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Home >> Chevrolet >> 2023 >> Tahoe SSV >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 11 (Engine Mechanical - 3.0L (Lm2) Diesel - Repair Instructions (1 Of 11)) >> Repair Instructions >> Lower Crankcase Extension Replacement (4WD, with RC1, with F47) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. GM5148872Courtesy of GENERAL MOTORS COMPANY

    Clean the threads on the engine oil temperature sensor (1) and apply sealant to the threads. Adhesives, Fluids, Lubricants, and Sealers

    2. CAUTION:

    Refer to Component Fastener Tightening Caution .

  2. Engine Oil Temperature Sensor (1) - Install and tighten - Fastener Specifications
  3. Oil Filter Bypass Valve (4) - Install and tighten - Fastener Specifications
  4. Clean the threads on the engine oil pressure sensor (5) and apply sealant to the threads. Adhesives, Fluids, Lubricants, and Sealers
  5. Engine Oil Pressure Sensor (5) - Install and tighten - Fastener Specifications
  6. GM5148869Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Thermostat Gasket (5, 8) - Install NEW [2x]

  7. Thermostat Bypass Hose (6, 10) - Install [2x]
    8. CAUTION:

    Refer to Fastener Caution .

  8. Thermostat Bypass Pipe Bolt (7, 9) - Install and tighten [4x] - Fastener Specifications
  9. GM5932415Courtesy of GENERAL MOTORS COMPANY

    Timing Indicator Bracket (2) - Install

  10. Engine Front Cover Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
    11. NOTE:

    Ensure that the sealing surface is clear of oil, grease and old sealant material.

  11. Clean all sealing surfaces.
  12. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  13. GM5148170Courtesy of GENERAL MOTORS COMPANY
    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

  14. 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
  15. GM5148167Courtesy of GENERAL MOTORS COMPANY

    Oil Pump Gasket (5) - Install NEW

  16. Upper Oil Pan Gasket (4) - Install NEW
    17. NOTE:

    Check that the 2 guide pins (1, 3) from the lower crankcase extension sit correctly in the engine block.

  17. Lower Crankcase Extension (2) - Install
  18. GM5148168Courtesy of GENERAL MOTORS COMPANY
    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]

    19. NOTE:

    Take note that there are different bolt lengths.

  19. Lower Crankcase Extension Bolt- M6 (1, 2, 3) - Install and hand tighten [14x]
    20. CAUTION:

    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.

  20. Lower Crankcase Extension Bolt- M8 (4) - Tighten in sequence [7x] - Fastener Specifications
  21. Lower Crankcase Extension Bolt- M6 (1, 2, 3) - Tighten in sequence [14x] - Fastener Specifications
  22. Connect the electrical connectors and install the wiring harness retainers as necessary.
  23. GM5209212Courtesy of GENERAL MOTORS COMPANY

    Oil Pump Suction Pipe Gasket (3) - Install NEW

  24. Oil Pump Suction Pipe (2) - Install
  25. Oil Pump Suction Pipe Bolt (1) - Install and tighten - Fastener Specifications
  26. GM5145487Courtesy of GENERAL MOTORS COMPANY

    Timing Belt (1) @Oil Pump Sprocket (2) - Install

  27. Timing Belt (1) @Crankshaft - Install
  28. Oil Pump Sprocket (2) - Install
  29. Oil Pump Drive Bolt (3) - Install and hand tighten
  30. GM5145486Courtesy of GENERAL MOTORS COMPANY

    Install the EN-47634  Holder (1) and the EN-956  Extension (4) to the oil pump sprocket (2).

  31. Oil Pump Drive Bolt (3) - Install and tighten - Fastener Specifications
  32. Remove the EN-47634  Holder (1) and the EN-956  Extension (4) from the oil pump sprocket (2).
  33. GM5148269Courtesy of GENERAL MOTORS COMPANY
    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

  34. Apply a 6 mm (0.236 in) bead at the two locations b. Adhesives, Fluids, Lubricants, and Sealers
  35. GM5148273Courtesy of GENERAL MOTORS COMPANY

    Install the EN-52452  Front Crankshaft Seal Installer (1) to the crankshaft.

  36. Install and hand tighten the 2 bolts (2) of the EN-52452  Front Crankshaft Seal Installer (1).
  37. GM5148276Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Front Oil Seal (1) - Install NEW

  38. Check that the crankshaft front oil seal (1) sits correctly on the crankshaft and the 2 pins (2, 4).
  39. Remove the 2 bolts (5) from the EN-52452  Front Crankshaft Seal Installer (3).
  40. Remove the EN-52452  Front Crankshaft Seal Installer (3) from the crankshaft.
  41. GM5190250Courtesy of GENERAL MOTORS COMPANY

    Engine Front Cover Bolt (1) - Install and tighten in sequence [8x] - Fastener Specifications

  42. GM5137111Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Pulley (1) - Install

  43. Crankshaft Pulley Bolt (2) - Install and hand tighten [4x]
  44. GM5137110Courtesy of GENERAL MOTORS COMPANY

    Install the EN-49979  Crankshaft Holder (1) with EN-956-1  Extension (3).

  45. Crankshaft Pulley Bolt (2) - Install and tighten in sequence [4x] - Fastener Specifications
  46. Remove the EN-49979  Crankshaft Holder (1) with EN-956-1  Extension (3).
  47. GM5766443Courtesy of GENERAL MOTORS COMPANY

    Secure the EN-52446-3  Base (1) in a vice.

  48. Install the 4 EN-52446-4  Studs (3) in base.
  49. Place the timing chain lower cover (2) outward facing side up on the base.
  50. Install EN-52446-2  Seal Protector (4) onto the EN-52446-3  Base (1).
  51. 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).
  52. Remove the EN-52446-2  Seal Protector (4).
  53. GM5766445Courtesy of GENERAL MOTORS COMPANY

    Install the EN-52446-1  Installer (1) on the NEW crankshaft rear oil seal (4).

  54. Install 4 washers (2) onto the EN-52446-4  Studs.
  55. Install the 4 EN-52446-5  Nuts (3) onto the studs.
  56. Hand tighten the 4 EN-52446-5  Nuts (3) evenly until the NEW crankshaft rear oil seal (4) is fully seated in the cover.
  57. Remove the EN-52446  Assembly from the NEW crankshaft rear oil seal (4).
  58. GM5145916Courtesy of GENERAL MOTORS COMPANY
    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.

  59. Install the 4 EN-52446-4  Studs (2).
  60. Install the 4 EN-52446-5  Nuts (3) and hand tighten.
  61. GM5145915Courtesy of GENERAL MOTORS COMPANY
    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

  62. 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
  63. Apply a 6 mm (0.236 in) bead at the two locations b. Adhesives, Fluids, Lubricants, and Sealers
  64. GM5145917Courtesy of GENERAL MOTORS COMPANY
    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).

  65. Timing Chain Lower Cover (1) - Install
  66. Check that the crankshaft rear oil seal sits correct on the crankshaft.
  67. Remove the EN-52446-2  Seal Protector (3).
  68. GM5389340Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Cover Bolt (1, 2) - Install

  69. Timing Chain Cover Bolt (1, 2) - Tighten in sequence [16x] - Fastener Specifications
  70. GM5145853Courtesy of GENERAL MOTORS COMPANY
    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

  71. GM5199046Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Ensure the alignment pins are properly aligned when installing the oil pan.

    Lower Oil Pan (1) - Install NEW

  72. GM5145845Courtesy of GENERAL MOTORS COMPANY

    Oil Pan Bolt (1) - Install and hand tighten [23x]

  73. Oil Pan Bolt (1) - Tighten in sequence [23x] - Fastener Specifications
  74. GM5133550Courtesy of GENERAL MOTORS COMPANY

    Automatic Transmission Flex Plate (1) - Install

  75. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  76. Automatic Transmission Flex Plate Bolt (2) - Install NEW and hand tighten [8x]
  77. GM5137110Courtesy of GENERAL MOTORS COMPANY
    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).

    78. CAUTION:

    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.

  78. Automatic Transmission Flex Plate Bolt - Tighten in sequence [8x] - Fastener Specifications
  79. Remove the EN-49979  Holder (1) with EN-956-1  Extension (3).
  80. GM5608843Courtesy of GENERAL MOTORS COMPANY

    Thermostat Bypass Hose (2) @Thermostat Bypass Pipe - Install

  81. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  82. GM5206143Courtesy of GENERAL MOTORS COMPANY

    Engine Oil Cooler Gasket- Small (3) - Install NEW

  83. Engine Oil Cooler Gasket- Large (2) - Install NEW
  84. Engine Oil Cooler (1) - Install
  85. GM5206140Courtesy of GENERAL MOTORS COMPANY

    Engine Oil Cooler Bolt (1) - Install and tighten [5x] - Fastener Specifications

  86. GM5881279Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Thermostat Gasket (1) - Install NEW

  87. Thermostat Bypass Hose (2) - Install
  88. GM5881278Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications

  89. Thermostat Bypass Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
  90. Install the electrical harness to the engine coolant air bleed hose stud.
  91. GM5134389Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Thermostat Gasket (4) @Thermostat Bypass Hose - Install NEW

  92. Thermostat Bypass Hose (2) - Install
  93. Thermostat Bypass Pipe Bolt (3) - Install and tighten [2x] - Fastener Specifications
  94. Thermostat Bypass Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type
  95. GM5589733Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The front axle may have to be maneuvered to install it into the vehicle.

    Front Axle (1) - Install

  96. Front Axle Vent Hose - Connect
  97. GM5589730Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bolt (1) - Install and tighten - Fastener Specifications

  98. GM5589729Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bolt (2) - Install

  99. Front Differential Carrier Bracket Nut (1) - Install and tighten - Fastener Specifications
  100. GM5568922Courtesy of GENERAL MOTORS COMPANY

    Drivetrain and Front Suspension Frame Front Crossmember (1) - Install

  101. GM5568896Courtesy of GENERAL MOTORS COMPANY

    Drivetrain and Front Suspension Frame Reinforcement Bolt (2) - Install [4x]

  102. Using the EN-45059-A  Angle Meter, Install and tighten the 4 drivetrain and front suspension frame reinforcement nuts (1). Fastener Specifications
  103. GM5568832Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution

    Front Differential Carrier Bolt (2) - Install NEW

  104. Front Differential Carrier Nut (1) - Install
  105. GM5589726Courtesy of GENERAL MOTORS COMPANY

    Connect the front drive axle actuator electrical connector (1).

  106. Reposition the harness and secure the two harness retainers (2).
  107. Remove the jack supporting the differential carrier.
  108. GM5121838Courtesy of GENERAL MOTORS COMPANY

    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.

  109. GM5595902Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Drive Shaft Seal (2) - Install NEW

  110. Front Wheel Drive Shaft Retaining Ring (1) - Install NEW
  111. 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
  112. Support the steering knuckle with a suitable jack stand.
  113. GM5588259Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Install steering knuckle side first

    Front Wheel Drive Half Shaft-Left Side (1) - Install

  114. Ensure that the left side wheel drive shaft (1) is fully seated in front differential carrier by pulling on the inner joint.
    115. NOTE:

    Prior to installing the front shock absorber, you MUST apply anti-corrosion wax to the frame shock tower.

  115. Apply anti-corrosion wax to the frame shock tower. ANTI-CORROSION TREATMENT AND REPAIR
  116. GM5613680Courtesy of GENERAL MOTORS COMPANY

    Front Shock Absorber- Left Side (1) - Install

  117. GM5613678Courtesy of GENERAL MOTORS COMPANY

    Front Shock Absorber Nut- Left Side (1) - Install and tighten [3x] - Fastener Specifications

  118. GM5681196Courtesy of GENERAL MOTORS COMPANY

    Reposition the air line, then install and tighten the air line nut (1). Fastener Specifications

  119. GM5613679Courtesy of GENERAL MOTORS COMPANY

    Front Shock Absorber Bolt- Left Side (1) - Install and tighten [2x] - Fastener Specifications

  120. GM5613681Courtesy of GENERAL MOTORS COMPANY

    Reposition and install the chassis wiring harness bracket (1) to the frame shock tower.

  121. GM5613676Courtesy of GENERAL MOTORS COMPANY

    Connect the electrical connector for the electronic suspension wheel front vertical accelerometer (1) and the front air shock harness electrical connector (2).

  122. GM5604913Courtesy of GENERAL MOTORS COMPANY

    Front Upper Control Arm Ball Stud Nut- Left Side (1) - Install and tighten - Fastener Specifications

  123. GM5588267Courtesy of GENERAL MOTORS COMPANY

    Steering Linkage Outer Tie Rod- Left Side - Install

  124. Steering Linkage Outer Tie Rod Nut- Left Side (1) - Install and tighten - Fastener Specifications
  125. GM5615179Courtesy of GENERAL MOTORS COMPANY

    Install the left side electronic suspension wheel front vertical accelerometer (3) with the harnesses (1).

  126. Electronic Suspension Rear Vertical Accelerometer Bolt- Left Side (2) - Install and tighten - Fastener Specifications
  127. GM5582579Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Speed Sensor- Left Side (2) - Install

  128. Front Wheel Speed Sensor Bolt- Left Side (1) - Install and tighten - Fastener Specifications
  129. Install the left side front wheel speed sensor bracket (4).
  130. Front Wheel Speed Sensor Bracket Bolt- Left Side (3) - Install and tighten - Fastener Specifications
  131. GM5518506Courtesy of GENERAL MOTORS COMPANY

    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:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  132. Front Brake Caliper- Left Side (1) - Install
  133. Front Brake Caliper Bolt- Left Side (2) - Install and tighten [2x] - Fastener Specifications
  134. GM5527943Courtesy of GENERAL MOTORS COMPANY

    Front Brake Hose Bracket Bolt- Left Side (1) - Install and tighten - Fastener Specifications

  135. GM5517176Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Only the left front wheel is equipped with the front disc brake pad wear sensor.

    Front Disc Brake Pad Wear Sensor- Left Side (1) @Front Brake Caliper - Install

  136. GM5580467Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution

    Front Wheel Drive Shaft Nut- Left Side (1) - Install NEW and hand tighten

  137. GM5121838Courtesy of GENERAL MOTORS COMPANY

    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.

  138. GM5595902Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Drive Shaft Seal (2) - Install NEW

  139. Front Wheel Drive Shaft Retaining Ring (1) - Install NEW
  140. 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
  141. Support the steering knuckle with a suitable jack stand.
  142. GM5591240Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Install steering knuckle side first

    Front Wheel Drive Half Shaft- Right Side (1) - Install

  143. Ensure that the right front wheel drive half shaft (1) is fully seated in front differential carrier by pulling on the inner joint.
  144. GM5591248Courtesy of GENERAL MOTORS COMPANY

    Front Upper Control Arm Ball Stud Nut- Right Side (1) - Install and tighten - Fastener Specifications

  145. GM5591251Courtesy of GENERAL MOTORS COMPANY

    Steering Linkage Outer Tie Rod- Right Side - Install

  146. Steering Linkage Outer Tie Rod Nut- Right Side (1) - Install and tighten - Fastener Specifications
  147. GM5615183Courtesy of GENERAL MOTORS COMPANY

    Install the right side harness (1) and the electronic suspension wheel front vertical accelerometer (3).

  148. Electronic Suspension Rear Vertical Accelerometer Bolt- Right Side (2) - Install and tighten - Fastener Specifications
  149. GM5591242Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Speed Sensor- Right Side (2) - Install

  150. Front Wheel Speed Sensor Bolt- Right Side (1) - Install and tighten - Fastener Specifications
  151. Install the right side front wheel speed sensor bracket (4).
  152. Front Wheel Speed Sensor Bracket Bolt- Right Side (3) - Install and tighten - Fastener Specifications
  153. GM5591236Courtesy of GENERAL MOTORS COMPANY

    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:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  154. Front Brake Caliper- Right Side (1) - Install
  155. Front Brake Caliper Bolt- Right Side (2) - Install and tighten [2x] - Fastener Specifications
  156. GM5591237Courtesy of GENERAL MOTORS COMPANY

    Front Brake Hose Bracket Bolt- Right Side (1) - Install and tighten - Fastener Specifications

  157. GM5591238Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Drive Shaft Nut- Right Side (1) - Install NEW and hand tighten

  158. Have an assistant apply the brakes.
    159. CAUTION:

    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.

  159. Front Wheel Drive Shaft Nut- Right Side (1) - Tighten - Fastener Specifications
  160. Front Wheel Drive Shaft Nut- Left Side (1) - Tighten - Fastener Specifications
  161. Remove the steering knuckle supports.
  162. GM5591026Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Support the front stabilizer shaft (3).

    Front Stabilizer Shaft (3) - Install

  163. Front Stabilizer Shaft Clamp (2) - Install [2x]
  164. Front Stabilizer Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
  165. GM5633900Courtesy of GENERAL MOTORS COMPANY

    Front Stabilizer Shaft Link- Right Side@Lower Control Arm - Install

  166. Front Stabilizer Shaft Link Nut- Right Side (1) - Install and tighten - Fastener Specifications
  167. GM5633908Courtesy of GENERAL MOTORS COMPANY

    Front Stabilizer Shaft Link- Left Side@Front Lower Control Arm - Install

  168. Front Stabilizer Shaft Link Nut- Left Side (1) - Install and tighten - Fastener Specifications
  169. GM5608009Courtesy of GENERAL MOTORS COMPANY

    Remove the DT-21366  Converter Holding Strap (1) from the transmission which is retaining the torque converter.

  170. Position the transmission to the engine assembly. Raise or lower the transmission as required using a suitable jack.
  171. GM5647019Courtesy of GENERAL MOTORS COMPANY

    Automatic Transmission (1) - Install

  172. GM5739769Courtesy of GENERAL MOTORS COMPANY

    Transmission Bolt (1) - Install and tighten - Fastener Specifications

  173. GM5136887Courtesy of GENERAL MOTORS COMPANY

    Transmission Stud (1) - Install and tighten [2x] - Fastener Specifications

  174. GM5136473Courtesy of GENERAL MOTORS COMPANY

    Transmission Stud (1) - Install and tighten - Fastener Specifications

  175. Transmission Bolt (2) - Install and tighten - Fastener Specifications
  176. GM5136415Courtesy of GENERAL MOTORS COMPANY

    Transmission Stud (1) - Install and tighten [4x] - Fastener Specifications

  177. GM5739206Courtesy of GENERAL MOTORS COMPANY

    Engine Wiring Harness Channel (1) - Install

  178. GM5646918Courtesy of GENERAL MOTORS COMPANY

    Connect the transmission wiring harness connector (1).

  179. Position the wiring harness then install the 2 wiring harness retainers (2).
  180. GM5867343Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Vent Hose (2) @Transfer Case - Install

  181. Install the transfer case vent hose retainer (1) to the fuel feed and return pipe.
  182. GM5135431Courtesy of GENERAL MOTORS COMPANY

    Transmission Vent Hose (2) @Transmission - Install

  183. Install the transmission vent hose retainer (1) to the transmission.
  184. GM5617142Courtesy of GENERAL MOTORS COMPANY

    Fuel Cooler Bolt (2) - Install and tighten - Fastener Specifications

  185. Fuel Cooler Support Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
  186. GM5617621Courtesy of GENERAL MOTORS COMPANY

    Retainer (2) - Install

  187. GM5644353Courtesy of GENERAL MOTORS COMPANY

    Install the fuel lines with the fuel cooler (3) as necessary.

  188. Fuel Feed and Return Front Hose Bracket Nut (1) - Install and tighten - Fastener Specifications
  189. GM5644313Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Seal (5) - Install NEW

  190. 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.
  191. Automatic Transmission Fluid Cooling Exchanger Nut (3) - Install and tighten - Fastener Specifications
  192. Transmission Fluid Cooler Pipe Bolt (2) - Install and tighten - Fastener Specifications
  193. Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Install and tighten [2x] - Fastener Specifications
  194. GM5627087Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Pipe Seal (2) - Install NEW [2x]

  195. Transmission Fluid Cooler Inlet and Outlet Pipe (1) - Install
  196. GM5617646Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications

  197. Uncap the fittings and unplug the holes of the transmission.
  198. GM5157649Courtesy of GENERAL MOTORS COMPANY

    Reposition the fuel heater inlet and outlet bracket.

  199. Fuel Heater Inlet and Outlet Bolt (1) @Transmission - Install and tighten - Fastener Specifications
  200. GM5157640Courtesy of GENERAL MOTORS COMPANY

    Reposition the fuel heater inlet and outlet bracket.

  201. Fuel Heater Inlet and Outlet Nut (1) @Transmission - Install and tighten - Fastener Specifications
  202. GM5606810Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Adapter Gasket (3) - Install NEW

  203. Transfer Case (2) - Install
  204. Transfer Case Nut (1) - Install and tighten [6x] - Fastener Specifications
  205. Connect the wiring harness retainers.
  206. Remove the transmission jack from the transfer case.
  207. GM5606248Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Vent Hose (1) - Install

  208. GM5605434Courtesy of GENERAL MOTORS COMPANY

    Reposition the wiring harness and install the wiring harness retainer (3) in to the transfer case.

  209. Connect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
  210. Connect the transfer case two/four wheel drive actuator electrical connector (1).
  211. GM4960510Courtesy of GENERAL MOTORS COMPANY

    Transmission Heat Shield (3) - Install

  212. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  213. Transmission Heat Shield Bolt (2) - Install and tighten - Fastener Specifications
  214. Transmission Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
  215. Connect the wiring harness retainers.
  216. GM5185017Courtesy of GENERAL MOTORS COMPANY

    Exhaust Front Bracket (2) - Install

  217. Catalytic Converter Brace Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
  218. Connect the wiring harness retainers.
  219. GM5590452Courtesy of GENERAL MOTORS COMPANY

    Transmission Mount (2) - Install

  220. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  221. Transmission Mount Bolt (1) - Install and tighten [2x] - Fastener Specifications
  222. Raise the transmission into place.
  223. GM4974120Courtesy of GENERAL MOTORS COMPANY

    Transmission Support Crossmember (1) - Install

  224. GM4974118Courtesy of GENERAL MOTORS COMPANY

    Transmission Support Crossmember Bolt (2) - Install [4x]

  225. Transmission Support Crossmember Nut (1) - Install and tighten [4x] - Fastener Specifications
  226. GM4971868Courtesy of GENERAL MOTORS COMPANY

    Transmission Mount Nut (1) - Install and tighten [2x] - Fastener Specifications

  227. Remove the transmission jack.
  228. GM5674935Courtesy of GENERAL MOTORS COMPANY

    Wiring Harness (1) - Install

  229. Wiring Harness Retainer (3) - Install [4x]
  230. GM5591284Courtesy of GENERAL MOTORS COMPANY

    Propeller Shaft (1) - Install

  231. GM5591283Courtesy of GENERAL MOTORS COMPANY

    Align the reference marks made between the differential drive pinion gear yoke and the propeller shaft.

  232. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  233. Install the 4 rear propeller shaft bolts (1) and tighten in a crisscross pattern. Fastener Specifications
  234. GM5590596Courtesy of GENERAL MOTORS COMPANY

    Apply a thin layer of grease to the splines of the transfer case front output shaft (1). Adhesives, Fluids, Lubricants, and Sealers

  235. Loosely install a NEW transfer case front output shaft boot clamp (2) to the transfer case front output shaft boot groove.
  236. Align the reference marks made between the transfer case front output shaft and the front axle propeller shaft.
  237. Front Axle Propeller Shaft (3) - Install
  238. GM5044025Courtesy of GENERAL MOTORS COMPANY

    Ensure the transfer case front output shaft boot (1) is fully engaged into the groove of the transfer case front output shaft.

  239. Using the DT-35910  Drive Axle Seal Clamp Pliers (2), crimp the transfer case front output shaft boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).
  240. GM4968633Courtesy of GENERAL MOTORS COMPANY

    { If equipped }Transfer Case Skid Shield (2) - Install

  241. { If equipped }Transfer Case Skid Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications
  242. GM5611961Courtesy of GENERAL MOTORS COMPANY

    Automatic Level Control Air Supply Reservoir (2) - Install

  243. Install the 3 automatic level control air compressor bolts (1) and tighten. Fastener Specifications
  244. GM5611960Courtesy of GENERAL MOTORS COMPANY

    Install the chassis wire harness clip (1) to the automatic level control air supply reservoir.

  245. GM5732852Courtesy of GENERAL MOTORS COMPANY

    Install the air line (2) and clip the 2 air line retainers (1).

  246. GM5675037Courtesy of GENERAL MOTORS COMPANY

    Install the EN-52579  Crankshaft Rotator (1).

  247. GM5137326Courtesy of GENERAL MOTORS COMPANY

    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:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  248. Using the EN - 52579  Crankshaft Rotator, rotate the crankshaft balancer clockwise ONLY, to align the transmission torque converter bolt with the starter opening.
    249. NOTE:

    For proper alignment of all transmission torque converter bolts, install the first transmission torque converter bolt in the oval shaped hole.

  249. Transmission Torque Converter Bolt (1) - Install and tighten [6x] - Fastener Specifications
  250. GM5675037Courtesy of GENERAL MOTORS COMPANY

    Remove the EN-52579  Crankshaft Rotator (1).

  251. GM5153591Courtesy of GENERAL MOTORS COMPANY

    Position the fuel heater inlet and outlet hoses.

  252. Transmission Cooler Bypass Valve Bracket Bolt (1) - Install and tighten - Fastener Specifications
  253. GM5629593Courtesy of GENERAL MOTORS COMPANY

    Fuel Heater Inlet and Outlet Bolt (2) - Install and tighten - Fastener Specifications

  254. GM5629570Courtesy of GENERAL MOTORS COMPANY

    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:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  255. Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
  256. Front Axle Propeller Shaft (1) Install
  257. Front Axle Propeller Shaft Washer (3) - Install [3x]
  258. Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications
  259. GM5608699Courtesy of GENERAL MOTORS COMPANY

    Thermostat Bypass Hose (2) @Thermostat Bypass Pipe - Install

  260. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  261. GM5206138Courtesy of GENERAL MOTORS COMPANY

    Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (3) @Engine Oil Cooler - Install

  262. Engine Oil Cooler Coolant Inlet Hose (4) @Engine Oil Cooler - Install
  263. Engine Oil Cooler Coolant Outlet Hose (5) @Engine Oil Cooler - Install
  264. Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
  265. Hose Clamp (2) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  266. GM5240726Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Coolant Return Pipe (2) - Install

  267. Thermostat Bypass Pipe Bolt (3) - Install and tighten - Fastener Specifications
  268. GM5485237Courtesy of GENERAL MOTORS COMPANY

    Thermostat Bypass Hose (1) - Install

  269. Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
  270. GM5135048Courtesy of GENERAL MOTORS COMPANY

    Oil Level Indicator Seal (2) - Install NEW

  271. Oil Level Indicator Tube (1) @Lower Crankcase Extension - Install
  272. GM5485778Courtesy of GENERAL MOTORS COMPANY

    Oil Level Indicator Tube Bolt (1) - Install and tighten - Fastener Specifications

  273. GM5485774Courtesy of GENERAL MOTORS COMPANY

    Clip (2) @Oil Level Indicator Tube - Install

  274. Oil Level Indicator Tube Stud (1) - Install and tighten - Fastener Specifications
  275. GM5485779Courtesy of GENERAL MOTORS COMPANY

    Engine Oil Level Indicator (1) - Install

  276. GM5485772Courtesy of GENERAL MOTORS COMPANY

    Engine Wiring Harness Bracket (2) - Install

  277. Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  278. GM5174667Courtesy of GENERAL MOTORS COMPANY

    Rotate the accessory drive primary belt tensioner (1) clockwise.

    279. NOTE:

    Ensure the proper routing of the accessory drive primary belt.

  279. Install the accessory drive primary belt (2) around all pulleys.
  280. GM5619156Courtesy of GENERAL MOTORS COMPANY

    Engine Front Cover (2) - Install

  281. Engine Front Cover Bolt (1) - Install and tighten - Fastener Specifications
  282. GM5608921Courtesy of GENERAL MOTORS COMPANY

    Starter Solenoid Cable (1) - Install

  283. Engine Wiring Harness Ground Nut (2) - Install and tighten - Fastener Specifications
  284. GM5835544Courtesy of GENERAL MOTORS COMPANY

    Install the heater coolant pump and heater water auxiliary pump bracket as assembly (2).

  285. Heater Inlet Pipe Bracket Stud (1) - Install and tighten - Fastener Specifications
  286. GM5835729Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Inlet and Outlet Pipe (2) - Install

  287. Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
  288. GM5387083Courtesy of GENERAL MOTORS COMPANY

    Starter (1) - Install

  289. GM5609871Courtesy of GENERAL MOTORS COMPANY

    Electrical Connector (1) - Connect

  290. Install the protective sleeve (2).
  291. GM5609862Courtesy of GENERAL MOTORS COMPANY

    Starter Bolt (1) - Install and tighten [3x] - Fastener Specifications

  292. GM5152987Courtesy of GENERAL MOTORS COMPANY

    Starter Solenoid Cable (3) - Install

  293. Starter Solenoid Cable Nut (1) - Install and tighten - Fastener Specifications
  294. Wiring Harness Conduit Nut (2) - Install and tighten - Fastener Specifications
  295. GM5608813Courtesy of GENERAL MOTORS COMPANY

    Starter Heat Shield (1) - Install

  296. GM5674667Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Components removed for graphic clarity.

    Engage the starter heat shield (2) into the retainer (1).

  297. Starter Heat Shield Bolt (3) - Install and tighten [2x] - Fastener Specifications
  298. GM5184846Courtesy of GENERAL MOTORS COMPANY

    Exhaust System Front Gasket (2) - Install NEW

  299. Nitrogen Oxides Catalytic Converter (1) - Install
  300. GM5341378Courtesy of GENERAL MOTORS COMPANY

    Exhaust Front Pipe Nut (1) - Install and tighten [2x] - Fastener Specifications

  301. GM5634664Courtesy of GENERAL MOTORS COMPANY

    Catalytic Converter Brace Bracket (3) - Install

  302. Wiring Harness Retainer (2) @Catalytic Converter Brace Bracket (3) - Install
  303. Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  304. GM5340362Courtesy of GENERAL MOTORS COMPANY

    Exhaust Front Pipe Nut (1) - Install and tighten [2x] - Fastener Specifications

  305. GM5341429Courtesy of GENERAL MOTORS COMPANY

    Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications

  306. GM5151789Courtesy of GENERAL MOTORS COMPANY

    Coat the exhaust particulate matter sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

    307. CAUTION:

    Refer to Component Fastener Tightening Caution .

  307. Exhaust Particulate Matter Sensor (1) - Install and tighten - Fastener Specifications
  308. GM5150652Courtesy of GENERAL MOTORS COMPANY

    Coat the nitrogen oxides sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

  309. Nitrogen Oxides Sensor- Position 3 (1) - Install and tighten - Fastener Specifications
  310. GM5149436Courtesy of GENERAL MOTORS COMPANY

    Coat the nitrogen oxides sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

  311. Nitrogen Oxides Sensor- Position 2 (1) - Install and tighten - Fastener Specifications
  312. GM5615234Courtesy of GENERAL MOTORS COMPANY

    Coat the exhaust gas temperature sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

  313. Exhaust Gas Temperature Sensor- Position 3 (1) - Install and tighten - Fastener Specifications
  314. GM5618615Courtesy of GENERAL MOTORS COMPANY

    With the aid of an assistant, install the charge air cooler, condenser, fan and radiator assembly (1) to the vehicle.

  315. GM5618579Courtesy of GENERAL MOTORS COMPANY

    Radiator Air Upper Baffle (1) - Install

  316. GM5618614Courtesy of GENERAL MOTORS COMPANY

    Air Conditioning Compressor and Condenser Hose Clip (2) @Engine Cooler Fan - Install [2x]

  317. Air Conditioning Compressor and Condenser Hose Retainer (1) @Engine Cooler Fan - Install [2x]
  318. GM5618584Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Pipe Clip (1) @Engine Cooler Fan - Install [2x]

  319. GM5821211Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Some components not shown for graphic clarity.

    Wiring Harness Retainer (3) @Engine Cooler Fan - Install

  320. Electrical Connector (2) @Engine Cooler Fan - Connect
  321. GM5618611Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Pipe Clip (4) @Engine Cooler Fan - Install

  322. Electrical Connector (3) @Engine Cooler Fan - Connect [2x]
  323. Electrical Connector (2) @Engine Coolant Temperature Sensor - Connect
  324. Wiring Harness Retainer (1) @Engine Cooler Fan - Install
  325. GM5618404Courtesy of GENERAL MOTORS COMPANY

    Radiator Inlet Hose (3) @Engine Radiator - Install

  326. Radiator Inlet Hose Clamp (4) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  327. Radiator Surge Tank Inlet Hose (2) @Engine Radiator - Install
  328. Radiator Surge Tank Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  329. GM5821209Courtesy of GENERAL MOTORS COMPANY

    Accessory Wiring Junction Block (2) - Move into position

  330. Engine Wiring Harness Fuse Block Bracket Bolt (1) - Install and tighten - Fastener Specifications
  331. GM5613690Courtesy of GENERAL MOTORS COMPANY

    Radiator Outlet Hose (2) @Engine Radiator - Install

  332. Radiator Outlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  333. GM5618296Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Surge Tank (2) - Install

  334. Charge Air Cooler Coolant Reservoir Bolt (1) - Install and tighten - Fastener Specifications
  335. GM5618882Courtesy of GENERAL MOTORS COMPANY
    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

  336. Air Conditioning Compressor and Condenser Hose (2) - Install
  337. Air Conditioning Compressor and Condenser Hose Nut (1) - Install and tighten - Fastener Specifications
  338. GM5618102Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Some components not shown for graphic clarity.

    Air Conditioning Compressor and Condenser Hose Seal (1) - Install NEW

  339. Air Conditioning Condenser and Evaporator Hose (2) - Install
  340. GM5618100Courtesy of GENERAL MOTORS COMPANY

    Air Conditioning Condenser and Evaporator Hose Nut (1) - Install and tighten - Fastener Specifications

  341. Remove the caps from the fittings and plugs from the holes before installing the transmission fluid cooler pipes.
  342. GM5618664Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Some components not shown for graphic clarity.

    Transmission Fluid Cooler Seal (3) - Install NEW

  343. Transmission Fluid Cooler Inlet and Outlet Pipe (2) @Transmission Fluid Auxiliary Cooler- Left Side - Install
  344. Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
  345. GM5618665Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Seal (3) - Install NEW

  346. Transmission Fluid Cooler Inlet and Outlet Pipe (2) @Transmission Fluid Auxiliary Cooler- Right Side - Install
  347. Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
  348. GM5618118Courtesy of GENERAL MOTORS COMPANY

    Insert the charge air cooler coolant hose (2) through the radiator air side baffle and install to the engine auxiliary radiator.

  349. Charge Air Cooler Coolant Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  350. GM5617846Courtesy of GENERAL MOTORS COMPANY

    Radiator Air Side Baffle (1) - Move into position

  351. Radiator Air Side Baffle Retainer (2) - Install
  352. GM5617848Courtesy of GENERAL MOTORS COMPANY

    Radiator Air Side Baffle (1) - Move into position

  353. Radiator Air Side Baffle Retainer (2) - Install [4x]
  354. GM5617849Courtesy of GENERAL MOTORS COMPANY

    Move the radiator air front lower baffle (1) into position and engage the retainers to the engine auxiliary radiator.

  355. GM5605789Courtesy of GENERAL MOTORS COMPANY

    Front End Upper Tie Bar (1) - Install

  356. GM5605762Courtesy of GENERAL MOTORS COMPANY

    Front End Upper Tie Bar Bolt (1) - Install and tighten - Fastener Specifications

  357. GM5605761Courtesy of GENERAL MOTORS COMPANY

    Front End Upper Tie Bar Bolt (1) - Install and tighten [3x] - Fastener Specifications

  358. GM5605760Courtesy of GENERAL MOTORS COMPANY

    Front End Upper Tie Bar Bolt (1) - Install and tighten - Fastener Specifications

  359. GM5605759Courtesy of GENERAL MOTORS COMPANY

    Front End Upper Tie Bar Bolt (1) - Install and tighten [3x] - Fastener Specifications

  360. Move the wiring harness into position and clip to the front end upper tie bar.
  361. GM5879437Courtesy of GENERAL MOTORS COMPANY

    Install the retainer (2) and the hood primary latch release cable (1) to the upper tie bar.

  362. GM5573765Courtesy of GENERAL MOTORS COMPANY

    Connect the hood release cable (3).

  363. Connect the clip and the electrical connector.
  364. GM5617391Courtesy of GENERAL MOTORS COMPANY

    Electrical Connector (1) @Horn (2) - Connect

  365. GM5666045Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Headlamp Bracket- Left Side and Right Side (2) - Install [2x]

  366. Front End Upper Tie Bar Bolt- Left Side and Right Side (1) @Headlamp Bracket - Install and tighten [8x] - Fastener Specifications
  367. GM5819260Courtesy of GENERAL MOTORS COMPANY

    Front Grille Support Reinforcement (2) - Install

  368. Front Grille Support Bracket Bolt (1) - Install and tighten [4x] - Fastener Specifications
  369. GM5572426Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Right side shown, left side similar.

    Install the left and right side front end sheet metal diagonal braces (2).

  370. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  371. Install and tighten the 2 left and 2 right side front end sheet metal diagonal brace bolts (1). Fastener Specifications
  372. GM5020580Courtesy of GENERAL MOTORS COMPANY

    Intake Air Duct (2) - Install

  373. Intake Air Duct Retainer (1) - Install
  374. GM5572432Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Install the left and right side front end sheet metal diagonal braces (2).

  375. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  376. Install and tighten the 2 left and 2 right side front end sheet metal diagonal brace bolts (1). Fastener Specifications
  377. GM5548894Courtesy of GENERAL MOTORS COMPANY

    Connect the electrical connector.

  378. Front Bumper Shutter (2) - Install
  379. Front Bumper Shutter Bolt (1) - Install and tighten [9x] - Fastener Specifications
  380. GM5544169Courtesy of GENERAL MOTORS COMPANY

    Front Bumper Fascia Upper Stiffener (1) - Install

  381. GM5544167Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Install and tighten the left and right side front bumper fascia upper stiffener bolts (2). Fastener Specifications

  382. Tighten the left and right side front bumper fascia upper stiffener nuts (1). Fastener Specifications
  383. GM5520784Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Connect all electrical connectors.

  384. Secure the wiring harness retaining tab.
  385. Secure the front headlamp guide pin to the front bumper fascia guide (1).
  386. Front Headlamp (2) - Install

    [2x]

  387. GM5520782Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Headlamp Bolt (1) - Install and tighten [6x] - Fastener Specifications

  388. GM5520779Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Headlamp Bolt (1) - Install and tighten [6x] - Fastener Specifications

  389. GM5537676Courtesy of GENERAL MOTORS COMPANY

    With the aid of an assistant, install the fascia. (2)

  390. Install the 9 grille clips (1).
    391. 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.

  391. Connect the electrical connectors. INLINE HARNESS CONNECTOR END VIEWS - INDEX
  392. GM5537674Courtesy of GENERAL MOTORS COMPANY

    Install the front bumper fascia (1) to the left and right side front bumper fascia guides and the front headlamps.

  393. Remove the tape from both headlamps.
  394. GM5537672Courtesy of GENERAL MOTORS COMPANY

    Front Grille Bolt (1) - Install and tighten [6x] - Fastener Specifications

  395. GM5549574Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Install and tighten the left and right side front bumper fascia support brace bolts (1). Fastener Specifications

  396. GM5537669Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Tighten the 2 left and right side front bumper fascia guide bolts (1). Fastener Specifications

  397. Install and tighten the left and right side front bumper fascia bolts (2). Fastener Specifications
  398. GM5541784Courtesy of GENERAL MOTORS COMPANY

    Intake Air Splash Shield (2) - Install

  399. Intake Air Baffle Retainer (1) - Install [9x]
  400. GM5541781Courtesy of GENERAL MOTORS COMPANY

    Hood Secondary Latch Release Handle (2) - Install

  401. Hood Latch Actuator Bolt (1) - Install and tighten [2x] - Fastener Specifications
  402. GM5607471Courtesy of GENERAL MOTORS COMPANY

    Auxiliary Radiator Inlet Hose (2) @Engine Auxiliary Radiator - Install

  403. Auxiliary Radiator Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  404. GM5171779Courtesy of GENERAL MOTORS COMPANY

    Oil Filler Cap - Remove

  405. Intake Manifold Cover (2) - Install
  406. Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
  407. Fill the engine oil to the proper level with NEW engine oil. Engine Oil and Oil Filter Replacement
  408. Oil Filler Cap - Install
  409. Recharge the refrigerant. Refrigerant Recovery and Recharging
  410. GM5572721Courtesy of GENERAL MOTORS COMPANY

    Attach GE-46143-A  Cooling System Adapter (1) to the charge air cooler surge tank.

  411. Attach Vac-N-Fill cap to GE-42401-A  Radiator Cap and Surge Tank Test Adapter (1).
  412. GM2846165Courtesy of GENERAL MOTORS COMPANY

    Attach the vacuum gauge assembly (1) to the Vac-N-Fill cap (2).

  413. GM2846166Courtesy of GENERAL MOTORS COMPANY

    Attach the fill hose (1) to the barb fitting on the vacuum gauge assembly (2).

    Ensure that the valve is closed.

    414. NOTE:

    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.

  414. Prepare a quantity of coolant in the graduated reservoir slightly greater than the charge air cooling system capacity.
  415. Inspect the concentration of the coolant mixture using GE-26568  Coolant and Battery Fluid Tester.
  416. GM2846170Courtesy of GENERAL MOTORS COMPANY
    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).

  417. Place the fill hose in the graduated reservoir (1).
  418. Install the vacuum tank (2) on the graduated reservoir with the fill hose routed through the cut-out area (3) in the vacuum tank.
  419. GM2846171Courtesy of GENERAL MOTORS COMPANY

    Attach the venturi assembly (1) to the vacuum tank (2).

  420. GM2846172Courtesy of GENERAL MOTORS COMPANY

    Attach a shop air hose to the venturi assembly (1).

    Ensure the valve (2) on the venturi assembly is closed.

  421. GM2846173Courtesy of GENERAL MOTORS COMPANY

    Attach the vacuum hose (1) to the vacuum gauge assembly (2) and the vacuum tank (3).

  422. GM2846175Courtesy of GENERAL MOTORS COMPANY

    Open the valve (1) on the venturi assembly (2). The vacuum gauge will begin to rise and a hissing noise will be present.

  423. GM2846177Courtesy of GENERAL MOTORS COMPANY

    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.

  424. To aid in the fill process, position the graduated reservoir above the coolant fill port.
  425. GM2846183Courtesy of GENERAL MOTORS COMPANY

    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.

  426. Close the valve on the venture assembly.
  427. 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 .

  428. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
  429. GM3242386Courtesy of GENERAL MOTORS COMPANY

    Once the vacuum gauge reaches zero (1), close the valve on the vacuum gauge assembly and repeat steps 422 - 429.

  430. GM5572721Courtesy of GENERAL MOTORS COMPANY

    Detach the Vac-N-Fill cap from the GE-46143-A  Cooling System Adapter.

  431. Remove GE-46143-A  Cooling System Adapter (1) from the charge air cooler surge tank.
  432. Fill the cooling system to the proper level.
    433. NOTE:

    After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.

  433. Detach the vacuum hose form the vacuum gauge assembly.
  434. GM2857825Courtesy of GENERAL MOTORS COMPANY

    Attach the extraction hose (1) to the vacuum hose (2).

  435. GM2857827Courtesy of GENERAL MOTORS COMPANY

    Open the valve (1) on the venturi assembly (2) to start a vacuum draw.

  436. GM2857829Courtesy of GENERAL MOTORS COMPANY

    Use the extraction hose (1) to draw out coolant to the proper level.

  437. 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.
  438. Install the charge air cooler coolant filler cap.
  439. GM5034973Courtesy of GENERAL MOTORS COMPANY

    GE-42401-2  Adapter Assembly (3) - Install

  440. GE-42401-3  Radiator Test Adapter - Female (2) - Install
  441. GE-47716-8  Vac-N-Fill Cap (1) - Install
  442. GM2846165Courtesy of GENERAL MOTORS COMPANY

    Attach the vacuum gauge assembly (1) to the Vac-N-Fill cap (2).

  443. GM2846166Courtesy of GENERAL MOTORS COMPANY

    Attach the fill hose (1) to the barb fitting on the vacuum gauge assembly (2).

    Ensure that the valve is closed.

    444. NOTE:

    Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.

    NOTE:

    Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.

  444. 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.
  445. Inspect the concentration of the coolant mixture using GE-26568  Coolant and Battery Fluid Tester.
  446. GM2846170Courtesy of GENERAL MOTORS COMPANY
    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).

  447. Place the fill hose in the graduated reservoir (1).
  448. Install the vacuum tank (2) on the graduated reservoir with the fill hose routed through the cut-out area (3) in the vacuum tank.
  449. GM2846171Courtesy of GENERAL MOTORS COMPANY

    Attach the venturi assembly (1) to the vacuum tank (2).

  450. GM2846172Courtesy of GENERAL MOTORS COMPANY

    Attach a shop air hose to the venturi assembly (1).

    Ensure the valve (2) on the venturi assembly is closed.

  451. GM2846173Courtesy of GENERAL MOTORS COMPANY

    Attach the vacuum hose (1) to the vacuum gauge assembly (2) and the vacuum tank (3).

  452. GM2846175Courtesy of GENERAL MOTORS COMPANY

    Open the valve (1) on the venturi assembly (2). The vacuum gauge will begin to rise and a hissing noise will be present.

  453. GM2846177Courtesy of GENERAL MOTORS COMPANY

    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.

  454. To aid in the fill process, position the graduated reservoir above the coolant fill port.
  455. GM2846183Courtesy of GENERAL MOTORS COMPANY

    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.

  456. Close the valve on the venture assembly.
  457. 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 .

  458. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
  459. GM3242386Courtesy of GENERAL MOTORS COMPANY

    Once the vacuum gauge reaches zero (1), close the valve on the vacuum gauge assembly and repeat steps 452 - 459.

  460. GM5034973Courtesy of GENERAL MOTORS COMPANY

    GE-47716-8  Vac-N-Fill Cap (1) - Remove

  461. GE-42401-3  Radiator Test Adapter - Female (2) - Remove
  462. GE-42401-2  Adapter Assembly (3) - Remove
  463. Adjust the cooling system to the proper level. Adhesives, Fluids, Lubricants, and Sealers
  464. If the cooling system level is over the maximum level allowed within the radiator surge tank, perform steps 464 - 468 until the correct level is achieved.
    465. NOTE:

    After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.

  465. Detach the vacuum hose form the vacuum gauge assembly.
  466. GM2857825Courtesy of GENERAL MOTORS COMPANY

    Attach the extraction hose (1) to the vacuum hose (2).

  467. GM2857827Courtesy of GENERAL MOTORS COMPANY

    Open the valve (1) on the venturi assembly (2) to start a vacuum draw.

  468. GM2857829Courtesy of GENERAL MOTORS COMPANY

    Use the extraction hose (1) to draw out coolant to the proper level.

  469. 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.
  470. Start the engine and check for fuel leaks.
  471. Run the engine speed at about 1, 000 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.
  472. Inspect for oil leaks.
  473. Place the ignition in service mode. Power Mode Description and Operation
  474. Turn off the air conditioning.
  475. Set the parking brake.
  476. Press the accelerator and brake pedal for two seconds at the same time, then release.
    477. NOTE:
    • 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.
  477. 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.
  478. Install the radiator surge tank cap.
  479. 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.
    1. Run the engine speed at 3500 RPM for three minutes.
    2. Lower the engine speed to 1200 RPM and run for three minutes.
    3. Raise the engine speed to 3500 RPM and run for three minutes.
    4. Lower the engine speed to 1200 RPM and run for three minutes.
    480. NOTE:

    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.

  480. Fill the radiator surge tank to the cold fill line and wait two minutes.
    1. Repeat steps 476 - 479 until the ACSF cycle completes with the coolant level maintained in the surge tank for the entire process.
  481. Turn ignition off.
  482. Allow the engine to cool
  483. Adjust the coolant level in the surge tank to the cold fill line.
  484. Perform a final inspection for the proper engine oil and coolant levels.
  485. Start the engine and check for coolant leaks.
  486. Front Wheelhouse Liner- Left Side and Right Side - Install [2x] - Front Wheelhouse Liner Replacement
  487. GM5512332Courtesy of GENERAL MOTORS COMPANY
    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

  488. Underbody Splash Shield Bolt (2) - Install and tighten [2x] - Fastener Specifications
  489. GM5512311Courtesy of GENERAL MOTORS COMPANY

    Underbody Splash Shield (1) - Install

  490. GM5512320Courtesy of GENERAL MOTORS COMPANY

    Underbody Skid Shield Bolt (2) - Install and tighten [4x] - Fastener Specifications

  491. Front Bumper Fascia Skid Plate Bolt (1) - Install and tighten [4x] - Fastener Specifications
  492. Check the transmission fluid level. Transmission Fluid Level and Condition Check
  493. Turn service mode off.
  494. With the vehicle off the hoist and on flat level ground, use the scan tool to reset trim heights. Trim Height Inspection
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