Installation Procedure
Position charge air cooler outlet air tube (2) perpendicular to charge air cooler (2) and install.
- Retainer Spring (1) - Engage
- Verify connection is properly made by pulling and pushing on the tube at the quick connector location.
Auxiliary Radiator Front Duct (1) - Install
Auxiliary Radiator Duct Retainer (1) - Install [2x]
Auxiliary Radiator Duct Retainer (1) - Install [3x]
- NOTE:
The front bumper fascia will rest in place by guides on the center support upper structure.
With the aid of an assistant, install the fascia. (1)
Install the left side of the front bumper fascia (1) to the front bumper fascia guide (2) and the front headlamp (3).
Reposition the front bumper fascia on the right side to gain access to the electrical connector (1).
- Connect the electrical connector.
Install the right side of the front bumper fascia (1) to the front bumper fascia guide (2) and the front headlamp (3).
- CAUTION:
Refer to Fastener Caution .
Front Bumper Fascia Bolt (1) - Install and tighten [6x] - Fastener Specifications
Front Bumper Fascia Center Air Deflector Screw (1) - Install and tighten [10x] - Fastener Specifications
Reposition the right front wheelhouse liner (1) to install the right side upper front bumper fascia bolt (2).
- Install and tighten the right side upper front bumper fascia bolt (2). Fastener Specifications
Front Bumper Fascia Bolt- Right Side (3) - Install and tighten [2x] - Fastener Specifications
- Front Tire Front Air Deflector Bolt- Right Side (2) - Install and tighten - Fastener Specifications
- Front Wheelhouse Liner Bolt- Right Side (1) - Install and tighten [4x] - Fastener Specifications
Reposition the left front wheelhouse liner (1) to install the left side upper front bumper fascia bolt (2).
- Install and tighten the left side upper front bumper fascia bolt (2). Fastener Specifications
Front Bumper Fascia Bolt- Left Side (3) - Install and tighten [2x] - Fastener Specifications
- Front Tire Front Air Deflector Bolt- Left Side (2) - Install and tighten - Fastener Specifications
- Front Wheelhouse Liner Bolt- Left Side (1) - Install and tighten [4x] - Fastener Specifications
- Remove the support and lower the vehicle.
Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Install
- Retainer Spring (1) - Engage
Position the air conditioning refrigerant heat exchanger to its original position.
- Air Conditioning Evaporator Tube Clip Bracket Bolt (4) - Install and tighten - Fastener Specifications
- Air Conditioning Evaporator Thermal Expansion Valve Seal (3) - Install NEW
- Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (2) @ Air Conditioning Refrigerant Heat Exchanger - Install
- Air Conditioning Compressor Hose Nut (1) - Install and tighten - Fastener Specifications
- Recharge the refrigerant. Refrigerant Recovery and Recharging
- Inspect for refrigerant leaks.
- Start vehicle and listen for whistling at the charge air cooler outlet air tube quick connect located at the charge air cooler.
Verify the charge air cooler inlet and outlet air tube quick connect seal condition and location prior to installation. Seal must be evenly seated in the quick connector body and sealing surface must be free of deformation and damage. Deformed or damaged seals can lead to reduced engine power and/or engine stalling.
DO NOT insert fingers inside quick connect to manipulate duct during disassembly/assembly. Rubber pad gloves increase risk to dislodge seal.