Installation Procedure
Generator(2) - Install
- Generator Bolt(1) - Install and tighten [3X] - Fastener Specifications
Electrical Connector(4) - Connect
- Starter Solenoid Cable(3) - Install
- Engine Wiring Harness Generator Lead Nut (2) - Install and tighten - Fastener Specifications
- Protective Cap(1) - Install
Auxiliary Water Pump(2) - Install
- Charge Air Cooler Front Bracket Bolt(1) - Install and tighten[2x] - Fastener Specifications
Position the engine wiring harness (3) into place.
- Engine Wiring Harness Retainer(1)@Charge Air Cooler Coolant Pump Relay Bracket - Install
- Electrical Connector(2)@Auxiliary Water Pump - Connect
Auxiliary Radiator Inlet Pipe(2)@Auxiliary Water Pump - Install
- Heater Outlet Hose Clamp - (1)Engage - Hose Clamp Replacement Guidelines - Spring Type
Charge Air Cooler Coolant Hose(2)@Auxiliary Water Pump - Install
- Charge Air Cooler Coolant Hose Clamp(1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise, then hold tension.
- Install the accessory drive primary belt (2) onto the last idler pulley. Check to ensure that the drive belt is centered on each pulley, and fully seated into ribbed pulleys.
- Slowly release tension from the drive belt tensioner (1).
- Inspect the accessory drive primary belt (2) again to ensure centered on each pulley.
Turbocharger Coolant Return Pipe(3) - Install
- Turbocharger Coolant Feed and Return Pipe Gasket(2) - Install NEW[2x]
- Turbocharger Coolant Feed and Return Pipe Bolt(1) - Install and tighten - Fastener Specifications
Retaining Clip(1) - Install
Turbocharger Heat Shield(1) - Install
Turbocharger Heat Shield Bolt(1) - Install and tighten[3x] - Fastener Specifications
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]
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
- Fill the cooling system to the proper level. Cooling System Draining and Filling (LSY GE 47716)Cooling System Draining and Filling (LSY Static Fill)Cooling System Draining and Filling (LSY with V03 Static Fill)Cooling System Draining and Filling (L3B Static Fill)Cooling System Draining and Filling (L3B GE 47716)Cooling System Draining and Filling (LSY with V03 GE 47716)Cooling System Draining and Filling (LF4 Static Fill)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