Installation Procedure
- Position the clutch actuator cylinder pipe in the vehicle.
Remove the cap or plug from the exposed hose and clutch master cylinder fittings.
- Connect the clutch actuator cylinder pipe (3) to the clutch master cylinder pipe.
- Install the clutch actuator cylinder pipe retaining clip (1) to the clutch master cylinder pipe.
- Connect the clutch actuator cylinder pipe (3) to the transmission.
- Install the clutch actuator cylinder pipe retaining clip (1) to the transmission.
- Install NEW zip ties (2) that hold the clutch master cylinder pipe (3) in place.
Turbocharger Exhaust Pipe Gasket (2) - Install NEW
- Warm Up Three-Way Catalytic Converter (1) - Install
- CAUTION:
Refer to Fastener Caution .
Catalytic Converter Nut (1) - Install and tighten [4x] - Fastener Specifications
- NOTE:
A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers
CAUTION:Refer to Component Fastener Tightening Caution .
Using a suitable tool, install and tighten the heated oxygen sensor (1). Fastener Specifications
- Connect the heated oxygen sensor electrical connector.
Using a suitable tool, install and tighten the heated oxygen sensor (1). Fastener Specifications
- Connect the heated oxygen sensor electrical connector.
Catalytic Converter Brace (3) - Install
- Catalytic Converter Brace Bracket Nut (1) - Install and tighten [5x] - Fastener Specifications
Catalytic Converter Gasket (2) - Install NEW
- With the aid of an assistant, install the exhaust muffler (1).
Exhaust Muffler Hanger Bracket Nut (1) - Install and tighten [4x] - Fastener Specifications
Electrical Connector (1) - Connect
Electrical Connector (1) - Connect
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator- Right Side (2) - Install [2x]
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator- Left Side (2) - Install [2x]
Exhaust Pipe Clamp (1) - Tighten [2x] - Fastener Specifications
Catalytic Converter Nut (1) - Install and tighten [2x] - Fastener Specifications
Floor Panel Reinforcement (2) - Install
- Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Install and tighten [6x] - Fastener Specifications
Underbody Rear Air Deflector- Right Side (5) - Install
- Underbody Rear Air Deflector Nut- Right Side (3) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Bolt- Right Side (2) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Nut- Right Side (4) - Install and tighten [2x] - Fastener Specifications
- Rear Wheelhouse Liner Bolt- Right Side (1) - Install and tighten - Fastener Specifications
Underbody Rear Air Deflector- Left Side (5) - Install
- Underbody Rear Air Deflector Nut- Left Side (2) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Bolt- Left Side (3) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Nut- Left Side (4) - Install and tighten [2x] - Fastener Specifications
- Rear Wheelhouse Liner Bolt- Left Side (1) - Install and tighten - Fastener Specifications
Rear Tire Front Air Deflector- Left Side and Right Side (2) - Install [2x]
- Rear Tire Front Air Deflector Bolt- Left Side and Right Side (1) - Install and tighten [4x] - Fastener Specifications
- Lower the vehicle.
Turbocharger Heat Shield (1) - Install
Turbocharger Heat Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications
Radiator Outlet Pipe Seal (2) - Install NEW
- Radiator Outlet Pipe (1) - Install
Radiator Outlet Pipe Bolt (2) - Install and tighten - Fastener Specifications
- Radiator Outlet Pipe Bolt (1) - Install and tighten - Fastener Specifications
Wiring Harness Retainer (1) - Install [2x]
Heater Outlet Hose (4) @ Auxiliary Heater Inlet Hose Tee - Install
- Heater Outlet Hose Clamp (3) @ Auxiliary Heater Inlet Hose Tee - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Inlet Hose (2) @ Heater Core - Install
- Heater Inlet Hose Retainer (1) - Engage
Radiator Outlet Pipe Bolt (1) - Install and tighten - Fastener Specifications
Radiator Outlet Hose (2) @ Radiator Outlet Pipe - Install
- Radiator Outlet Hose Clamp (1) @ Radiator Outlet Pipe - Engage - Hose Clamp Replacement Guidelines - Spring Type
Air Cleaner Assembly (2) - Install
- Air Cleaner Bolt (1) - Install and tighten - Fastener Specifications
- Install all retainers and wiring harnesses to the air cleaner assembly as necessary.
- Connect the 2 mass airflow sensor electrical connectors.
Auxiliary Air Cleaner Outlet Duct (4) - Install
- Air Cleaner Outlet Duct Clamp (3) - Tighten - Fastener Specifications
- Air Cleaner Outlet Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten - Fastener Specifications
Front End Sheet Metal Cross Brace- Left Side and Right Side (3) - Install [2x]
- Front Suspension Strut Upper Mounting Nut- Left Side and Right Side (2) - Install and tighten [4x] - Fastener Specifications
- Front End Sheet Metal Cross Brace Bolt- Left Side and Right Side (1) - Install and tighten [6x] - Fastener Specifications
- Install all wiring harness retainers to the front end sheet metal cross braces.
Radiator Air Upper Baffle- Upper (3) - Install
- Radiator Air Upper Baffle Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Radiator Air Upper Baffle Retainer (1) - Install [5x]
Transmission Control Module (1) @ Engine Control Module Bracket (2) - Install
- Engine Control Module Bracket (2) - Install
Engine Control Module Bracket Bolt (1) - Install and tighten [3x] - Fastener Specifications
Engine Control Module (1) - Install
- Connect the electrical connectors.
Radiator Surge Tank Outlet Pipe (3) - Install
- Radiator Surge Tank Inlet Hose Clamp (4) @ Engine Radiator - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose Clip (2) @ Engine Control Module Bracket - Install
- Radiator Surge Tank Inlet Hose Clamp (1) @ Radiator Surge Tank Inlet Hose - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Bleed the clutch hydraulic system. Hydraulic Clutch System Bleeding
- Fill the cooling system to the proper level. Cooling System Draining and Filling (LSY GE 47716) , or Cooling System Draining and Filling (LSY Static Fill) , or Cooling System Draining and Filling (LSY with V03 Static Fill) , or Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716) , or Cooling System Draining and Filling (LSY with V03 GE 47716) , or Cooling System Draining and Filling (LF4 Static Fill) , or Cooling System Draining and Filling (LF4 GE 47716)
- Connect the negative battery cable. Battery Negative Cable Disconnection and Connection
- Start the engine and check for coolant leaks.
- Inspect the exhaust system for leaks.