Installation Procedure
- 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.
Fuel Injection Fuel Rail Insulator (1) - Install
Wiring Harness (2) @ Fuel Injection Fuel Rail Insulator (1) - Install
Water Outlet Seal (2) - Install NEW
- Engine Coolant Flow Control Valve (1) - Install
Engine Coolant Flow Control Valve Bolt (1) - Install [4x] - Fastener Specifications
Electrical Connector (2) @ Engine Coolant Temperature Sensor - Connect
- Electrical Connector (1) @ Engine Coolant Flow Control Valve - Connect [2x]
Engine Oil Cooler Coolant Inlet Hose (4) @ Engine Coolant Flow Control Valve - Install
- Engine Coolant Air Bleed Hose (3) @ Engine Coolant Flow Control Valve - Install
- Engine Coolant Air Bleed Hose (2) @ Engine Coolant Flow Control Valve - Install
- Hose Clamp (1) - Engage [3x] - Hose Clamp Replacement Guidelines - Spring Type
Radiator Inlet Hose (3) @ Engine Coolant Flow Control Valve - Install
- Thermostat Bypass Hose (2) @ Engine Coolant Flow Control Valve - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Intake Manifold Gasket (2) - Install NEW
- NOTE:
Check that the 2 pins (4) of the intake manifold are seated correctly in the cylinder head.
Intake Manifold (3) - Install
- Intake Manifold Bolt - Install, but do NOT tighten [7x]
- Charge Air Cooler Outlet Air Tube (2) @ Throttle Body - Install
- Electrical Connector @ Throttle Body (1) - Connect
- CAUTION:
Refer to Fastener Caution .
Intake Manifold Bolt (1) - Tighten in sequence [7x] - Fastener Specifications
Radiator Surge Tank Inlet Pipe Bracket (2) - Reposition [2x]
- Radiator Surge Tank Outlet Hose Clip Bracket Nut (1) - Tighten [2x] - Fastener Specifications
Reposition the wiring harness (3) and connect as necessary.
- Retainer (1) @ Intake Manifold (2) - Install [7x]
Evaporative Emission Canister Purge Pump (2) - Install
- Evaporative Emission Canister Purge Pump Bolt (1) - Install and tighten [3x] - Fastener Specifications
- Connect the electrical connector.
Evaporative Emission Pipe (1) - Install
- Connect the quick connect. Plastic Collar Quick Connect Fitting Service
Evaporative Emission Canister Purge Tube (2) - Install
- Connect the evaporative emission canister purge tube quick connects (1). Plastic Collar Quick Connect Fitting Service
- Connect the evaporative emission canister purge tube (2) to the retainer (3).
Upper Intake Manifold Bracket (2) - Install
- Upper Intake Manifold Cover Nut (1) - Install and tighten [2x] - Fastener Specifications
Upper Intake Manifold Cover Bracket Bolt (1) @ Upper Intake Manifold Bracket (2) - Install and tighten [2x] - Fastener Specifications
Wiring Harness (4) - Reposition
- Retainer (2) @ Upper Intake Manifold Bracket (3) - Install [3x]
- Electrical Connector (1) - Connect [3x]
Oil Level Indicator Tube Seal (2) - Install NEW
- Oil Level Indicator Tube (1) - Install
Oil Level Indicator Tube Bracket Bolt (1) - Install - Fastener Specifications
- Electrical Connector (1) @ Oil Level Indicator (3) - Install
Connect the electrical connector. (1)
Oil Level Indicator (1) - Install
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Install
- NOTE:
Ensure the engine sight shield retainers fully engage the intake manifold cover studs.
Push down on the front of the intake manifold cover (1).
- Install the oil fill cap.
- Connect the battery. - Battery Negative Cable Disconnection and Connection
- Fill the cooling system. 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 (LSY with V03 GE 47716)
- Start the engine and check for leaks.
- Perform the throttle body idle air flow compensation reset. Throttle Body Idle Air Flow Compensation Reset