Installation Procedure
Clean the threads on the engine oil temperature sensor (1) and apply sealant to the threads. Adhesives, Fluids, Lubricants, and Sealers
- Engine Oil Temperature Sensor (1) - Install and tighten - Fastener Specifications
- Oil Filter Bypass Valve (4) - Install and tighten - Fastener Specifications
- Clean the threads on the engine oil pressure sensor (5) and apply sealant to the threads. Adhesives, Fluids, Lubricants, and Sealers
- Engine Oil Pressure Sensor (5) - Install and tighten - Fastener Specifications
-
Fig 1: Identifying Lower Crankcase Extension Pins, Engine Block Core Hole Plugs, Thermostat Bypass Hoses, Bolts And Gaskets
Courtesy of GENERAL MOTORS COMPANY
Engine Coolant Thermostat Gasket (5, 8) - Install NEW [2x]
- Thermostat Bypass Hose (6, 10) - Install [2x]
- Thermostat Bypass Pipe Bolt (7, 9) - Install and tighten [4x] - Fastener Specifications
Timing Indicator Bracket (2) - Install
- Engine Front Cover Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Clean all sealing surfaces.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- NOTE:
The bolts must be installed and fastened to final torque specification immediately after the component is installed.
Apply a 4 mm (0.157 in) bead of sealer (1) along the perimeter of the sealing surface and at the center location, dimension a. Adhesives, Fluids, Lubricants, and Sealers
- Apply a 6 mm (0.236 in) bead of sealer (2) at 4 locations on each end of the perimeter sealing surface, dimension b. Adhesives, Fluids, Lubricants, and Sealers
Oil Pump Gasket (5) - Install NEW
- Upper Oil Pan Gasket (4) - Install NEW
- Lower Crankcase Extension (2) - Install
- NOTE:
Install all lower crankcase extension bolts hand tight only prior to the tightening sequence.
Lower Crankcase Extension Bolt - M8 (4) - Install NEW and hand tighten [7x]
- Lower Crankcase Extension Bolt - M6 (1, 2, 3) - Install and hand tighten [14x]
- Lower Crankcase Extension Bolt - M8 (4) - Tighten in sequence [7x] - Fastener Specifications
- Lower Crankcase Extension Bolt - M6 (1, 2, 3) - Tighten in sequence [14x] - Fastener Specifications
- Connect the electrical connectors and install the wiring harness retainers as necessary.
Oil Pump Suction Pipe Seal (3) - Install NEW
- Oil Pump Suction Pipe (2) - Install
- Oil Pump Suction Pipe Bolt (1) - Install and tighten - Fastener Specifications
Timing Belt (1) @ Oil Pump Sprocket (2) - Install
- Timing Belt (1) @ Crankshaft - Install
- Oil Pump Sprocket (2) - Install
- Oil Pump Drive Bolt (3) - Install and hand tighten
Install the EN-47634 Holder (1) and the EN-956 Extension (4) to the oil pump sprocket (2).
- Oil Pump Drive Bolt (3) - Install and tighten - Fastener Specifications
- Remove the EN-47634 Holder (1) and the EN-956 Extension (4) from the oil pump sprocket (2).
- NOTE:
Ensure proper use of room temperature vulcanizing (RTV) sealant. Adhesives, Fluids, Lubricants, and Sealers
Apply a 4 mm (0.157 in) bead of sealer along the crankshaft front oil seal sealing path (1), dimension a. Adhesives, Fluids, Lubricants, and Sealers
- Apply a 6 mm (0.236 in) bead at the two locations b. Adhesives, Fluids, Lubricants, and Sealers
Install the EN-52452 Front Crankshaft Seal Installer (1) to the crankshaft.
- Install and hand tighten the 2 bolts (2) of the EN-52452 Front Crankshaft Seal Installer (1).
Crankshaft Front Oil Seal (1) - Install NEW
- Check that the crankshaft front oil seal (1) sits correctly on the crankshaft and the 2 pins (2, 4).
- Remove the 2 bolts (5) from the EN-52452 Front Crankshaft Seal Installer (3).
- Remove the EN-52452 Front Crankshaft Seal Installer (3) from the crankshaft.
Engine Front Cover Bolt (1) - Install and tighten in sequence [8x] - Fastener Specifications
Crankshaft Pulley (1) - Install
- Crankshaft Pulley Bolt (2) - Install and hand tighten [4x]
Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
- Crankshaft Pulley Bolt (2) - Install and tighten in sequence [4x] - Fastener Specifications
- Remove the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
Secure the EN-52446-3 Base (1) in a vice.
- Install the 4 EN-52446-4 Studs (3) in base.
- Place the timing chain lower cover (2) outward facing side up on the base.
- Install EN-52446-2 Seal Protector (4) onto the EN-52446-3 Base (1).
- Install the NEW crankshaft rear oil seal (5) to the EN-52446-3 Base (1), using the EN-52446-2 Seal Protector (4) to center the NEW crankshaft rear oil seal (5).
- Remove the EN-52446-2 Seal Protector (4).
Install the EN-52446-1 Installer (1) on the NEW crankshaft rear oil seal (4).
- Install 4 washers (2) onto the EN-52446-4 Studs.
- Install the 4 EN-52446-5 Nuts (3) onto the studs.
- Hand tighten the 4 EN-52446-5 Nuts (3) evenly until the NEW crankshaft rear oil seal (4) is fully seated in the cover.
- Remove the EN-52446 Assembly from the NEW crankshaft rear oil seal (4).
- NOTE:
If service part comes with seal protector then use inner seal protector ring to slip the seal lip over the crankshaft snout, instead of EN-52446-2 Seal Protector (1).
Install the EN-52446-2 Seal Protector (1) to the crankshaft.
- Install the 4 EN-52446-4 Studs (2).
- Install the 4 EN-52446-5 Nuts (3) and hand tighten.
- NOTE:
- Observe the locations for additional sealer (2) while applying the sealant path.
- The bolts must be installed and fastened to final torque specification immediately after the component is installed.
Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Apply a 4.0 mm (0.158 in) bead of sealer along the timing chain lower cover sealing path (1), dimension a. Adhesives, Fluids, Lubricants, and Sealers
- Apply a 6 mm (0.236 in) bead at the two locations b. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
If service part comes with seal protector then use inner seal protector ring to slip the seal lip over the crankshaft snout, instead of EN-52446-2 Seal Protector (3).
Align the timing chain lower cover (1) with the two transmission locating pins (2).
- Timing Chain Lower Cover (1) - Install
- Check that the crankshaft rear oil seal sits correct on the crankshaft.
- Remove the EN-52446-2 Seal Protector (3).
Timing Chain Cover Bolt (1, 2) - Install
- Timing Chain Cover Bolt (1, 2) - Tighten in sequence [16x] - Fastener Specifications
- NOTE:
- Ensure that the sealing surface is clear of oil, grease and old sealant material.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- The bolts must be installed and fastened to final torque specification immediately after the component is installed.
Apply a 4.0 mm (0.158 in) bead of sealer (1) to the oil pan sealing surface. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
Ensure the alignment pins are properly aligned when installing the oil pan.
Lower Oil Pan (1) - Install NEW
Oil Pan Bolt (1) - Install and hand tighten [23x]
- Oil Pan Bolt (1) - Tighten in sequence [23x] - Fastener Specifications
Automatic Transmission Flex Plate (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.
- Automatic Transmission Flex Plate Bolt (2) - Install NEW and hand tighten [8x]
- NOTE:
Have an additional technician hold the EN-49979 Holder (1) with the EN-956-1 Extension (3) in place.
Install the EN-49979 Holder (1) with EN-956-1 Extension (3).
- Automatic Transmission Flex Plate Bolt - Tighten in sequence [8x] - Fastener Specifications
- Remove the EN-49979 Holder (1) with EN-956-1 Extension (3).
Thermostat Bypass Hose (2) @ Thermostat Bypass Pipe - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Engine Oil Cooler Seal (3) - Install NEW
- Engine Oil Cooler Gasket (2) - Install NEW
- Engine Oil Cooler (1) - Install
Engine Oil Cooler Bolt (1) - Install and tighten [5x] - Fastener Specifications
Engine Coolant Thermostat Gasket (1) - Install NEW
- Thermostat Bypass Hose (2) - Install
Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
- Thermostat Bypass Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Install the electrical harness to the engine coolant air bleed hose stud.
Engine Coolant Thermostat Gasket (4) @ Thermostat Bypass Hose - Install NEW
- Thermostat Bypass Hose (2) - Install
- Thermostat Bypass Pipe Bolt (3) - Install and tighten [2x] - Fastener Specifications
- Thermostat Bypass Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type
Drivetrain and Front Suspension Frame Front Crossmember (1) - Install
Drivetrain and Front Suspension Frame Reinforcement Bolt (2) - Install [4x]
- Drivetrain and Front Suspension Frame Reinforcement Nut (1) - Install and tighten [4x] - Fastener Specifications
Remove the DT-21366 Converter Holding Strap (1) from the transmission which is retaining the torque converter.
- Position the transmission to the engine assembly. Raise or lower the transmission as required using a suitable jack.
Automatic Transmission (1) - Install
Transmission Bolt (1) - Install and tighten - Fastener Specifications
Transmission Stud (1) - Install and tighten [2x] - Fastener Specifications
Transmission Stud (1) - Install and tighten - Fastener Specifications
- Transmission Bolt (2) - Install and tighten - Fastener Specifications
Transmission Stud (1) - Install and tighten [4x] - Fastener Specifications
Engine Wiring Harness Channel (1) - Install
Install the wiring harness and engage the 2 wiring harness retainers (2).
- Connect the transmission wiring harness connector (1).
Transmission Vent Hose (2) @ Transmission - Install
- Install the transmission vent hose retainer (1) to the transmission.
Fuel Cooler Bolt (2) - Install and tighten - Fastener Specifications
- Fuel Cooler Support Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
Retainer (2) - Install
Install the fuel lines with the fuel cooler (3) as necessary.
- Fuel Feed and Return Front Hose Bracket Nut (1) - Install and tighten - Fastener Specifications
- Raise the transmission into place.
Transmission Support Crossmember (1) - Install
Transmission Support Crossmember Bolt (3) - Install [4x]
- Transmission Support Crossmember Nut (2) - Install and tighten [4x] - Fastener Specifications
- Transmission Mount Nut (1) - Install and tighten - Fastener Specifications
- Remove the transmission jack.
Wiring Harness (1) - Install
- Wiring Harness Retainer (3) - Install [4x]
Connect the wiring harness retainers.
- Transmission Heat Shield (1) - Install
- Transmission Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Transmission Heat Shield Bolt (2) - Install and tighten - Fastener Specifications
Exhaust Front Bracket (2) - Install
- Catalytic Converter Brace Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Connect the wiring harness retainers.
Propeller Shaft (1) - Install
Align the reference marks made between the differential drive pinion gear yoke and the propeller shaft.
- 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.
- Install the 4 rear propeller shaft bolts (1) and tighten in a crisscross pattern. Fastener Specifications
Install the EN-52579 Crankshaft Rotator (1).
If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component 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.
- Using the EN-52579 Crankshaft Rotator, rotate the crankshaft balancer clockwise ONLY, to align the transmission torque converter bolt with the starter opening.
- Transmission Torque Converter Bolt (1) - Install and tighten [6x] - Fastener Specifications
Remove the EN-52579 Crankshaft Rotator (1).
Transmission Fluid Cooler Seal (5) - Install NEW
- Remove the suitable strap or wire then reposition the transmission fluid cooling exchanger with automatic transmission fluid cooler inlet and outlet pipes (4) onto the transmission as necessary.
- Automatic Transmission Fluid Cooling Exchanger Nut (3) - Install and tighten - Fastener Specifications
- Transmission Fluid Cooler Pipe Bolt (2) - Install and tighten - Fastener Specifications
- Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Install and tighten [2x] - Fastener Specifications
Transmission Fluid Cooler Pipe Seal (2) - Install NEW [2x]
- Transmission Fluid Cooler Inlet and Outlet Pipe (1) - Install
Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
Position the fuel heater inlet and outlet hoses.
- Transmission Cooler Bypass Valve Bracket Bolt (1) - Install and tighten - Fastener Specifications
Fuel Heater Inlet and Outlet Bolt (2) - Install and tighten - Fastener Specifications
- Fuel Heater Inlet and Outlet Nut (1) - Install and tighten - Fastener Specifications
Fuel Heater Inlet and Outlet Bolt (1) - Install and tighten - Fastener Specifications
Thermostat Bypass Hose (2) @ Thermostat Bypass Pipe - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (3) @ Engine Oil Cooler - Install
- Engine Oil Cooler Coolant Inlet Hose (4) @ Engine Oil Cooler - Install
- Engine Oil Cooler Coolant Outlet Hose (5) @ Engine Oil Cooler - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Hose Clamp (2) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Coolant Return Pipe (2) - Install
- Thermostat Bypass Pipe Bolt (3) - Install and tighten - Fastener Specifications
Thermostat Bypass Hose (1) - Install
- Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
Oil Level Indicator Seal (2) - Install NEW
- Oil Level Indicator Tube (1) @ Lower Crankcase Extension - Install
Oil Level Indicator Tube Bolt (1) - Install and tighten - Fastener Specifications
Clip (2) @ Oil Level Indicator Tube - Install
- Oil Level Indicator Tube Stud (1) - Install and tighten - Fastener Specifications
Engine Oil Level Indicator (1) - Install
Engine Wiring Harness Bracket (2) - Install
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
-
Rotate the accessory drive primary belt tensioner (1) clockwise.
- Install the accessory drive primary belt (2) around all pulleys.
Engine Front Cover (2) - Install
- Engine Front Cover Bolt (1) - Install and tighten - Fastener Specifications
Starter Solenoid Cable (1) - Install
- Engine Wiring Harness Ground Nut (2) - Install and tighten - Fastener Specifications
Install the heater coolant pump and heater water auxiliary pump bracket as assembly (2).
- Heater Inlet Pipe Bracket Stud (1) - Install and tighten - Fastener Specifications
Transmission Fluid Cooler Inlet and Outlet Pipe (2) - Install
- Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
Starter (1) - Install
Electrical Connector (1) - Connect
- Install the protective sleeve (2).
Starter Bolt (1) - Install and tighten [3x] - Fastener Specifications
Starter Solenoid Cable (3) - Install
- Starter Solenoid Cable Nut (1) - Install and tighten - Fastener Specifications
- Wiring Harness Conduit Nut (2) - Install and tighten - Fastener Specifications
Starter Heat Shield (1) - Install
- NOTE:
Components removed for graphic clarity.
Engage the starter heat shield (2) into the retainer (1).
- Starter Heat Shield Bolt (3) - Install and tighten [2x] - Fastener Specifications
Exhaust System Front Gasket (2) - Install NEW
- Nitrogen Oxides Catalytic Converter (1) - Install
Exhaust Front Pipe Nut (1) - Install and tighten [2x] - Fastener Specifications
Catalytic Converter Brace Bracket (3) - Install
- Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) - Install
- Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Front Pipe Nut (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications
Coat the exhaust particulate matter sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Exhaust Particulate Matter Sensor (1) - Install and tighten - Fastener Specifications
Coat the nitrogen oxides sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Nitrogen Oxides Sensor - Position 3 (1) - Install and tighten - Fastener Specifications
Coat the nitrogen oxides sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Nitrogen Oxides Sensor - Position 2 (1) - Install and tighten - Fastener Specifications
Coat the exhaust gas temperature sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Exhaust Gas Temperature Sensor - Position 3 (1) - Install and tighten - Fastener Specifications
With the aid of an assistant, install the charge air cooler, condenser, fan and radiator assembly (1) to the vehicle.
Radiator Air Upper Baffle (1) - Install
Air Conditioning Compressor and Condenser Hose Clip (2) @ Engine Cooler Fan - Install [2x]
- Air Conditioning Compressor and Condenser Hose Retainer (1) @ Engine Cooler Fan - Install [2x]
Transmission Fluid Cooler Pipe Clip (1) @ Engine Cooler Fan - Install [2x]
- NOTE:
Some components not shown for graphic clarity.
Wiring Harness Retainer (3) @ Engine Cooler Fan - Install
- Electrical Connector (2) @ Engine Cooler Fan - Connect
Transmission Fluid Cooler Pipe Clip (4) @ Engine Cooler Fan - Install
- Electrical Connector (3) @ Engine Cooler Fan - Connect [2x]
- Electrical Connector (2) @ Engine Coolant Temperature Sensor - Connect
- Wiring Harness Retainer (1) @ Engine Cooler Fan - Install
Radiator Inlet Hose (3) @ Engine Radiator - Install
- Radiator Inlet Hose Clamp (4) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose (2) @ Engine Radiator - Install
- Radiator Surge Tank Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Accessory Wiring Junction Block (2) - Move into position
- Engine Wiring Harness Fuse Block Bracket Bolt (1) - Install and tighten - Fastener Specifications
Radiator Outlet Hose (2) @ Engine Radiator - Install
- Radiator Outlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Charge Air Cooler Surge Tank (2) - Install
- Charge Air Cooler Coolant Reservoir Bolt (1) - Install and tighten - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
CAUTION:Refer to Air Conditioning Sealing Washers Oil or Lubricant Exposure Caution .
Air Conditioning Compressor and Condenser Hose Seal (3) - Install NEW
- Air Conditioning Compressor and Condenser Hose (2) - Install
- Air Conditioning Compressor and Condenser Hose Nut (1) - Install and tighten - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
Air Conditioning Condenser and Evaporator Hose Seal (1) - Install NEW
- Air Conditioning Condenser and Evaporator Hose (2) - Install
Air Conditioning Condenser and Evaporator Hose Nut (1) - Install and tighten - Fastener Specifications
- Remove the caps from the fittings and plugs from the holes before installing the transmission fluid cooler pipes.
- NOTE:
Some components not shown for graphic clarity.
Transmission Fluid Cooler Seal (3) - Install NEW
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Fluid Auxiliary Cooler - Left Side - Install
- Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
Transmission Fluid Cooler Seal (3) - Install NEW
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Fluid Auxiliary Cooler - Right Side - Install
- Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
Insert the charge air cooler coolant hose (2) through the radiator air side baffle and install to the engine auxiliary radiator.
- Charge Air Cooler Coolant Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Radiator Air Side Baffle (1) - Move into position
- Radiator Air Side Baffle Retainer (2) - Install
Radiator Air Side Baffle (1) - Move into position
- Radiator Air Side Baffle Retainer (2) - Install [4x]
Move the radiator air front lower baffle (1) into position and engage the retainers to the engine auxiliary radiator.
Front End Upper Tie Bar (1) - Install
Front End Upper Tie Bar Bolt (1) - Install and tighten - Fastener Specifications
Front End Upper Tie Bar Bolt (1) - Install and tighten [3x] - Fastener Specifications
Front End Upper Tie Bar Bolt (1) - Install and tighten - Fastener Specifications
Front End Upper Tie Bar Bolt (1) - Install and tighten [3x] - Fastener Specifications
- Move the wiring harness into position and clip to the front end upper tie bar.
Install the retainer (2) and the hood primary latch release cable (1) to the upper tie bar.
Connect the hood release cable (3).
- Connect the clip and the electrical connector.
Electrical Connector (1) @ Horn (2) - Connect
- NOTE:
Left side shown, right side similar.
Headlamp Bracket - Left Side and Right Side (2) - Install [2x]
- Front End Upper Tie Bar Bolt - Left Side and Right Side (1) @ Headlamp Bracket - Install and tighten [8x] - Fastener Specifications
Front Grille Support Reinforcement (2) - Install
- Front Grille Support Bracket Bolt (1) - Install and tighten [4x] - Fastener Specifications
- NOTE:
Right side shown, left side similar.
Install the left and right side front end sheet metal diagonal braces (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.
- Install and tighten the 2 left and 2 right side front end sheet metal diagonal brace bolts (1). Fastener Specifications
Intake Air Duct (2) - Install
- Intake Air Duct Retainer (1) - Install
- NOTE:
Left side shown, right side similar.
Install the left and right side front end sheet metal diagonal braces (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.
- Install and tighten the 2 left and 2 right side front end sheet metal diagonal brace bolts (1). Fastener Specifications
Connect the electrical connector.
- Front Bumper Shutter (2) - Install
- Front Bumper Shutter Bolt (1) - Install and tighten [9x] - Fastener Specifications
Front Bumper Fascia Upper Stiffener (1) - Install
- NOTE:
Left side shown, right side similar.
Install and tighten the left and right side front bumper fascia upper stiffener bolts (2). Fastener Specifications
- Tighten the left and right side front bumper fascia upper stiffener nuts (1). Fastener Specifications
- NOTE:
Left side shown, right side similar.
Connect all electrical connectors.
- Secure the wiring harness retaining tab.
- Secure the front headlamp guide pin to the front bumper fascia guide (1).
- Front Headlamp (2) - Install
[2x]
- NOTE:
Left side shown, right side similar.
Headlamp Bolt (1) - Install and tighten [6x] - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Headlamp Bolt (1) - Install and tighten [6x] - Fastener Specifications
With the aid of an assistant, install the fascia. (2)
- Install the 9 grille clips (1).
- Connect the electrical connectors. Inline Harness Connector End Views - Index
Install the front bumper fascia (1) to the left and right side front bumper fascia guides and the front headlamps.
- Remove the tape from both headlamps.
Front Grille Bolt (1) - Install and tighten [6x] - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Install and tighten the left and right side front bumper fascia support brace bolts (1). Fastener Specifications
- NOTE:
Left side shown, right side similar.
Tighten the 2 left and right side front bumper fascia guide bolts (1). Fastener Specifications
- Install and tighten the left and right side front bumper fascia bolts (2). Fastener Specifications
Intake Air Splash Shield (2) - Install
- Intake Air Baffle Retainer (1) - Install [9x]
Hood Secondary Latch Release Handle (2) - Install
- Hood Latch Actuator Bolt (1) - Install and tighten [2x] - Fastener Specifications
Auxiliary Radiator Inlet Hose (2) @ Engine Auxiliary Radiator - Install
- Auxiliary Radiator Inlet Hose Clamp (1) - 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
- Fill the engine oil to the proper level with NEW engine oil. Engine Oil and Oil Filter Replacement
- Oil Filler Cap - Install
- Recharge the refrigerant. Refrigerant Recovery and Recharging
Attach GE-46143-A Cooling System Adapter (1) to the charge air cooler surge tank.
- Attach Vac-N-Fill cap to GE-42401-A Radiator Cap and Surge Tank Test Adapter (1).
Attach the vacuum gauge assembly (1) to the Vac-N-Fill cap (2).
Attach the fill hose (1) to the barb fitting on the vacuum gauge assembly (2).
Ensure that the valve is closed.
- Prepare a quantity of coolant in the graduated reservoir slightly greater than the charge air cooling system capacity.
- Inspect the concentration of the coolant mixture using GE-26568 Coolant and Battery Fluid Tester.
- NOTE:
Prior to installing the vacuum tank onto the graduated reservoir, ensure that the drain valve located on the bottom of the tank is closed.
Pour the coolant mixture into the graduated reservoir (1).
- Place the fill hose in the graduated reservoir (1).
- Install the vacuum tank (2) on the graduated reservoir with the fill hose routed through the cut-out area (3) in the vacuum tank.
Attach the venturi assembly (1) to the vacuum tank (2).
Attach a shop air hose to the venturi assembly (1).
Ensure the valve (2) on the venturi assembly is closed.
Attach the vacuum hose (1) to the vacuum gauge assembly (2) and the vacuum tank (3).
Open the valve (1) on the venturi assembly (2). The vacuum gauge will begin to rise and a hissing noise will be present.
Continue to draw vacuum until the needle stops rising (1). This should be 610-660 mm Hg (24-26 in Hg).
Coolant hoses may start to collapse. This is normal due to vacuum draw.
- To aid in the fill process, position the graduated reservoir above the coolant fill port.
Slowly open the valve (1) on the vacuum gauge assembly (2). When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
- Close the valve on the venture assembly.
- If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss.
If vacuum loss is observed, refer to Loss of Coolant .
- Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
Once the vacuum gauge reaches zero (1), close the valve on the vacuum gauge assembly and repeat steps 316 - 323.
Detach the Vac-N-Fill cap from the GE-46143-A Cooling System Adapter.
- Remove GE-46143-A Cooling System Adapter (1) from the charge air cooler surge tank.
- Fill the cooling system to the proper level.
- Detach the vacuum hose form the vacuum gauge assembly.
Attach the extraction hose (1) to the vacuum hose (2).
Open the valve (1) on the venturi assembly (2) to start a vacuum draw.
Use the extraction hose (1) to draw out coolant to the proper level.
- The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.
- Install the charge air cooler coolant filler cap.
GE-42401-2 Adapter Assembly (3) - Install
- GE-42401-3 Radiator Test Adapter - Female (2) - Install
- GE-47716-8 Vac-N-Fill Cap (1) - Install
Attach the vacuum gauge assembly (1) to the Vac-N-Fill cap (2).
Attach the fill hose (1) to the barb fitting on the vacuum gauge assembly (2).
Ensure that the valve is closed.
- Prepare a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water in a quantity that is slightly greater than the maximum capacity of the cooling system.
- Inspect the concentration of the coolant mixture using GE-26568 Coolant and Battery Fluid Tester.
- NOTE:
Prior to installing the vacuum tank onto the graduated reservoir, ensure that the drain valve located on the bottom of the tank is closed.
Pour the coolant mixture into the graduated reservoir (1).
- Place the fill hose in the graduated reservoir (1).
- Install the vacuum tank (2) on the graduated reservoir with the fill hose routed through the cut-out area (3) in the vacuum tank.
Attach the venturi assembly (1) to the vacuum tank (2).
Attach a shop air hose to the venturi assembly (1).
Ensure the valve (2) on the venturi assembly is closed.
Attach the vacuum hose (1) to the vacuum gauge assembly (2) and the vacuum tank (3).
Open the valve (1) on the venturi assembly (2). The vacuum gauge will begin to rise and a hissing noise will be present.
Continue to draw vacuum until the needle stops rising (1). This should be 610 - 660 mm Hg (24 - 26 in Hg).
Coolant hoses may start to collapse. This is normal due to vacuum draw.
- To aid in the fill process, position the graduated reservoir above the coolant fill port.
Slowly open the valve (1) on the vacuum gauge assembly (2). When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
- Close the valve on the venture assembly.
- If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss.
If vacuum loss is observed, refer to Loss of Coolant .
- Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
Once the vacuum gauge reaches zero (1), close the valve on the vacuum gauge assembly and repeat steps 346 - 353.
GE-47716-8 Vac-N-Fill Cap (1) - Remove
- GE-42401-3 Radiator Test Adapter - Female (2) - Remove
- GE-42401-2 Adapter Assembly (3) - Remove
- Adjust the cooling system to the proper level. Adhesives, Fluids, Lubricants, and Sealers
- If the cooling system level is over the maximum level allowed within the radiator surge tank, perform steps 358 - 362 until the correct level is achieved.
- Detach the vacuum hose form the vacuum gauge assembly.
Attach the extraction hose (1) to the vacuum hose (2).
Open the valve (1) on the venturi assembly (2) to start a vacuum draw.
Use the extraction hose (1) to draw out coolant to the proper level.
- The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.
- Start the engine and check for fuel leaks.
- Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature. Check the vehicle oil pressure gauge and confirm that the engine has acceptable oil pressure, listen for unusual noises. If necessary, install an oil pressure gauge and measure the engine oil pressure.
- Inspect for oil leaks.
- Place the ignition in service mode. Power Mode Description and Operation
- Turn off the air conditioning.
- Set the parking brake.
- Press the accelerator and brake pedal for two seconds at the same time, then release.
- There will NOT be a message on the Driver Information Center (DIC) to indicate that the ACSF is activated.
- It may take up to 60 seconds for the ACSF procedure to become audible.
- Start and run the engine at 1200 RPM for three minutes while adding coolant mixture as the level drops below the fill mark on the radiator surge tank until the level stabilizes.
- Install the radiator surge tank cap.
- Run the engine as follows while watching the coolant temperature gauge ensuring that the temperature is rising, but not overheating. If the radiator surge tank empties during the procedure below, stop the process and fill the radiator surge tank with the coolant mixture to the fill mark and start the procedure over.
- Run the engine speed at 3500 RPM for three minutes.
- Lower the engine speed to 1200 RPM and run for three minutes.
- Raise the engine speed to 3500 RPM and run for three minutes.
- Lower the engine speed to 1200 RPM and run for three minutes.
- Fill the radiator surge tank to the cold fill line and wait two minutes.
- Repeat steps 370 - 373 until the ACSF cycle completes with the coolant level maintained in the surge tank for the entire process.
- Turn ignition off.
- Allow the engine to cool
- Adjust the coolant level in the surge tank to the cold fill line.
- Perform a final inspection for the proper engine oil and coolant levels.
- Start the engine and check for coolant leaks.
- Front Wheelhouse Liner - Left Side and Right Side - Install [2x] - Front Wheelhouse Liner Replacement
- NOTE:
The proper position of the underbody skid shield is between the front bumper fascia extension and the front frame.
Underbody Skid Shield (3) - Install
- Underbody Splash Shield Bolt (2) - Install and tighten [2x] - Fastener Specifications
Underbody Splash Shield (1) - Install
Underbody Skid Shield Bolt (2) - Install and tighten [4x] - Fastener Specifications
- Front Bumper Fascia Skid Plate Bolt (1) - Install and tighten [4x] - Fastener Specifications
- Check the transmission fluid level. Transmission Fluid Level and Condition Check
Refer to Component Fastener Tightening Caution .
Refer to Fastener Caution .
Ensure that the sealing surface is clear of oil, grease and old sealant material.
Check that the 2 guide pins (1, 3) from the lower crankcase extension sit correctly in the engine block.
Take note that there are different bolt lengths.
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
For proper alignment of all transmission torque converter bolts, install the first transmission torque converter bolt in the oval shaped hole.
Ensure the proper routing of the accessory drive primary belt.
Refer to Component Fastener Tightening Caution .
When installing the wiring harness connector of the front bumper fascia, verify that the wiring harness connector is properly installed. Failure to properly install the wiring harness connector, may result in improper performance, component damage, system malfunction, and damage to the wiring and or connectors.
Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.
Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.
After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.
Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.
Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.
After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.
If you are unable to maintain the coolant level at the cold fill line of the surge tank and the surge tank empties while the process is running, turn the ignition off. The vehicle will only allow one ACSF process per key cycle.