Installation Procedure
Fuel Injector Wiring Harness (3) - Install
- Retainer (2) - Engage [9x]
- Electrical Connector (1) - Connect [7x]
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Camshaft Housing Cover Insulator (1) - Install
Exhaust Gas Recirculation Pipe Bracket (5) - Install
- Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Reposition harness and hoses, then connect electrical connectors as needed.
Charge Air Cooler Bracket (2) - Install
- Charge Air Cooler Bolt (1) - Install [5x] - Fastener Specifications
Engine Coolant Air Bleed Hose Clip (1) - Install
Oil Filler Tube Support Stud (1) - Install - Fastener Specifications
Engine Wiring Harness Bracket (3) - Install
- Engine Wiring Harness Bracket Nut (1) - Install [2x] - Fastener Specifications
Turbocharger Bracket Bolt (1) - Install and tighten - Fastener Specifications
Intake Manifold Resonator (2) - Install
- Engage the retaining spring (1).
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
Install the upper intake manifold bracket (2) with nitrogen oxides sensor attached.
- Upper Intake Manifold Brace Nut (1) - Install and tighten [3x] - Fastener Specifications
Charge Air Cooler (1) - Install
Charge Air Cooler Bolt (1) - Install [4x] - Fastener Specifications
Charge Air Cooler Inlet Air Hose (2) - Install
- Charge Air Cooler Inlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Charge Air Cooler Outlet Air Hose (2) - Install
- Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Wiring Harness Retainer (4) @Charge Air Cooler - Install
Engine Wiring Harness (4) - Reposition
- Wiring Harness Retainer (2) @Charge Air Cooler - Install [3x]
- Electrical Connector (3) @Charge Air Cooler - Connect [2x]
- Electrical Connector (1) @Nitrogen Oxides Sensor - Connect
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:
Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Install and hand tighten [2x]
- Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Tighten [2x] - Fastener Specifications
Install the exhaust gas recirculation outlet pipe bolt (2). Fastener Specifications
- Install the turbocharger coolant return hose clip (1).
Install the 2 exhaust gas recirculation pipe bolts (1). Fastener Specifications
Install the turbocharger coolant feed and return pipe bolt (3). Fastener Specifications
Engine Coolant Air Bleed Hose (2) - Reposition
Engine Coolant Outlet Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
Install the rear engine wiring harness channel (2).
- Install the 3 engine wiring harness bracket nuts (1) and tighten. Fastener Specifications
Air Cleaner Outlet Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten - Fastener Specifications
Air Cleaner Outlet Front Duct (2) - Install
- Air Cleaner Outlet Front Duct Clamp (1) - Tighten [2x] - Fastener Specifications
Oil Filler Cap - Remove
- Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
- Plenum Front Panel Outer Reinforcement - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1/5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
- Start the engine and check for exhaust leaks.
Refer to Fastener Caution .