cover off the back side of the connector. (3) Locate cavities C2 and C14. (4) Drill through the connector cavities with a 3/32 drill bit by hand. Do not use an electric drill. It is critical to not pierce any other wire or connector terminal. (5) Locate the YELLOW/RED and WHITE wires with terminal ends. (6) Insert the terminal end into the connector slot as (7) Install the new black plastic connector cover supplied in the kit. Use electrical tape to protect the new wires added to the connector. (8) Connect the three PCM connectors to the PCM. Connector A in the lowest position, connector B second from bottom and connector C third from bottom. The connectors are keyed and will only mate into the proper position. (9) Reinstall the air box assembly and turbo inlet (clean air) hose. Ensure all clamps, lines, and fittings are properly installed C2 C14 Yellow/Red White FRONT FASCIA REMOVAL (1) Remove the fender well splash shield attaching screws. There are 2 screws per side. (2) Remove the nuts attaching the front fascia to the front fender flange. There are 3 nuts per side. (3) Remove the 5 screws that attach the bottom of the front fascia to the radiator close out panel. (4) Remove the 3 screws that attach the top of the front fascia to theupper radiator core support. (5) Disconnect the fog lamp and turn signal wire harness connectors. (6) Carefully remove the front fascia from the vehicle and set aside. (7) Remove radiator closeout panel. K68587010 04/02/04 Page 8 of 11
Fig. 16 Intercooler Sprayer Pump Hole Placement in Reservoir K68587010 04/02/04 Page 9 of 11
WINDSHIELD WASHER RESERVOIR MODIFICATION (1) Disconnect the washer hose at the pump and drain the reservoir. (2) Disconnect the wire harness connector from the washer pump. (3) Remove the 3 reservoir attachment fasteners and remove the reservoir from the vehicle. (4) Drill a 3/4" hole in the front of the reservoir. Refer to Fig. 16 for proper hole placement. (5) Remove all debris from the reservoir. Fig. 18 Intercooler Sprayer Tubing Assembly Fig. 17 Pump P-Clip Mounting Position INTERCOOLER SPAYER PUMP INSTALLATION (1) Install the pump grommet supplied in the kit into the drilled hole using glass cleaner as a lubricant. (2) Insert the intercooler sprayer pump into the grommet using glass cleaner as a lubricant. (3) Reattach the reservoir onto the vehicle. (4) Route and connect the intercooler sprayer pump wire lead from the PCM area to the pump. Use the provided tie straps to secure the wire lead in place. (5) Slide the P-clip over the intercooler sprayer pump and rotate the pump in the grommet toward the center of the vehicle. (6) Mark and drill the 1/8 P-clip attachment hole through the sheet metal in front of the reservoir. Make sure to position the pump inboard enough to not interfere with the fog lamp bracket (Fig. 17). (7) Install the 1/8 X3/4 screw through the P-clamp and into the sheet metal. (8) Connect the windshield washer pump wire connector and hose. Fig. 19 Intercooler Sprayer Bracket Location K68587010 04/02/04 Page 10 of 11
INTERCOOLER SPRAYER TUBING AND NOZZLE INSTALLATION NOTES: 1. USE BOILING WATER TO SOFTEN PLASTIC TUBING IN ORDER TO GET THEM TO SLIP OVER FITTING NIPPLES. 2. ALL FLUID LINES MUST BE FLUSHED THOROUGHLY AFTER EACH ASSEMBLY STEP TO PREVENT CLOGGING OF NOZZLES. (1) Apply two foam squares to each of the nozzle brackets on the side that touches the intercooler. (2) Locate the brackets on each end of the face of the intercooler. Make sure the bracket attachment feet are facing inward (Fig. 19). (3) Insert a bracket tie strap into each bracket mounting hole and through the vanes of the intercooler core section. Guide the tie strap end toward the bottom the intercooler to prevent it from entering the radiator/air conditioner core. (4) Secure each tie strap by attaching the plastic tie strap lock on the backside of the intercooler core section. Cut the excess tie strap once installed. (5) Thread one spray nozzle into each of the bracket holes. Make sure to aim the outlet of the spray nozzle inward. (6) Cut a 4 pieces of the 4mm tubing. The length depends on the desired routing. (7) Connect one end of each piece of 4mm tubing to the outlet of the 4mm 4-way connector. (8) Connect the other end of each piece of 4mm tubing to one of the spray nozzle barbs. (9) Route and secure all intercooler sprayer lines with the tie straps provided. (10) Use a solvent to remove all of the residue from the inside of the rubber 10mm-6mm elbow connector and the rubber 6mm-4mm connector. If the connectors are not properly cleaned, the Bond All Gel will not adhere. (11) Press the 10mm end of the elbow connector onto the intercooler sprayer pump outlet. (12) Cut 2 short pieces of 6mm tubing. The length depends on the desired routing. (13) Attach both pieces of 6mm tubing to each end of the inline water filter. (14) Apply some Bond All Gel to the end of one of the 6mm tubes and insert it into the 6mm end of the 10mm-6mm elbow connector. (15) Apply some Bond All Gel to the other 6mm tube and insert it into the 6mm end of the 6mm-4mm connector. (16) Cut a short piece of the 4mm tubing. The length depends on the desired routing. (17) Apply some Bond All Gel to one end of the piece of 4mm tubing and insert it into the 6mm end of the 6mm-4mm connector. (18) Insert the check valve into the other end of the piece of 4mm tubing. Make sure to point the arrow on the check valve in the direction of flow. (19) Cut a short piece of the 4mm tubing. The length depends on the desired routing. (20) Insert the outlet end of the check valve into the end of the piece of 4mm tubing. (21) Insert the other end of the piece of 4mm tubing into the 4mm inlet of the 4-way connector. (22) Secure all tubing away from harm using tie straps provided (23) Reinstall radiator closeout panel. FRONT FASCIA INSTALLATION (1) Carefully place the front fascia on the vehicle. (2) Install the 3 screws that attach the top of the front fascia to the upper radiator core support. (3) Install the 5 screws that attach the bottom of the front fascia to the radiator close out panel. (4) Connect the fog lamp and turn signal wire harness connectors. (5) Install the nuts attaching the front fascia to the front fender flange. There are 3 nuts per side. (6) Install the fender well splash shield attaching screws. There are 2 screws per side. (7) Reinstall battery and connect the positive and negative battery cables. K68587010 04/02/04 Page 11 of 11