Installation Procedure
Intake Manifold Gasket (3) - Install NEW [6x]
- Intake Manifold (1) - Install
- Intake Manifold Bolt (2) - Install and hand tighten [9x]
- Intake Manifold Bolt (2) - Tighten in sequence [9x] - Fastener Specifications
Intake Manifold Insulator (1) - Install
- Intake Manifold Insulator Retainer (2) - Install [2x]
Position the engine wiring harness channel (3) at the front of the engine, attach retainer at intake manifold, and connect electrical connectors as needed.
- Engine Wiring Harness Bracket Bolt (2) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Install a NEW exhaust gas recirculation cooler inlet pipe gasket (3).
- Install a NEW exhaust gas recirculation pipe seal (2).
- Install the exhaust gas recirculation pipe (1).
- NOTE:
Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).
Turbocharger Coolant Feed and Return Pipe Bolt (3) - Install and tighten - Fastener Specifications
- Turbocharger Coolant Return Hose (2) @Turbocharger Coolant Feed Pipe - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications .
Exhaust Gas Recirculation Outlet Pipe Bolt (2) - Install and tighten - Fastener Specifications
- Install the turbocharger coolant return hose clip (1).
- NOTE:
Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Exhaust Gas Recirculation Cooler Bolt (1) - Install and tighten [2x] - Fastener Specifications .
Engine Coolant Air Bleed Hose (2) - Reposition
- Engine Coolant Outlet Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
Install the rear engine wiring harness channel (2).
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [3x] - Fastener Specifications .
Intake Air Pressure and Temperature Sensor (2) - Install
- Intake Air Pressure and Temperature Sensor Bolt (1) - Install and tighten - Fastener Specifications
- Connect the intake air pressure and temperature sensor electrical connector.
Oil Level Indicator Tube Seal (2) @Oil Level Indicator Tube - Install NEW
- Oil Level Indicator Tube (1) @Lower Crankcase Extension - Install
- NOTE:
With aid of assistant reposition the engine wiring harness and note the routing of oil level indicator tube.
Oil Level Indicator Tube (2) - Install
- Oil Level Indicator Tube Bolt (1) - Install and tighten - Fastener Specifications
Engine Oil Level Indicator (1) - Install
Connect electrical connector and clip the glow plug wiring harness (1) to the intake manifold.
Clip the engine coolant temperature sensor wiring harness (1) to the intake manifold.
Exhaust Gas Recirculation Coolant Return Pipe (4) - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Pipe Bolt (3) - Install and tighten - Fastener Specifications
- Wiring Harness Retainer (2) @Exhaust Gas Recirculation Coolant Return Pipe - Install
Exhaust Gas Recirculation Coolant Return Pipe (3) @Exhaust Gas Recirculation Coolant Return Pipe - Install
- Turbocharger Coolant Return Hose (2) @Exhaust Gas Recirculation Coolant Return Pipe - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Thermostat Bypass Hose (1) - Install
- Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
Exhaust Gas Recirculation Cooler Water Bypass Inlet Hose (2) @Thermostat Bypass Hose - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Air Cleaner Outlet Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten - Fastener Specifications
Air Cleaner Lower Housing (1) - Install
Air Cleaner Nut (1) - Install and tighten - Fastener Specifications
Accessory Wiring Junction Block (2) - Install
- Engine Wiring Harness Fuse Block Bracket Bolt (1) - Install and tighten - Fastener Specifications
Electrical Connector (1) @Air Cleaner Lower Housing - Install
- Install all retainers to the air cleaner lower housing.
Air Cleaner Upper Housing (2) - Install
- Air Cleaner Housing Cover Bolt (1) - Install and tighten [3x] - Fastener Specifications
- Connect the mass airflow sensor electrical connector.
Intake Air Duct (2) - Install
- Intake Air Duct Retainer (1) - Install
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
Throttle Body Gasket (3) - Install NEW
- Throttle Body (2) - Install
- Throttle Body Bolt (1) - Install and tighten [3x] - Fastener Specifications
- Connect the throttle body electrical connector.
Charge Air Cooler Outlet Air Hose (2) - Install
- Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Clip (2) @Oil Level Indicator Tube - Install
- Oil Level Indicator Tube Stud (1) - Install and tighten - Fastener Specifications
Engine Wiring Harness Bracket (2) - Install
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
- Front Wheelhouse Liner- Left Side - Install - Front Wheelhouse Liner Replacement
- Plenum Front Panel Outer Reinforcement - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
- 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 (Static LM2) , or Cooling System Draining and Filling (GE 47716 LM2)
- Start the engine and check for coolant leaks.
Refer to Fastener Caution .