Upper And Lower Housing

WARNING: This page is about a different car, the 2004 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.

Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing (Fig 1). Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 in.) diameter. The single small check ball is approximately 4.8 mm (3/16 in.) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 in.) in diameter.

Fig 1: Locating Check Ball Locations In Upper Housing
Courtesy of DAIMLERCHRYSLER CORP.
Position assembled transfer plate and upper housing separator plate on upper housing (Fig 2). Be sure filter screen is seated in proper housing recess.

Fig 2: Installing Transfer Plate On Upper Housing
Courtesy of DAIMLERCHRYSLER CORP.
Install the ECE check ball into the transfer plate (Figure). The ECE check ball is approximately 4.8 mm (3/16 in.) in diameter.
Position lower housing separator plate on transfer plate (Fig 3).

Fig 3: Positioning Lower Housing Separator Plate On Transfer Plate
Courtesy of DAIMLERCHRYSLER CORP.
Install lower housing on assembled transfer plate and upper housing (Fig 4).

Fig 4: Installing Lower Housing On Transfer Plate And Upper Housing
Courtesy of DAIMLERCHRYSLER CORP.
Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 N.m (35 in. lbs.) torque. Start at center and work out to sides when tightening screws (Fig 4).