Installation Procedure
- CAUTION:
Refer to Fastener Caution .
Turbocharger Stud (1) - Install NEW and tighten [2x] - Fastener Specifications
- WARNING:
When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury.
Turbocharger Oil Return Pipe Gasket (5) - Install NEW
- Turbocharger Oil Feed Pipe Gasket (4) - Install NEW
- Turbocharger Oil Return Pipe Gasket (3) - Install NEW
- Turbocharger Oil Feed Pipe (2) @ Compressor Air Intake Turbocharger - Install
- Turbocharger Oil Feed Pipe Bolt (1) @ Compressor Air Intake Turbocharger - Install and tighten [2x] - Fastener Specifications
Turbocharger Gasket (2) - Install NEW
- Turbocharger Assembly (1) - Install
Turbocharger Nut (1) - Install NEW and hand tighten [2x]
- Turbocharger Bolt (2) - Install NEW and hand tighten [2x]
- Tighten the 2 turbocharger nuts (1) and the 2 turbocharger bolts (2) in sequence. Fastener Specifications
Turbocharger Oil Feed Pipe Bolt (4) - Install and tighten [4x] - Fastener Specifications
- Turbocharger Brace (3) - Install
- Turbocharger Bracket Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Turbocharger Brace Nut (1) - Install and tighten - Fastener Specifications
Positive Crankcase Ventilation Tube (1) - Install NEW
Reposition the front axle vent hose (3), and electrical harness (4).
- Electrical Connector (2) - Connect [2x]
- Retainer (1) - Connect [3x]
Turbocharger Coolant Feed and Return Pipe Gasket (2) - Install NEW
- Turbocharger Coolant Feed and Return Pipe (1) - Install
Turbocharger Coolant Feed and Return Pipe Bolt (1) - Install [2x] - Fastener Specifications
Turbocharger Coolant Feed Hose (2) @ Turbocharger Coolant Feed and Return Pipe - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Turbocharger Coolant Feed and Return Pipe (2) @ Exhaust Manifold Outlet Pipe - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Compressor Air Intake Turbocharger Wastegate Actuator Rod (3) @ Turbocharger Wastegate Actuator - Connect
- Compressor Air Intake Turbocharger Wastegate Actuator Link Clip (2) - Install
- Compressor Air Intake Turbocharger Wastegate Actuator Link Spring (1) - Install
Catalytic Converter Gasket (3) - Install NEW
- Exhaust Pipe Clamp (2) - Install NEW but do NOT tighten.
- Warm Up Three-Way Catalytic Converter (1) - Install
Catalytic Converter Brace (3) - Install
- Catalytic Converter Brace Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
- NOTE:
Inspect on all sides of the warm up three-way catalytic converter to verify it is fully seated prior to tightening the exhaust pipe clamp.
Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications
Front Crossmember Brace (2) - Install
- Front Crossmember Brace Nut (1) - Install and tighten [4x] - Fastener Specifications
Catalytic Converter Gasket (2) - Install NEW
- Exhaust Muffler (1) - Install
Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Install
- Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Install
Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Install
- Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Install
Electrical Connector (1) @ Exhaust Control Valve Actuator - Connect [2x]
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
- CAUTION:
Refer to Component Fastener Tightening Caution .
NOTE:A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound already applied to the threads. IF a sensor is removed and is to be reinstalled, the threads MUST have an anti-seize compound applied before installation. Adhesives, Fluids, Lubricants, and Sealers
Using the appropriate tool, install the heated oxygen sensor (1). Fastener Specifications
- Connect the electrical connector.
- Ensure the phenolic spacer remains in place.
- Use the EN-51007 Global Engine Support Fixture to lower the right side of the engine onto the engine mount.
Engine Mount Bracket (1) - Install
- CAUTION:
Refer to Torque-to-Yield Fastener Caution .
Engine Mount Bracket Bolt (1) - Install NEW and tighten [4x] - Fastener Specifications
- Use the EN-51007 Global Engine Support Fixture to lower the engine onto the engine mount.
Engine Mount Nut (1) - Install NEW and tighten - Fastener Specifications
Water Pump Cover (2) - Install
- Water Pump Cover Bolt (1) - Install and tighten [3x] - Fastener Specifications
Retainer (1) - Install
Charge Air Cooler Inlet Air Tube (2) @ Turbocharger (3) - Install
- Retainer Spring (1) - Engage
Turbocharger Heat Shield (1) - Install
Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
- CAUTION:
Refer to Component Fastener Tightening Caution .
NOTE:A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound already applied to the threads. IF a sensor is removed and is to be reinstalled, the threads MUST have an anti-seize compound applied before installation. Adhesives, Fluids, Lubricants, and Sealers
Using the EN-6179 Heated Oxygen Sensor Remover/Installer, install the heated oxygen sensor (1). Fastener Specifications
- Connect the electrical connector.
Air Cleaner Assembly (1) - Install
Air Cleaner Bolt (1) - Install and tighten - Fastener Specifications
- Connect the electrical connector and install all wiring harnesses to the air cleaner assembly.
Air Cleaner Outlet Duct (1) - Install
- Electrical Connector @ Evaporative Emission Canister Purge Solenoid Valve - Connect
Positive Crankcase Ventilation Tube (3) - Connect - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Install
Push down on the front of the intake manifold cover (2).
- Intake Manifold Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Install the oil fill cap.
- Connect the battery. Battery Negative Cable Disconnection and Connection
- Fill the engine oil to the proper level with NEW engine oil. Engine Oil and Oil Filter Replacement (RWD)
- Perform the turbocharger wastegate learn. Turbocharger Wastegate Learn
- Inspect the exhaust system for leaks.
Ensure that the catalytic converter gasket is fully seated on the warm up three-way catalytic converter inlet flange.
Refer to Fastener Caution .
Phenolic spacer must be present to prevent galvanic/corrosive reaction and/or excessive temperature conduction between engine mount bracket and engine mount. Replace mount if phenolic spacer is missing or damaged. Failure to ensure phenolic spacer is intact and not damaged can lead to premature failure of engine mount and/or engine mount bracket.