Installation Procedure
- NOTE:
Some components not shown for graphic clarity.
Apply RTV silicone sealant on the engine front cover split lines (1). The required thickness of the sealing bead is 8 mm (0.3150 in) by 4 mm (0.1575 in). Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
Some components not shown for graphic clarity.
Camshaft Cover Seal (2) - Install NEW
- Camshaft Cover (1) - Install
- CAUTION:
Refer to Fastener Caution .
NOTE:Some components not shown for graphic clarity.
Camshaft Housing Cover Bolt (1) - Install and hand tighten [15x]
- Camshaft Housing Cover Bolt (2) - Tighten in sequence [15x] - Fastener Specifications
EN-46101 Spark Plug Tube Seal Guides (1) - Remove [3x]
Upper Intake Manifold Bracket (3) - Install
- Radiator Surge Tank Inlet Pipe Bracket (2) - Install
- Upper Intake Manifold Cover Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
Engine Wiring Harness (3) - Install
- Engine Wiring Harness Retainer (1) - Install [5x]
Radiator Surge Tank Inlet Hose (4) - Install
- Radiator Surge Tank Inlet Hose Clip (3) @ Radiator Surge Tank Inlet Pipe Bracket - Connect
Air Cleaner Outlet Duct (1) - Install
Retainer Spring (4) - Engage
- Air Cleaner Outlet Duct Clamp (3) - Tighten - Fastener Specifications
- Charge Air Bypass Valve Hose (2) - Install
- Charge Air Bypass Valve Hose Clamp (1) - Tighten - Fastener Specifications
Install the NEW positive crank ventilation foul air tube (2) and secure the 2 positive crankcase ventilation tube connectors (1).
Lower Intake Manifold Gasket (2) - Install NEW [6x]
- Intake Manifold (1) - Install
If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Remove loose debris from internal and external threads using compressed air.
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
- Lower Intake Manifold Bolt (1) - Install and hand tighten [6x]
- Lower Intake Manifold Bolt (1) - Tighten in sequence [6x] - Fastener Specifications
- Connect all electrical connectors.
- NOTE:
Some components not shown for graphic clarity.
Positive Crankcase Ventilation Foul Air Tube (2) - Install
- Positive Crankcase Ventilation Tube Connector (1) - Connect [2x] - Plastic Collar Quick Connect Fitting Service
Fuel Pipe Shield (1) - Install
Wiring Harness (3) - Install
- Retainer (2) - Install [3x]
- Engine Rear Noise Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Engine Rear Noise Shield Bolt (1) - Install and tighten - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
Charge Air Cooler Cover Seal (3) - Install NEW [2x]
- Intake Manifold Gasket (2) - Install NEW
- Charge Air Cooler Cover (1) - Install
- NOTE:
Some components not shown for graphic clarity.
Charge Air Cooler Cover Bolt (2) - Install and hand tighten [12x]
- Charge Air Cooler Cover Bolt (2) - Tighten in sequence [12x] - Fastener Specifications
- Charge Air Cooler Bolt (1) - Install and hand tighten [2x]
- Charge Air Cooler Bolt (1) - Tighten in sequence [2x] - Fastener Specifications
- Connect the electrical connector.
Charge Air Cooler Inlet Air Tube Seal (4) - Install NEW
- Charge Air Cooler Inlet Pipe (3) - Install
- Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
- Charge Air Cooler Inlet Air Tube Bolt (1) - Install and tighten [2x] - Fastener Specifications
Charge Air Bypass Valve (3) - Install
- Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
- Charge Air Bypass Valve Hose Clamp (1) - Tighten - Fastener Specifications
Charge Air Cooler Inlet Air Tube Seal (4) - Install NEW
- Charge Air Cooler Inlet Pipe (3) - Install
- Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
- Charge Air Cooler Inlet Air Tube Bolt (1) - Install and tighten [2x] - Fastener Specifications
Charge Air Bypass Valve (3) - Install
- Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
- Charge Air Bypass Valve Hose Clamp (1) - Tighten - Fastener Specifications
Charge Air Cooler Coolant Pipe Seal (3) - Install NEW [4x]
- Supercharger Water Manifold Gasket (2) - Install NEW [2x]
- Supercharger Water Manifold (1) - Install
Charge Air Cooler Coolant Manifold Bolt (1) - Install and tighten [4x] - Fastener Specifications
Charge Air Cooler Coolant Hose (4) - Install
- Charge Air Cooler Coolant Hose Clamp (3) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Charge Air Cooler Coolant Hose (2) - Install
- Charge Air Cooler Coolant Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Turbocharger Wastegate Actuator Vacuum Tank (2) - Install
- Turbocharger Wastegate Actuator Vacuum Tank Bolt (1) - Install and tighten [2x] - Fastener Specifications
Electrical Connector (1) @ Charge Air Bypass Valve (2) - Connect
Charge Air Bypass Valve Tube (1) @ Charge Air Bypass Valve - Connect - Plastic Collar Quick Connect Fitting Service
Electrical Connector (1) @ Charge Air Bypass Valve (2) - Connect
Charge Air Bypass Valve Tube (1) @ Charge Air Bypass Valve - Connect - Plastic Collar Quick Connect Fitting Service
Turbocharger Wastegate Actuator Vacuum Source Tube @ Vacuum Pump - Connect - Plastic Collar Quick Connect Fitting Service
Charge Air Bypass Valve Vacuum Tank Tube (3) - Connect - Plastic Collar Quick Connect Fitting Service
Turbocharger Wastegate Actuator Vacuum Tank Solenoid Valve Tube (3) @ Auxiliary Air Cleaner Outlet Duct - Connect - Plastic Collar Quick Connect Fitting Service
Turbocharger Wastegate Actuator Vacuum Tank Bolt (3) - Install and tighten [2x] - Fastener Specifications
- Connect the turbocharger wastegate regulator solenoid valve electrical connector.
Turbocharger Wastegate Actuator Vacuum Tank Bolt (3) - Install and tighten [2x] - Fastener Specifications
- Connect the turbocharger wastegate regulator solenoid valve electrical connector.
Evaporative Emission Canister Purge Tube (1) - Install
- Evaporative Emission Canister Purge Tube (1) - Connect [2x] - Plastic Collar Quick Connect Fitting Service
Oil Filler Cap - Remove
- Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
- NOTE:
Left side shown, right side similar.
Front End Sheet Metal Diagonal Brace- Right Side (3) - Install
- Front End Sheet Metal Cross Brace Bolt- Right Side (1) - Install and tighten Fastener Specifications
- Front End Sheet Metal Diagonal Brace Nut- Right Side (1) - Install and tighten Fastener Specifications
- NOTE:
Left side shown, right side similar.
Front End Sheet Metal Cross Brace- Right Side (3) - Install
- Install the engine wire harness retainers to the front end sheet metal cross brace.
- Front Suspension Strut Upper Mounting Nut- Right Side (2) - Install and tighten [2x] Fastener Specifications
- Front End Sheet Metal Cross Brace Bolt- Right Side (1) - Install and tighten [3x] Fastener Specifications
Radiator Air Upper Baffle (3) - Install
- Radiator Air Upper Baffle Bolt (2) - Install and tighten [2x] Fastener Specifications
- Radiator Air Upper Baffle Retainer (1) - Install [5x]
Plenum Front Panel (1) - Install
Plenum Front Panel Bolt (1) - Install and tighten [4x] - Fastener Specifications
- Plenum Front Panel Nut (2) - Install and tighten [3x]
Plenum Front Panel Nut (1) - Install and tighten [3x] - Fastener Specifications
- Plenum Front Panel Bolt (2) - Install and tighten [3x] - Fastener Specifications
- Install the forward lamp wiring harness extension (3) into the plenum front panel.
- Connect the electrical connector.
Air Inlet Deflector Water Deflector (1) - Install
Air Inlet Deflector Water Deflector Retainer (1) - Install [2x]
Install the windshield wiper system module (2) in the vehicle.
- Windshield Wiper System Module Bolt (1) - Install and tighten [2x] Fastener Specifications
- Connect the windshield wiper motor electrical connector.
- Connect the battery negative cable. - Battery Negative Cable Disconnection and Connection
Windshield Wiper System Module Shield (1) - Install
Air Inlet Grille Panel (2) - Install
- Install the air inlet grille panel (2) between both hood hinges.
- Connect the windshield washer nozzle hose to the windshield washer pump hose.
- Air Inlet Grille Panel Retainer (1) - Install [6x]
- NOTE:
Left side shown, right side similar.
Front Compartment Side Sight Shield- Left Side and Right Side (2) - Install [2x]
- Front Compartment Side Sight Shield Retainer- Left Side and Right Side (1) - Install [6x]
- NOTE:
Left side shown, right side similar.
Air Inlet Grille Panel Extension- Left Side and Right Side (2) - Install [2x]
- Air Inlet Grille Panel Retainer- Left Side and Right Side (1) - Install [4x]
Install the 2 hood rear outer air inlet seal (2) to the left and right side.
- Install the 4 hood rear outer air inlet seal retainer (1) to the left and right side.
- NOTE:
Left side shown, right side similar.
Air Inlet Grille Panel Extension- Left Side and Right Side (1) - Install [2x]
- Remove the masking tape from the top edge of the left and right side service parts.
- Using a 50/50 mixture of isopropyl alcohol and clean drinkable water with a clean towel, remove any left over adhesive residue from the masking tape.
- Install the 2 left and right side air inlet grille panel extension (1).
- NOTE:
Left side shown, right side similar.
Windshield Wiper Arm- Left Side and Right Side (3) - Install [2x]
- Clean the left and right side windshield wiper transmission pivot shaft splines with a soft wire brush before installing the windshield wiper arm (3).
- Windshield Wiper Arm Nut- Left Side and Right Side (2) - Install and tighten [2x] - Fastener Specifications
- Position the left and right side windshield wiper arm (3) on the windshield wiper transmission pivot shaft.
- Windshield Wiper Arm Finish Cap- Left Side and Right Side (1) - Install [2x]
If required, realign the left side and right side windshield wipers to their respective alignment circles (1) on the windshield.
- Lubricate the windshield with clean washer fluid.
- Run the windshield wipers for two complete cycles then turn off the windshield wipers.
- Ensure the windshield wipers are in the full park position.
- Inspect the windshield wipers for proper position to the alignment circles (1) on the windshield.
- Fill the charge air cooling system. Refer to Cooling System Draining and Filling (LF4 Static Fill) , or Cooling System Draining and Filling (LF4 GE 47716)