Installation Procedure
Engine Coolant Thermostat Housing Seal (4) - Install NEW
- Engine Coolant Thermostat Housing Gasket (3) - Install NEW
- Engine Coolant Thermostat Housing (2) - Install
- Engine Coolant Thermostat Housing Bolt (1) - Install and tighten [3x] - Fastener Specifications
Connect the engine electrical wiring harness (2) to the back of the engine.
- Engine Coolant Temperature Sensor Electrical Connector (1) - Connect
Heater Inlet Pipe Seal (3) - Install NEW
- Heater Outlet Pipe Gasket (2) - Install NEW
- Heater Inlet and Outlet Pipe (1) - Install
Heater Inlet and Outlet Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
Heater Outlet Hose (4) @ Heater Inlet and Outlet Pipe - Install
- Heater Outlet Hose Clamp (3) @ Heater Inlet and Outlet Pipe - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Inlet Hose (2) @ Heater Inlet and Outlet Pipe - Install
- Heater Inlet Hose Clamp (1) @ Heater Inlet and Outlet Pipe - Engage - Hose Clamp Replacement Guidelines - Spring Type
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]
Fuel Feed Pipe (1) - Install
- Fuel Feed Pipe Fitting (1) - Connect - Metal Collar Quick Connect Fitting Service
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 Outlet Duct (1) @ Turbocharger Air Inlet Adapter - 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).
Turbocharger Wastegate Actuator Vacuum Source Tube (2) - Install
- Turbocharger Wastegate Actuator Vacuum Source Tube (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Charge Air Bypass Valve Vacuum Tank Tube (2) - Install
- Charge Air Bypass Valve Vacuum Tank Tube (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Clamp (1) - Engage [2x] - 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
Oil Filler Cap - Remove
- Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Engine Rear Noise Shield (1) - Install
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
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.
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]
Front Compartment Side Sight Shield (2) - Install
- Front Compartment Side Sight Shield Retainer (1) - Install [3x]
Air Inlet Grille Panel Extension (2) - Install
- Air Inlet Grille Panel Retainer (1) - Install [2x]
Install the hood rear outer air inlet seal (2) to the left and right side.
- Install the 2 hood rear outer air inlet seal retainer (1) to the left and right side.
Air Inlet Grille Panel Extension (1) - Install [2x]
- Install the air inlet grille panel extension (1).
- Remove the masking tape from the top edge of the service part.
- 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.
Windshield Wiper Arm (3) - Install [2x]
- Clean the windshield wiper transmission pivot shaft splines with a soft wire brush before installing the windshield wiper arm (3).
- Position the windshield wiper arm (3) on the windshield wiper transmission pivot shaft.
- Windshield Wiper Arm Nut (2) - Install and tighten Fastener Specifications
- Windshield Wiper Arm Finish Cap (1) - Install
If required, realign the 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 cooling system to the proper level. 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.
Refer to Fastener Caution .
Refer to Fastener Caution .