Installation Procedure
- Timing Chain Tensioner Seal (1) - Install
- Oil Pump (1) - Install
- Oil Pump Bolt (1) - Install and hand tighten [4x]
- Oil Pump Bolt (1) - Tighten in sequence [4x] - Fastener Specifications
- Apply a 3 mm (0.118 in) bead of RTV sealant on the engine front cover (1). Adhesives, Fluids, Lubricants, and SealersNOTE:
- Install and align the front cover within 10 minutes of applying the sealer.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Apply a 5 mm (0.197 in) bead of RTV sealant on the engine front cover (2). Adhesives, Fluids, Lubricants, and Sealers
- Engine Front Cover (2) - Install
- Engine Front Cover Bolt (1, 3) - Install and hand tighten [10x]
- Engine Front Cover Bolt (1, 3) - Tighten in sequence [10x] - Fastener Specifications
- If the engine front cover is reused, perform the following steps:NOTE:
If the engine front cover is reused, the crankshaft front oil seal (3) must be replaced.
- For proper orientation, note the installation direction of the crankshaft front oil seal (3). The crankshaft front oil seal is a reverse-lip design. Install with "THIS SIDE OUT" displayed as shown.
- Do NOT lubricate the crankshaft front oil seal sealing surface.
- Install the crankshaft front oil seal (3) with "THIS SIDE OUT" facing away from the engine.
- Install the NEW crankshaft front oil seal (3) to the EN-51091 Crankshaft Front Oil Seal Installer (2).
- Install the EN-41478-A Crankshaft Front Oil Seal Installer (1) and the EN-51091 Crankshaft Front Oil Seal Installer (2) into the crankshaft.
- Rotate the EN-51091 Crankshaft Front Oil Seal Installer (2) clockwise until the NEW crankshaft front oil seal (3) enters the engine front cover and seats into the bottom of the engine front cover.
- Remove the EN-41478-A Crankshaft Front Oil Seal Installer (1) and the EN-51091 Crankshaft Front Oil Seal Installer (2) from the crankshaft and engine front cover.
- Inspect the crankshaft front oil seal (3) for proper installation. The crankshaft front oil seal should be installed evenly and completely into the engine front cover.
NOTE: - Water Pump Gasket (2) - Install NEW [2x]
- Water Pump (1) - Install
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Water Pump Housing Bolt (1) - Install and hand tighten [6x]
- Water Pump Housing Bolt (1) - Tighten in sequence [6x] - Fastener Specifications
- Engine Coolant Temperature Sensor Electrical Connector (1) - Connect
- Radiator Inlet Hose (3) @Water Pump - Install
- Engine Coolant Air Bleed Hose (2) @Water Pump - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @Water Pump - Install
- Radiator Outlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Water Auxiliary Pump Hose (3) @Water Pump - Install
- Heater Inlet Hose (2) @Water Pump - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Air Conditioning Compressor (1) - Install
- Air Conditioning Compressor Bolt (1) - Loosely install
- Air Conditioning Compressor Stud (3) - Install and tighten - Fastener Specifications
- Air Conditioning Compressor Bolt (1) - Tighten - Fastener Specifications
- Air Conditioning Compressor Nut (2) - Install and tighten - Fastener Specifications
- Generator (1) - Install
- Generator Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Engine Cooler Fan (1) @Engine Radiator - Install
- Engine Coolant Fan Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Transmission Fluid Cooler Pipe Clip (1) - Secure
- Transmission Fluid Cooler Pipe Clip (2) - Install [2x]
- Transmission Fluid Cooler Pipe Bolt (1) - Install and tighten - Fastener Specifications
- Engine Oil Cooler Hose (1) @Engine Radiator - Install [2x]
- Engine Oil Cooler Pipe Bracket Bolt (3) - Install and tighten - Fastener Specifications
- Engine Oil Cooler Retainer (2) - Install [2x]
- Engine Oil Cooler Hose Clip (1) - Secure
- Position the wiring harness. (3)
- Electrical Connector (1) - Connect
- Wiring Harness Retainer (2) - Install [2x]
- Position the wiring harness. (2)
- Electrical Connector (3) - Connect
- Wiring Harness Retainer (1) - Install [2x]
- Radiator Inlet Hose (3) @Engine Radiator - Install
- Radiator Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Inlet Hose Clip (2) - Install
- Radiator Surge Tank Outlet Hose (3) - Move into position
- Radiator Surge Tank Outlet Hose Clip (2) - Install [2x]
- Apply a 3 mm (0.118 in) bead of RTV sealant on the oil pan (1). Adhesives, Fluids, Lubricants, and Sealers
- Apply a 5 mm (0.197 in) bead of RTV sealant on the oil pan (2). Adhesives, Fluids, Lubricants, and Sealers
- Oil Pan High Pressure Port Seal (2) - Install NEW [2x]
- Oil Pan Front Seal (3) - Install NEW
- Oil Pan (1) - Install
- Oil Pan Bolt (2, 3) - Install and hand tighten [16x]
- Oil Pan Bolt (2, 3) - Tighten in sequence [16x] - Fastener Specifications
- Electrical Connector (1) - Connect
- Crankshaft Balancer (1) - Loosely install
- Install the EN-41478-A
Crankshaft Front Oil Seal Installer (3) and the EN-41665-A
Crankshaft Balancer and Sprocket Installer (2) to the crankshaft.
- Using the EN-41665-A Crankshaft Balancer and Sprocket Installer (2) properly seat the crankshaft balancer (1).
- Remove the EN-41478-A Crankshaft Front Oil Seal Installer (3) and the EN-41665-A Crankshaft Balancer and Sprocket Installer (2).
- Crankshaft Balancer Bolt (1) - Install NEW and tighten - Fastener SpecificationsCAUTION:
Refer to Torque-to-Yield Fastener Caution
- Engine Wiring Harness (3) - Install
- Engine Wiring Harness Retainer (2) - Install
- Engine Wiring Harness Ground Stud (1) - Install and tighten [2x] - Ground Repair
- Install and tighten the transmission fluid auxiliary cooler pipe bracket nut (1). Fastener Specifications
- Transmission Fluid Cooler Pipe Clip Bracket (2) @Oil Pan - InstallNOTE:
Components removed in graphic to better illustrate service parts.
- Transmission Fluid Cooler Pipe Clip Bolt (1) @Oil Pan - Install and tighten - Fastener Specifications
- Electrical Connector@Knock Sensor (4) - Connect
- Oil Filter (1) - Install and tighten - Fastener Specifications
- Transmission Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Engine Oil Cooler Gasket (2) - Install NEW
- Engine Oil Cooler Hose (1) @Oil Pan - Install
- Engine Oil Cooler Adapter Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Electrical Connector (1) @Engine Oil Pressure Sensor - Connect
- Wiring Harness Retainer (2) @Engine Oil Cooler Hose - Install
- Engine Oil Pressure Sensor Sleeve (1) - Install
- Engine Oil Cooler Hose Bracket Nut (1) - Install and tighten - Fastener Specifications
- Lubricate the oil level indicator seal (2) with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Oil Level Indicator Seal (2) - Install NEW
- Oil Level Indicator Tube (1) @Oil Pan - Install
- Connect the wiring harness connectors (3) and retainers as needed.
- Engine Wiring Harness Retainer (1) @Oil Level Indicator Tube (2) - Connect
- Remove the M10-1.5 x 120mm (3) and the M10-1.5 x 45mm (2) bolts.
- Remove the EN-42386 Flywheel Holding Tool (2)
- Torque Converter Cover- Right Side (2) - Install
- Torque Converter Cover Bolt- Right Side (1) - Install and tighten - Fastener Specifications
- Torque Converter Cover- Left Side (2) - Install
- Torque Converter Cover Bolt- Left Side (1) - Install and tighten - Fastener Specifications
- Starter (1) - Install
- Electrical Connector (3) - Connect
- Protective Sleeve (4) - Install
- Starter Solenoid Cable (1) - Install
- Starter Solenoid Cable Nut (2) - Install and tighten - Fastener Specifications
- Starter Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Starter Solenoid Cable (2) - Install
- Battery Negative Cable Ground Bolt (1) - Install and tighten - Fastener Specifications
- Starter Heat Shield (2) - Install
- Starter Heat Shield Bolt (1) - Install and tighten - Fastener Specifications
- Starter Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Front Axle (1) - InstallNOTE:
The front axle may have to be maneuvered to install it into the vehicle.
- Front Axle Vent Hose - Connect
- Front Differential Carrier Bolt (1) - Install and tighten - Fastener Specifications
- Front Differential Carrier Bolt (2) - Install
- Front Differential Carrier Bracket Nut (1) - Install and tighten - Fastener Specifications
- Drivetrain and Front Suspension Frame Front Crossmember (1) - Install
- Drivetrain and Front Suspension Frame Reinforcement Bolt (2) - Install [4x]
- Using the EN-45059-A Angle Meter, install and tighten the 4 drivetrain and front suspension frame reinforcement nuts (1). Fastener Specifications
- Front Differential Carrier Bolt (2) - Install NEWCAUTION:
Refer to Torque-to-Yield Fastener Caution
- Front Differential Carrier Nut (1) - Install
- Using the EN-45059-A Angle Meter, tighten the front differential carrier nut (1). Fastener Specifications
- Install the heater coolant pump and heater water auxiliary pump bracket (2) as assembly.NOTE:
Some components not shown for graphic clarity.
- Heater Water Auxiliary Pump Bolt (1) - Install and tighten - Fastener Specifications
- Electrical Connector@Heater Coolant Pump (2) - Connect
- Connect the front drive axle actuator electrical connector (1).
- Install the harness and secure the two harness retainers (2).
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Front Axle Propeller Shaft (1) - Install
- Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
- Front Axle Propeller Shaft Washer (3) - Install [3x]
- Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener SpecificationsNOTE:
Support the front stabilizer shaft.
- Front Stabilizer Shaft (3) - Install
- Front Stabilizer Shaft Clamp (2) - Install [2x]
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Front Stabilizer Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
- Apply anti-corrosion wax to the frame shock tower. Anti-Corrosion Treatment and RepairNOTE:
Prior to installing the front shock absorber, you MUST apply anti-corrosion wax to the frame shock tower.
- Front Shock Absorber (1) - Install
- Front Shock Absorber Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Front Shock Absorber Nut (1) - Install and tighten [3x] - Fastener Specifications
- Connect the air line and install the air line nut (1). Fastener Specifications
- Reposition and install the chassis wiring harness bracket (1) to the frame shock tower.
- Connect the electrical connector for the electronic suspension wheel front vertical accelerometer (1) and the front air shock harness electrical connector (2).
- Front Wheelhouse Liner- Left Side - Install - Front Wheelhouse Liner Replacement
- Remove any buildup from the front differential carrier output shaft lead in chamfer (1) using an abrasive pad and wipe clean with a shop cloth.
- Front Wheel Drive Shaft Seal (2) - Install NEW
- Front Wheel Drive Shaft Retaining Ring (1) - Install NEW
- Apply a thin coating of grease to the splines of the front wheel drive half shaft and front differential carrier output shaft. Adhesives, Fluids, Lubricants, and Sealers
- Install the front wheel drive half shaft (1) into the wheel hub.NOTE:
Some components not shown for graphic clarity.
- Install the front wheel drive half shaft (1) into the front axle.
- Ensure that the left front wheel drive half shaft (1) is fully seated in front differential carrier by pulling on the inner joint.
- Support the steering knuckle with a suitable jack stand.
- Front Upper Control Arm Ball Stud Nut (1) - Install and tighten - Fastener Specifications
- Remove jack stand.
- Front Stabilizer Shaft Link@Front Lower Control Arm - Install
- Front Stabilizer Shaft Link Nut (1) - Install and tighten - Fastener Specifications
- Steering Linkage Outer Tie Rod - Install
- Steering Linkage Outer Tie Rod Nut (1) - Install and tighten - Fastener Specifications
- Electronic Suspension Wheel Front Vertical Accelerometer- Left Side (3) - Install
- Electronic Suspension Rear Vertical Accelerometer Bolt (2) - Install and tighten - Fastener Specifications
- Front Wheel Speed Sensor (2) - Install
- Front Wheel Speed Sensor Bolt (1) - Install and tighten - Fastener Specifications
- Front Wheel Speed Sensor Bracket (4) - Install
- Front Wheel Speed Sensor Bracket Bolt (3) - Install and tighten - Fastener Specifications
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Front Brake Caliper (1) - Install
- Front Brake Caliper Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Front Brake Hose Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Front Disc Brake Pad Wear Sensor (1) @Front Brake Caliper - InstallNOTE:
Only the left front wheel is equipped with the front disc brake pad wear sensor.
- Remove any buildup from the front differential carrier output shaft lead in chamfer (1) using an abrasive pad and wipe clean with a shop cloth.
- Front Wheel Drive Shaft Seal (2) - Install NEW
- Front Wheel Drive Shaft Retaining Ring (1) - Install NEW
- Apply a thin coating of grease to the splines of the front wheel drive half shaft and front differential carrier output shaft. Adhesives, Fluids, Lubricants, and Sealers
- Install the front wheel drive half shaft (1) into the wheel hub.NOTE:
Some components not shown for graphic clarity.
- Install the front wheel drive half shaft (1) into the front axle.
- Ensure that the right front wheel drive half shaft (1) is fully seated in front differential carrier by pulling on the inner joint.
- Support the steering knuckle with a suitable jack stand.
- Front Upper Control Arm Ball Stud Nut (1) - Install and tighten - Fastener Specifications
- Remove jack stand.
- Front Stabilizer Shaft Link@Lower Control Arm - Install
- Front Stabilizer Shaft Link Nut (1) - Install and tighten - Fastener Specifications
- Steering Linkage Outer Tie Rod - Install
- Steering Linkage Outer Tie Rod Nut (1) - Install and tighten - Fastener Specifications
- Electronic Suspension Wheel Front Vertical Accelerometer- Right Side (3) - Install
- Electronic Suspension Rear Vertical Accelerometer Bolt (2) - Install and tighten - Fastener Specifications
- Front Wheel Speed Sensor (2) - Install
- Front Wheel Speed Sensor Bolt (1) - Install and tighten - Fastener Specifications
- Front Wheel Speed Sensor Bracket (4) - Install
- Front Wheel Speed Sensor Bracket Bolt (3) - Install and tighten - Fastener Specifications
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Front Brake Caliper (1) - Install
- Front Brake Caliper Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Front Brake Hose Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Have an assistant apply the brakes.
- Front Wheel Drive Shaft Nut (1) - Install NEW and tighten - Fastener SpecificationsCAUTION:
Refer to Torque-to-Yield Fastener Caution
- Front Wheel Drive Shaft Nut (1) - Install NEW and tighten - Fastener SpecificationsCAUTION:
Refer to Torque-to-Yield Fastener Caution
- Front Differential Carrier Oil Filler Plug (1) - Remove
- Inspect the gear lubricant level, it should be 16-22 mm (0.6-0.9 in) below the plug opening.
- If the level is low, add gear lubricant until the level is 16-22 mm (0.6-0.9 in) below the plug opening. Use the appropriate axle lubricant: Adhesives, Fluids, Lubricants, and Sealers
- Front Differential Carrier Oil Filler Plug (1) - Install and tighten - Fastener Specifications
- Oil Level Indicator Tube Bolt (1) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Fuse Block Bracket (3) - Install
- Retaining Tab (1) - Engage
- Engine Wiring Harness Fuse Block Bracket Bolt (2) - Tighten [2x] - Fastener Specifications
- Electrical Connector (1) - Install [4x]
- Engine Wiring Harness Junction Block (3) - Install
- Retaining Tab (1) - Engage [4x]
- Engine Wiring Harness Junction Block Bolt (2) - Tighten [4x] - Fastener Specifications
- Starter Solenoid Cable (4) - Install
- Battery Positive Cable Nut (3) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Junction Block Cover (2) - Install
- Retaining Tab (1) - Engage [2x]
- Starter Solenoid Cable (2) - Install
- Battery Positive Cable Nut (1) - Install and tighten - Fastener Specifications
- Electrical Connector (3) - Connect
- Install the accessory drive auxiliary belt (1) following the instructions included with the accessory drive auxiliary belt.NOTE:
The OEM replacement stretchy accessory drive auxiliary belt (1) is packaged with a disposable installation tool and installation instructions.
- Inspect the accessory drive auxiliary belt (1) for proper installation and alignment.
- Rotate the crankshaft balancer (1) an additional 360 degrees to ensure proper accessory drive auxiliary belt installation.
- Position the accessory drive primary belt (4) on the belt idler pulley (2), fan and water pump pulley (3) and generator (1).
- Install the EN-51767-2
Stretchy Belt Installer (1) onto the crankshaft balancer.
- Position the accessory drive primary belt (2) on the crankshaft balancer.
- Slowly rotate the crankshaft balancer in a clockwise direction until the accessory drive primary belt (2) fully seats on the crankshaft balancer.
- Remove the EN-51767-2 Stretchy Belt Installer (1) from the crankshaft balancer.
- Inspect the accessory drive primary belt (1) for proper installation and alignment.
- Rotate the crankshaft balancer (1) and additional 360 degrees to ensure proper accessory drive primary belt installation.
- Air Cleaner Outlet Duct (3) - Install
- Air Cleaner Outlet Duct Clamp (2) - Tighten [2x] - Fastener Specifications
- Positive Crankcase Ventilation Fresh Air Tube (1) - Connect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Install engine wiring harness to air cleaner outlet duct bracket.
- Underbody Skid Shield (3) - Install
- Underbody Splash Shield Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Underbody Splash Shield (1) - Install
- Underbody Splash Shield Bolt (1) - Install and tighten [4x]
- Underbody Splash Shield Bolt (2) - Install and tighten [4x] - Fastener Specifications
- Install both front tire and wheel assemblies. Tire and Wheel Removal and Installation (Steel Wheel) , or Tire and Wheel Removal and Installation (Aluminum Wheel)
- Lower the vehicle.
- Fill the engine oil to the proper level with NEW engine oil.
- Install the oil level indicator. (1)
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
- Fill the cooling system. Cooling System Draining and Filling (GE 47716 L84, L87) , or Cooling System Draining and Filling (Static L84, L87)
- Start the engine and check for coolant leaks.
- Check for oil leaks.
- Turn service mode off.
- With the vehicle off the hoist and on flat level ground, use the scan tool to reset trim heights. Trim Height Inspection
CAUTION:
Refer to Fastener Caution .
CAUTION:
Refer to Fastener Caution .