Installation Procedure
Remove the DT-21366 Converter Holding Strap (1) from the transmission which is retaining the torque converter.
- Position the engine to the transmission assembly. Raise or lower the transmission as required using a suitable jack.
- CAUTION:
Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components.
If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break.
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.
- Engine Mount Frame Side Bolt- Right Side (1) - Install NEW and hand tighten [3x]
- Engine Mount Frame Side Bolt- Right Side (1) - Tighten in sequence [3x] - Fastener Specifications
- CAUTION:
Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components.
If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break.
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.
- Engine Mount Frame Side Bolt- Left Side (1) - Install NEW and hand tighten [3x]
- Engine Mount Frame Side Bolt- Left Side (1) - Tighten in sequence [3x] - Fastener Specifications
Remove the suitable engine lifting device.
- Remove the EN-52474 Engine Lift Hook Set (1).
Transmission Bolt (1) - Install and tighten - Fastener Specifications
- Remove the block of wood and floor jack from the transmission.
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
- Support the transmission with a suitable transmission jack.
Transmission Support Crossmember Nut (2) - Remove [4x]
- Transmission Support Crossmember Bolt (3) - Remove [4x]
Transmission Support Crossmember (1) - Remove
- Lower the transmission to gain access to the top and sides of the transmission.
Transmission Stud (1) - Install and tighten [4x] - Fastener Specifications
Transmission Vent Hose (2) @Transmission - Install
- Install the transmission vent hose retainer (1) to the transmission.
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
Fuel Cooler Bolt (2) - Install and tighten - Fastener Specifications
- Fuel Cooler Support Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
Retainer (2) - Install
- 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 HarnessWiring Harness Retainer (3) - Install [4x]
Automatic Level Control Air Supply Reservoir (2) - Install
- Install the 3 automatic level control air compressor bolts (1) and tighten. Fastener Specifications
Install the chassis wire harness clip (1) to the automatic level control air supply reservoir.
Install the air line (2) and clip the 2 air line retainers (1).
Install the engine wiring harness channel (1) on the transmission stud.
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).
Automatic Transmission Fluid Cooling Exchanger (1) - Install
Automatic Transmission Fluid Cooling Exchanger Nut (2) - Install and tighten - Fastener Specifications
- Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Position the fuel heater inlet and outlet hoses.
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 (3) - Install and tighten - Fastener Specifications
- Retainer (1) - Install [2x]
Transmission Cooler Bypass Valve Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Connect the wiring harness connectors and retainers on the left and right side of the engine.
Fuel Return Pipe (1) @Diesel Fuel Separator - Connect - Metal Collar Quick Connect Fitting Service
Fuel Pump Fuel Feed Hose (1) @High Pressure Diesel Fuel Pump - Connect - Metal Collar Quick Connect Fitting Service
Fuel Feed Pipe Clip Bolt (1) - Install and tighten - Fastener Specifications
Ground Cable (2) - Install
- Engine Wiring Harness Ground Bolt (1) - Install and tighten - Ground Repair
Thermostat Bypass Hose (2) @Thermostat Bypass Pipe - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Engine Oil Cooler Coolant Inlet Hose (5) @Engine Oil Cooler - Install
- Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (4) @Engine Oil Cooler - Install
- Engine Oil Cooler Coolant Outlet Hose (3) @Engine Oil Cooler - Install
- Engine Oil Cooler Coolant Inlet Hose Clamp (2) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Coolant Return Pipe (3) - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Pipe Bolt (2) - Install and tighten - Fastener Specifications
Thermostat Bypass Hose (3) - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
Electrical Connector (1) @Engine Coolant Flow Control Valve - Connect [3x]
- Reposition hoses and attach hose clips as needed.
Engine Coolant Heater Cord (1) - Install
- Engine Coolant Heater Cord Retainer (3) - Connect
- Engine Coolant Heater Cord (1) @Engine Coolant Heater - Connect
Radiator Inlet Hose (2) @Engine Coolant Flow Control Valve - Install
- Thermostat Bypass Hose (5) @Engine Coolant Flow Control Valve - Install
- Engine Oil Cooler Coolant Inlet Hose (4) @Engine Coolant Flow Control Valve - Install
- Thermostat Bypass Hose (3) @Engine Coolant Flow Control Valve - Install
- Hose Clamp (1) - Engage [4x] - Hose Clamp Replacement Guidelines - Spring Type
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 Wiring Harness Bracket (2) - Install
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Air Conditioning Compressor (1) - Install
Air Conditioning Compressor Bolt (1) - Install and hand tighten
Air Conditioning Compressor Stud (2) - Install and tighten - Fastener Specifications
- Air Conditioning Compressor Nut (1) - Install and tighten - Fastener Specifications
Air Conditioning Compressor Bolt (1) - Tighten - Fastener Specifications
Air Conditioning Compressor Bolt (1) - Tighten - Fastener Specifications
- CAUTION:
Refer to Air Conditioning Sealing Washers Oil or Lubricant Exposure Caution .
Air Conditioning Compressor and Condenser Hose Seal-Large (3) - Install NEW
- Air Conditioning Compressor and Condenser Hose Seal-Small (4) - Install NEW
- Air Conditioning Compressor and Condenser Hose (2) - Install
- Air Conditioning Compressor Nut (1) - Install and tighten - Fastener Specifications
Electrical Connector (1) - Connect [2x]
Generator (1) - Install
- Install hoses and wiring harness as needed.
Generator Bolt (1) - Install and tighten - Fastener Specifications
- Generator Bolt (2) - Tighten - Fastener Specifications
Generator Battery Jumper Cable (2) - Install
- Battery Positive Cable Nut (1) - Install and tighten - Fastener Specifications
Electrical Connector (1) - Connect
Engine Wiring Harness Bracket (4) - Install
- Engine Wiring Harness Bracket Bolt (3) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Retainer (2) - Install [2x]
- Radiator Inlet Hose Clip (1) - Clip
Drive Belt Tensioner (2) - Install
- Drive Belt Tensioner Bolt (1) - Install and tighten [2x] - Fastener Specifications
- NOTE:
Upon removal of the belt idler pulley, the retainer (3) and spacer (2) may detach from the pulley (1). If reinstalling the belt idler pulley, ensure the proper orientation, as shown before reassembling the belt idler pulley.
Ensure belt idler pulley components are installed in the proper orientation.
Belt Idler Pulley (1) - Install and tighten - Fastener Specifications
Engine Front Cover Stud (1) - Install and tighten [3x] - 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
Heater Water Auxiliary Pump Hose (3) @Water Pump Inlet Pipe - Install
- Radiator Outlet Hose (2) @Water Pump Inlet Pipe - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
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
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
Ground Cable (2) - Install
- Engine Wiring Harness Ground Bolt (1) - Install and tighten - 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
Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - 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 (3) - Install NEW [2x]
- Exhaust Gas Recirculation Pipe (2) - Install
- Exhaust Gas Recirculation Cooler Inlet Pipe Bolt (1) - Install and tighten [4x] - Fastener Specifications
Exhaust Gas Recirculation Outlet Pipe Gasket (2) - Install NEW
- Exhaust Gas Recirculation Pipe (1) - Install
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
Exhaust Gas Recirculation Pipe Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Connect the electrical connector (1).
Heater Inlet Hose Bracket (2) - Install
- Exhaust Gas Recirculation Valve Bracket Nut (1) - Install and tighten - Fastener Specifications
Exhaust Gas Recirculation Pipe Nut (1) - Install and tighten - Fastener Specifications
Exhaust Gas Recirculation Pipe Nut (1) - Install and tighten - Fastener Specifications
Install the 2 exhaust pressure differential sensor hoses to the exhaust gas recirculation cooler and engage the 2 exhaust pressure differential sensor hose clamps (1). Hose Clamp Replacement Guidelines - Spring Type
Install the exhaust pressure differential sensor hose (2) at the exhaust gas recirculation cooler and engage the exhaust pressure differential sensor hose clamp (1). Hose Clamp Replacement Guidelines - Spring Type
Install the exhaust pressure differential sensor to the exhaust gas recirculation valve hose and engage the exhaust pressure differential sensor hose clamp (1). Hose Clamp Replacement Guidelines - Spring Type
Exhaust Pressure Differential Sensor Bracket (2) - Install
- Exhaust Pressure Differential Sensor Bracket Stud (1) - Install [2x] - Fastener Specifications
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
- Exhaust Gas Recirculation Valve Cooling Feed Hose (2) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install
- Hose Clamp (1) - Engage [3x] - 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
- Hose Clamp (1) - Engage [3x] - Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Pipe Bracket (5) - Install
- Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Connect the electrical connectors, then reposition wiring harness and hoses as needed.
Exhaust Gas Recirculation Coolant Return Pipe (3) - Install
- Exhaust Gas Recirculation Coolant Return Pipe (3) @Exhaust Gas Recirculation Pipe Clip (2) - Install
- Hose Clamp (1) - Engage [2x] - 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
Electrical Connector (1) @Exhaust Back Pressure Valve - Connect
Turbocharger Coolant Feed and Return Pipe Gasket (3) - Install NEW
- Exhaust Gas Recirculation Valve Cooling Return Hose (2) - Install
- Exhaust Gas Recirculation Coolant Return Pipe Bolt (1) - 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
Exhaust System Front Gasket (3) - Install NEW
- Reductant Fluid Injector (2) - Install
- Emission Reduction Fluid Injector Clamp (1) - Install NEW - Fastener Specifications
Emission Reduction Fluid Exhaust Front Pipe Injector Supply Pipe Insulator (1) - Install
Coat the exhaust gas temperature sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Exhaust Gas Temperature 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 1 (1) - Install and tighten - Fastener Specifications
Exhaust Pipe Clamp (1) - 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
- Install retainers as needed.
Air Conditioning Refrigerant Heat Exchanger Nut (1) @Battery Tray - Install and tighten - Fastener Specifications
Air Conditioning Compressor and Condenser Hose Seal-Small (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-Large (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
Charge Air Cooler Bracket (2) - Install
- Charge Air Cooler Bolt (1) - Install and tighten [5x] - Fastener Specifications
Oil Filler Tube (3) - Install
- Oil Filler Tube Support Stud (2) - Install and tighten - Fastener Specifications
Connect the electrical connector. (3)
Position the engine wiring harness bracket (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
Turbocharger Bracket Bolt (1) - Install and 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
Coat the exhaust gas recirculation temperature sensor threads with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Exhaust Gas Recirculation Cooler Temperature Sensor (2) - Install and tighten - Fastener Specifications
Upper Intake Manifold Bracket (2) - Install
- Upper Intake Manifold Brace Nut (1) - Install and tighten [3x] - Fastener Specifications
Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) - Install NEW
- Exhaust Gas Recirculation Pipe Seal (2) - Install NEW
- Exhaust Gas Recirculation Pipe (1) - Install
- NOTE:
Support the exhaust gas recirculation pipe when loosening or tightening the bolts to ensure the pipe is not deformed.
Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).
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).
Exhaust Gas Recirculation Cooler Bolt (1) - Install and tighten [2x] - Fastener Specifications
Turbocharger Coolant Return Hose (2) @Turbocharger Coolant Feed Pipe - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed Pipe Bolt (3) - Install and tighten - Fastener Specifications
Engine Coolant Air Bleed Hose (2) - Install
- Engine Coolant Air Bleed Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Engine Coolant Outlet Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
Engine Coolant Air Bleed Hose Clip (1) - Install
Position the rear engine wiring harness channel (2).
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [3x] - Fastener Specifications
Charge Air Cooler (1) - Install
Charge Air Cooler Bolt (1) - Install and tighten [4x] - Fastener Specifications
Nitrogen Oxides Sensor- Position 1 (2) - Install and tighten - Fastener Specifications
- Connect the nitrogen oxides sensor electrical connector.
- Nitrogen Oxides Sensor Nut (1) - Install and tighten [2x] - Fastener Specifications
Wiring Harness Retainer (4) @Charge Air Cooler - Install
- Charge Air Cooler Coolant Hose (3) @Charge Air Cooler - Install
- Charge Air Cooler Coolant Hose (2) @Charge Air Cooler - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Wiring Harness Retainer (2) @Charge Air Cooler - Install [3x]
- Electrical Connector (1) @Charge Air Cooler - Connect [2x]
Intake Manifold Resonator (2) - Install
Charge Air Cooler Outlet Air Hose (2) - Install
- Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Charge Air Cooler Inlet Air Hose (2) - Install
- Charge Air Cooler Inlet Air Hose Clamp (1) - [2x] - Fastener Specifications
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
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.
Air Cleaner Outlet Front Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
With the aid of an assistant, install the charge air cooler, condenser, fan and radiator assembly (1) to the vehicle.
- Position the wiring harness and connect the harness retainers.
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.
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 Compressor and Condenser 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- Left Side and Right Side (1) - Install and tighten [6x] - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Headlamp Bolt- Left Side and Right Side (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
Plenum Front Panel Outer Reinforcement (1) - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
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 432 - 439.
Detach the Vac-N-Fill cap from the GE-46143-A Cooling System Adapter.
- Remove the 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 462 - 469.
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 474 - 478 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.
- With a cold system, add the coolant mixture to the fill line on the radiator surge tank.
- Start the engine and check for fuel leaks.
- 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.
- 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 487 - 490 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.
- 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 Fastener Caution .
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.