Installation Procedure
Engine Mount (1) - Install
- Connect electrical connector at the rear of engine mount.
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 component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the component. 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 NEW engine mount engine side bolts (1). Fastener Specifications
- Lower the engine.
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 component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Install and tighten the 3 NEW engine mount frame side bolts (1). Fastener Specifications
Chassis Wiring Harness (4) - Install
- Install the positive battery cable retainers to the chassis wiring harness front bracket.
- Chassis Front Wiring Harness Bracket Bolt- Front (3) - Install and tighten - Fastener Specifications
- Chassis Front Wiring Harness Bracket Bolt- Rear (1) - Install and tighten - Fastener Specifications
- Chassis Wiring Harness Front Bracket Retainer (2) - Install [2x]
Remove the EN-51768 Engine Support Fixture Adaptor Bolt - M8 and the EN-36857 Engine Lift Bracket (1) from the front of the left side cylinder head.
Turbocharger Coolant Feed and Return Pipe Gasket- Right Side Upper (1) - Install NEW
- NOTE:
Some components not shown for graphic clarity.
Engine Coolant Air Bleed Pipe Bolt- Right Side Upper (1) - Install and tighten - Fastener Specifications
{ If equipped }Ground Cable (2) - Install
- { If equipped }Engine Wiring Harness Ground Bolt (1) - Install and tighten - Ground Repair
Install the fuel injector wiring harness connector (1) to the engine coolant air bleed bracket.
- NOTE:
Some components not shown for graphic clarity.
Position the engine wiring harness channel (3) to the front of the engine.
- Engine Wiring Harness Bracket Bolt (2) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Catalytic Converter Brace Bracket (1) - Install
- Catalytic Converter Brace Bracket Bolt (2) - Install and tighten [2x] - Fastener Specifications
Catalytic Converter Gasket (3) - Install NEW
- Catalytic Converter Clamp (2) - Install NEW
- Nitrogen Oxides Catalytic Converter (1) - Install
- Install hoses and wiring harness as needed.
Catalytic Converter Brace Bracket Nut (1) - Tighten [2x] - Fastener Specifications
Fuel Cooler Coolant Cooler Inlet Hose - Install
- Fuel Heater Inlet and Outlet Nut (1) - Install and tighten - Fastener Specifications
Catalytic Converter Brace Bracket Nut (1) - Tighten [2x] - Fastener Specifications
- NOTE:
Quantity of fasteners may vary based on option content.
Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
{ If equipped }Battery Negative Cable Extension Cable Strap (1) @Catalytic Converter Brace Bracket - Install
- { If equipped }Catalytic Converter Brace Bracket Nut (2) - Install and tighten - Fastener Specifications
Install the exhaust gas recirculation cooler (1).
Exhaust Gas Recirculation Cooler Nut (1) - Install and tighten [4x] - Fastener Specifications
- Connect the electrical connector at exhaust gas recirculation cooler.
Exhaust Gas Recirculation Cooler Inlet Pipe Gasket- Upper (4) - Install NEW
- Exhaust Gas Recirculation Cooler Inlet Pipe Gasket- Lower (3) - Install NEW
- Exhaust Gas Recirculation Pipe (2) - Install
- Exhaust Gas Recirculation Cooler Inlet Pipe Bolt (1) - Install and tighten [4x] - Fastener Specifications
Exhaust Gas Recirculation Valve Cooler Gasket (2) - Install NEW
- Install the exhaust gas recirculation valve (1) with the exhaust gas recirculation valve hose.
Exhaust Gas Recirculation Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
Heater Inlet Hose Bracket (2) - Install
- Exhaust Gas Recirculation Valve Bracket Nut (1) - Install and tighten - Fastener Specifications
Exhaust Gas Recirculation Pipe Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Connect the electrical connector (1).
Exhaust Gas Recirculation Outlet Pipe Gasket (2) - Install NEW
- Exhaust Gas Recirculation Pipe (1) - Install
Exhaust Gas Recirculation Pipe Nut (1) - Install and tighten - Fastener Specifications
Exhaust Gas Recirculation Pipe Nut (1) - Install and tighten - Fastener Specifications
Position the exhaust pressure differential sensor bracket (2) into place.
- Exhaust Pressure Differential Sensor Bracket Stud (1) - Install and tighten [2x] - Fastener Specifications
Install the rear engine wiring harness channel (2).
- Install the 3 rear engine wiring harness channel nuts (1).
Exhaust Pressure Differential Sensor (1) - Install
Install the exhaust pressure differential sensor (2) to the exhaust gas recirculation cooler by engaging the hose clamp (1). Hose Clamp Replacement Guidelines - Spring Type
Install the exhaust pressure differential sensor to the exhaust gas recirculation valve hose by engaging the hose clamp (1). Hose Clamp Replacement Guidelines - Spring Type
Exhaust Pressure Differential Sensor (1) - Install
Exhaust Pressure Sensor Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Cooler Inlet Pipe (1) - Install
Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
Turbocharger Coolant Feed and Return Pipe (4) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install
- Exhaust Gas Recirculation Valve Cooling Return Hose (3) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Thermostat Bypass Hose (2) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Cooler Inlet Pipe (5) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install
- Exhaust Gas Recirculation Cooler Outlet Pipe (4) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install
- Heater Inlet Hose (3) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install
- Exhaust Gas Recirculation Coolant Return Pipe (2) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install
- Hose Clamp (1) - Engage [4x] - Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Valve Inlet Gasket (2) - Install NEW
- Exhaust Back Pressure Valve (1) - Install
Catalytic Converter Nut (1) - Install and tighten [3x] - Fastener Specifications
Turbocharger Coolant Feed and Return Pipe Gasket (3) - Install NEW
- Exhaust Gas Recirculation Valve Cooling Return Pipe (2) - Install
- Exhaust Gas Recirculation Valve Cooling Return Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
Electrical Connector (1) @Exhaust Back Pressure Valve - Connect
- Connect wiring harness retainers, as required.
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
- Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
- Wiring Harness Retainer (2) @Catalytic Converter Brace Bracket (3) - Install
Exhaust Front Pipe Nut (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications
Coat the threads of the exhaust particulate sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Exhaust Particulate Sensor (1) - Install and tighten - Fastener Specifications
Coat the threads with of the nitrogen oxides sensor - position 3 (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Nitrogen Oxides Sensor- Position 3 (1) - Install and tighten - Fastener Specifications
Coat the threads with of the nitrogen oxides sensor - position 2 (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Nitrogen Oxides Sensor- Position 2 (1) - Install and tighten - Fastener Specifications
Exhaust Gas Temperature Sensor (1) - Install and tighten - Fastener Specifications
- Front Wheelhouse Liner-Right Side (3) - Install - Front Wheelhouse Liner Replacement
Exhaust System Front Gasket (3) - Install NEW
- Reductant Fluid Injector (2) - Install
- Emission Reduction Fluid Injector Clamp (1) - Install NEW - Fastener Specifications
Exhaust Temperature Sensor - Position 2 (1) - Install - Fastener Specifications
Exhaust Temperature Sensor - Position 1 (1) - Install - Fastener Specifications
Coat the threads of the nitrogen oxides sensor (2) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Nitrogen Oxides Sensor (2) - Install and tighten - Fastener Specifications
Catalytic Converter Clamp (1) - Tighten - Fastener Specifications
Turbocharger Heat Shield (1) - Install
Turbocharger Heat Shield Nut (2) - Install and tighten - Fastener Specifications
- Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Gas Recirculation Temperature Sensor (2) - Install and tighten - Fastener Specifications
Battery Tray (1) - Install
- Engage all wire harness retainers to the battery tray.
Battery Tray Bolt (1) - Install and tighten [7x] - Fastener Specifications
Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) - Install NEW
- Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) - Install NEW
- Air Conditioning Refrigerant Heat Exchanger (2) - Install
- Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) - Install and tighten - Fastener Specifications
Air Conditioning Refrigerant Heat Exchanger Nut (1) @Battery Tray - Install and tighten - Fastener Specifications
Air Conditioning Compressor and Condenser Hose Seal (5) - Install NEW
- Air Conditioning Condenser and Evaporator Hose (1) - Install
- Air Conditioning Condenser and Evaporator Hose Clip (6) - Install
- Air Conditioning Compressor and Condenser Hose Seal (4) - Install NEW
- Air Conditioning Compressor and Condenser Hose (3) @Air Conditioning Refrigerant Heat Exchanger - Install
- Air Conditioning Compressor and Condenser Hose Nut (2) @Air Conditioning Refrigerant Heat Exchanger - 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) - Install and 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]
Battery (1) - Install
Battery Hold Down Retainer (2) - Install
- Battery Hold Down Retainer Bolt (1) - Install and tighten - Fastener Specifications
Battery Distribution Engine Compartment Fuse Block (2) - Install
- Retaining Tab (1) - Engage [3x]
Battery Positive Post Clamp Nut (1) - Tighten - Fastener Specifications
Electrical Connector (1) - Connect
Front Compartment Fuse Block Cover (2) - Install
- Retaining Tab (1) - Engage [2x]
Battery Hold Down Strap (2) - 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.
- Battery Hold Down Strap Bolt (1) - Install and tighten [2x] - Fastener Specifications
Air Cleaner Outlet Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
Air Cleaner Outlet Front Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
- Oil Filler Cap - Remove
Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
Plenum Front Panel Outer Reinforcement (1) - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
- Fill the cooling system to the proper level. Cooling System Draining and Filling (Static LM2) , or Cooling System Draining and Filling (GE 47716 LM2)
- Recharge the refrigerant. Refrigerant Recovery and Recharging
- Inspect the exhaust system for leaks.
Refer to Fastener Caution .
Refer to Component Fastener Tightening Caution .