Installation Procedure
Remove the engine (1) from the engine stand (2).
Remove the DT-21366 Converter Holding Strap (1) from the transmission which is retaining the torque converter.
- Position the engine to the transmission assembly.
Transmission Bolt (2) - Install and tighten [ 2x ] - Fastener Specifications
- Transmission Stud (1) - Install and tighten - Fastener Specifications
- Connect the required electrical connectors, retainers and reposition the wiring harness.
- 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.
NOTE:Work through the front wheelhouse opening to access the 3 engine mount frame side bolts (1).
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.
- Engine Mount Frame Side Bolt- Right Side (1) - Install 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.
NOTE:Work through the front wheelhouse opening to access the 3 engine mount frame side bolts (1).
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 component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Engine Mount Frame Side Bolt- Left Side (1) - Install and hand tighten [ 3x ]
- Engine Mount Frame Side Bolt- Left Side (1) - Tighten in sequence [ 3x ] - Fastener Specifications
- Remove the engine lift brackets and chains that are supporting the engine.
Remove the EN-36857 Engine Lift Bracket (1) and the EN-52059 Engine Support Fixture Adapter Bolt - M10 (2) from the cylinder head.
Remove the EN-36857 Engine Lift Bracket (1) and the EN-52059 Engine Support Fixture Adapter Bolt - M10 (2) from the cylinder head.
- Support the transmission with a suitable jack.
Transmission Mount Nut (1) - Remove
Transmission Support Crossmember Nut (1) - Remove [ 4x ]
- Transmission Support Crossmember Bolt (2) - Remove [ 4x ]
Transmission Support Crossmember (1) - Remove
- Lower the transmission to gain access to the top of the transmission.
Transmission Stud (1) - Install and tighten [ 5x ] - Fastener Specifications
Install the transmission vent hose clip bracket (2) to the transmission.
- Install and tighten the transmission vent hose clip bracket nut (1). Fastener Specifications
Install the fuel feed line assembly (3) on the transmission stud.
- Install and tighten the fuel feed and return front hose bracket nut (1). Fastener Specifications
- Install and tighten the fuel feed and return front hose bracket bolt (2). Fastener Specifications
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.
- For proper alignment of all transmission torque converter bolts, install the first transmission torque converter bolt in the oval shaped hole.
- Rotate the harmonic balancer center bolt clockwise ONLY, to align the transmission torque converter bolt with the starter opening.
- Transmission Torque Converter Bolt (1) - Install and tighten [ 6x ] - Fastener Specifications
Exhaust System Seal (1) - Install NEW
Exhaust System Seal (1) - Install NEW
Three-Way Catalytic Converter (1) - Install
Exhaust Front Pipe Nut- Right Side (1) - Install and hand tighten [ 3x ]
- Exhaust Front Pipe Nut- Right Side (1) - Tighten [ 3x ] - Fastener Specifications
Exhaust Front Pipe Nut- Left Side (1) - Install and hand tighten [ 3x ]
- Exhaust Front Pipe Nut- Left Side (1) - Tighten [ 3x ] - Fastener Specifications
Exhaust Muffler (2) @ Three-Way Catalytic Converter (3) - Connect
- Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications
Exhaust Front Pipe Heat Shield- Right Side (2) - Install
- Exhaust Heat Shield Bolt- Right Side (1) - Install and tighten - Fastener Specifications
Exhaust Front Pipe Heat Shield- Left Side (2) - Install
- Exhaust Heat Shield Bolt- Left Side (1) - Install and tighten - Fastener Specifications
Electrical Connector @ Heated Oxygen Sensor- Bank 2 Sensor 2 - Connect
- NOTE:
A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers
Using a suitable tool, install and tighten the heated oxygen sensor (1). Fastener Specifications
- Electrical Connector @ Heated Oxygen Sensor- Bank 2 Sensor 1 - Connect
Electrical Connector @ Heated Oxygen Sensor- Bank 1 Sensor 2 - Connect
- NOTE:
A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers
Using a suitable tool, install and tighten the heated oxygen sensor (1). Fastener Specifications
- Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 1 - Bank 1 Sensor 1 Connect
Transmission Support Crossmember (1) - Install
Transmission Support Crossmember Bolt (2) - Install [ 4x ]
- Transmission Support Crossmember Nut (1) - Install and tighten [ 4x ] - Fastener Specifications
Transmission Mount Nut (1) - Install and tighten - Fastener Specifications
- Remove the transmission jack.
Automatic Level Control Air Supply Reservoir (2) - Install
- Install the 3 automatic level control air compressor bolts (1) and tighten. Fastener Specifications
If equipped, 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).
{ If equipped } Install the wiring harness (2) as necessary and install the harness retainers (1) into the transmission support crossmember.
Engine Wiring Harness (3) - Install
- Engine Wiring Harness Retainer (2) - Install
- Engine Wiring Harness Ground Stud (1) - Install and tighten [ 2x ] - Ground Repair
Reposition the transmission cooler inlet and outlet pipe (1) as necessary.
- NOTE:
Components removed in graphic to better illustrate service parts.
Transmission Fluid Cooler Pipe Clip Bracket (2) @ Oil Pan - Install
- Transmission Fluid Cooler Pipe Clip Bolt (1) @ Oil Pan - Install and tighten - Fastener Specifications
Position the transmission fluid cooler inlet and outlet pipe bracket (2).
- Install and tighten the transmission fluid auxiliary cooler pipe bracket nut (1). Fastener Specifications
Engine Oil Cooler Gasket (2) - Install NEW
- Engine Oil Cooler Hose (1) @ Oil Pan - Install
Engine Oil Cooler Hose Bolt (1) - Install and tighten [ 2x ] - Fastener Specifications
Electrical Connector (1) @ Engine Oil Pressure Sensor - Connect
- Wiring Harness Retainer (2) @ Engine Oil Cooler Hose - Install
Engine Oil Pressure Sensor Sleeve (1) - Install
Engine Oil Cooler Hose Bracket Nut (1) - Install and tighten - Fastener Specifications
Transmission Converter Cover- Left Side (2) - Install
- Torque Converter Cover Bolt- Left Side (1) - Install and tighten - Fastener Specifications
Transmission Converter Cover- Right Side (2) - Install
- Torque Converter Cover Bolt- Right Side (1) - Install and tighten - Fastener Specifications
Starter (1) - Install
Electrical Connector (3) - Connect
- Protective Sleeve (4) - Install
- Starter Solenoid Cable (1) - Install
- Starter Solenoid Cable Nut (2) - Install and tighten - Fastener Specifications
Starter Mounting Bolt (1) - Install and tighten [ 2x ] - Fastener Specifications
Starter Solenoid Cable (2) - Install
- Battery Negative Cable Ground Bolt (1) - Install and tighten - Fastener Specifications
- NOTE:
Catalytic converter removed for graphic clarity.
Starter Heat Shield (2) - Install
- Starter Heat Shield Bolt (1) - Install and tighten - Fastener Specifications
Starter Heat Shield Bolt (1) - Install and tighten [ 2x ] - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
Install the heater coolant pump and heater water auxiliary pump bracket (2) as assembly.
- Heater Water Auxiliary Pump Bolt (1) - Install and tighten - Fastener Specifications
- Electrical Connector @ Heater Coolant Pump (2) - Connect
- CAUTION:
To tighten or loosen the fuel injection fuel rail fuel pressure sensor, apply force ONLY to the attached hexagon. Applying force to the plastic housing of the sensor may damage the sensor.
NOTE:Ensure the fuel rail threads are clean and free of any excess fuel, or the fuel rail pressure sensor will NOT seal properly.
Lubricate the threads and sealing surface of the fuel rail pressure sensor (2) with one drop of clean engine oil.
- Install the fuel rail pressure sensor (2) and hand tighten.
- Remove the fuel rail pressure sensor (2) from the fuel injection fuel rail (3) and re-lubricate with one drop of clean engine oil.
- Fuel Rail Pressure Sensor (2) @ Fuel Injection Fuel Rail (3) - Install and tighten - Fastener Specifications
- Electrical Connector (1) @ Fuel Rail Pressure Sensor (2) - Connect
Fuel Feed Pipe (1) - Install
- Fuel Feed Pipe (1) - Connect - Metal Collar Quick Connect Fitting Service
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling 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.
Fuel Pump Insulator (1) - Install
- Remove the covers from the cylinder head passages.
Intake Manifold Gasket (1) - Install NEW [ 8x ]
Clean all sealing surfaces.
- 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.
- Position the intake manifold and Intake manifold cover (1) to install harness retainers.
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [ 4x ]
- Move the intake manifold and intake manifold cover (2) into place.
- NOTE:
Some components not shown for graphic clarity.
Intake Manifold Bolt (1) - Hand tighten [ 10x ]
- Intake Manifold Bolt (1) - Tighten in sequence [ 10x ] - Fastener Specifications
Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold - Install - Plastic Collar Quick Connect Fitting Service
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [ 3x ]
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [ 4x ]
Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve - Connect
- Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor - Connect
- Engine Wiring Harness Retainer (2) @ Intake Manifold Cover - Install [ 2x ]
- Engine Wiring Harness Connector (1) @ Throttle Body - Connect
Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve - Install
- Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve - Engage - Plastic Collar Quick Connect Fitting Service
Water Pump Gasket (2) - Install NEW [ 2x ]
- Water Pump (1) - 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.
- Water Pump Housing Bolt (1) - Install and hand tighten [ 6x ]
- Water Pump Housing Bolt - Tighten in sequence [ 6x ] - Fastener Specifications
Air Conditioning Compressor (1) - Install
Air Conditioning Compressor Bolt (1) - Loosely install
- Air Conditioning Compressor Stud (3) - Install and tighten - Fastener Specifications
- Air Conditioning Compressor Bolt (1) - Tighten - Fastener Specifications
- Air Conditioning Compressor Nut (2) - Install and tighten - Fastener Specifications
Electrical Connector (1) @ Air Conditioning Compressor - Connect
Engine Coolant Temperature Sensor Electrical Connector (1) - Connect
Radiator Inlet Hose (3) @ Water Pump - Install
- Engine Coolant Air Bleed Hose (2) @ Water Pump - Install
- Hose Clamp (1) - Engage [ 2x ] - Hose Clamp Replacement Guidelines - Spring Type
Radiator Outlet Hose (2) @ Water Pump - Install
- Radiator Outlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Heater Water Auxiliary Pump Hose (3) @ Water Pump - Install
- Heater Inlet Hose (2) @ Water Pump - Install
- Hose Clamp (1) - Engage [ 2x ]
Generator (1) - Install
Generator Bolt (1) - Install and tighten [ 2x ] - Fastener Specifications
Starter Solenoid Cable (2) - Install
- Battery Positive Cable Nut (1) - Install and tighten - Fastener Specifications
- Electrical Connector (3) - Connect
- NOTE:
The OEM replacement accessory drive auxiliary belt (1) is packaged with a disposable installation tool and installation instructions.
Install the accessory drive auxiliary belt (1) following the instructions included with the accessory drive auxiliary belt.
- Inspect the accessory drive auxiliary belt (1) for proper installation and alignment.
Rotate the crankshaft balancer (1) an additional 360 degrees to ensure proper accessory drive auxiliary belt installation.
Position the accessory drive primary belt (4) on the belt idler pulley (2), fan and water pump pulley (3) and generator (1).
Install the EN-51767-2 Stretchy Belt Installer (1) onto the crankshaft balancer.
Position the accessory drive primary belt (2) on the crankshaft balancer.
- Slowly rotate the crankshaft balancer in a clockwise direction until the accessory drive primary belt (2) fully seats on the crankshaft balancer.
- Remove the EN-51767-2 Stretchy Belt Installer (1) from the crankshaft balancer.
Inspect the accessory drive primary belt (1) for proper installation and alignment.
Rotate the crankshaft balancer (1) and additional 360 degrees to ensure proper accessory drive primary belt installation.
Install the condenser, fan and radiator assembly (1) into its mounts and rotate forward into place.
Heater Inlet Hose (3) @ Heater Inlet and Outlet Hose Clip (1) - Install
Heater Outlet Hose Clip (2) @ Heater Water Auxiliary Pump Hose - Install
- Heater Outlet Hose (3) @ Radiator Surge Tank Outlet Hose - Install
- Heater Outlet Hose Clamp (4) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Outlet Hose (3) @ Heater Inlet and Outlet Hose Clip (1) - Install
Radiator Outlet Hose (2) @ Engine Radiator - Install
- Radiator Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Air Conditioning Compressor and Condenser Hose Seal (2) - Install NEW [ 2x ]
- Air Conditioning Condenser and Evaporator Hose (3) @ Air Conditioning Condenser - Install
- Air Conditioning Compressor and Condenser Hose (1) @ Air Conditioning Condenser - Install
Air Conditioning Compressor and Condenser Hose Nut (1) - Install and tighten - Fastener Specifications
- Air Conditioning Compressor and Evaporator Hose Nut (2) - Install and tighten - Fastener Specifications
Transmission Fluid Cooler Pipe Clip (1) - Secure
Transmission Fluid Cooler Pipe Fitting Seal (2) - Install NEW
- Transmission Fluid Cooler Inlet and Outlet Pipe (1) @ Transmission Fluid Auxiliary Cooler - Install
Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
Transmission Fluid Cooler Pipe Fitting Seal (3) - Install NEW
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Fluid Auxiliary Cooler - Install
- Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
Transmission Fluid Cooler Pipe Clip (2) - Install [ 2x ]
- Transmission Fluid Auxiliary Cooler Pipe Bolt (1) - Install and tighten - Fastener Specifications
Front End Upper Tie Bar (1) - Install
- Install the wiring harness.
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
- CAUTION:
Refer to Fastener Caution .
Front End Upper Tie Bar Bolt (1) - Install and tighten - Fastener Specifications
Front End Upper Tie Bar Bolt (1) @ Headlamp Bracket - Install and tighten [ 2x ] - Fastener Specifications
- Front End Upper Tie Bar Bolt (2) - Install and tighten - Fastener Specifications
Front End Upper Tie Bar Bolt- Right Side (1) - Install and tighten [ 3x ] - Fastener Specifications
Front End Upper Tie Bar Bolt- Left Side (1) - Install and tighten [ 3x ]
Front Grille Support Reinforcement (2) - Install
- Front Grille Support Bracket Bolt (1) - Install and tighten [ 4x ] - Fastener Specifications
Electrical Connector (2) - Connect
Connect the electrical connector.
- Hood Primary Latch Release Cable (1) - Install @ Hood Primary Latch
- Install the hood primary latch release cable (1) to the upper tie bar retainer (2).
- NOTE:
Right side shown, left side similar.
Front End Sheet Metal Diagonal Brace- Left Side and Right Side (2) @ Radiator Support - Install [ 2x ]
- 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.
- Front End Sheet Metal Diagonal Brace Bolt - Left Side and Right Side (1) - Install and tighten [ 4x ] - Fastener Specifications
Radiator Air Upper Baffle (1) - Install
- Engage the 6 integral retaining features (1).
Front End Sheet Metal Diagonal Brace (2) @ Upper Tie Bar - Install [ 2x ]
- 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.
- Front End Sheet Metal Diagonal Brace Bolt (1) @ Upper Tie Bar - Install and tighten [ 4x ] - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
Radiator Air Side Baffle - Right Side (2) - Install
- Radiator Air Side Baffle Retainer (1) - Install [ 4x ]
- NOTE:
Some components not shown for graphic clarity.
Radiator Air Side Baffle - Left Side (2) - Install
- Radiator Air Side Baffle Retainer (1) - Install [ 4x ]
Engine Oil Cooler Hose (1) @ Engine Radiator - Install [ 2x ]
- Engine Oil Cooler Pipe Bracket Bolt (3) - Install and tighten - Fastener Specifications
- Engine Oil Cooler Retainer (2) - Install [ 2x ]
- NOTE:
Some components not shown for graphic clarity.
Position the wiring harness.
- Electrical Connector (1) - Connect
- Wiring Harness Retainer (2) - Install [ 2x ]
- NOTE:
Some components not shown for graphic clarity.
Position the wiring harness.
- Electrical Connector (3) - Connect
- Wiring Harness Retainer (1) - Install [ 2x ]
- NOTE:
Some components not shown for graphic clarity.
Radiator Inlet Hose (3) @ Engine Radiator - Install
- Radiator Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Inlet Hose Clip (2) - Install
Radiator Surge Tank Outlet Hose (3) @ Heater Outlet Hose - Install
- Radiator Surge Tank Outlet Hose Clip (2) - Install [ 2x ]
- Heater Outlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Engine Wiring Harness Fuse Block Bracket (3) - Install
- Retaining Tab (1) - Engage
- Engine Wiring Harness Fuse Block Bracket Bolt (2) - 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 ]
Radiator Surge Tank Inlet Hose (2) @ Engine Radiator - Install
- Radiator Surge Tank Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Plenum Front Panel Outer Reinforcement (1) - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
Intake Air Duct Retainer (1) - Install
- Intake Air Duct (2) - Install
Front Bumper Shutter (2) - Install
- Front Bumper Shutter Bolt (1) - Install and tighten [ 9x ] - Fastener Specifications
- Connect the electrical connector at the front bumper shutter and position wiring harness.
Front Bumper Fascia Upper Stiffener (1) - Install
Install and tighten the left and right side front bumper fascia upper stiffener bolt (2). Fastener Specifications
- Tighten the left and right side front bumper fascia upper stiffener nut (1). Fastener Specifications
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 ]
Headlamp Bolt (1) - Install and tighten [ 6x ] - Fastener Specifications
Headlamp Bolt (1) - Install and tighten [ 6x ] - Fastener Specifications
Air Cleaner Assembly (2) - Install
- Air Cleaner Nut (2) - Install and tighten - Fastener Specifications
Air Cleaner Outlet Duct (3) - Install
- Air Cleaner Outlet Duct Clamp (2) - Install and tighten [ 2x ] - Fastener Specifications
- Positive Crankcase Ventilation Fresh Air Tube (1) - Connect - Plastic Collar Quick Connect Fitting Service
Connect the mass airflow sensor electrical connector (1) and install all engine wiring harnesses from the air cleaner assembly.
Air Cleaner Outlet Duct Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Engine Wiring Harness @ Air Cleaner Outlet Duct Bracket - Install
{ If equipped } Engine Coolant Heater Cord (1) @ Engine Coolant Heater - Connect
Connect the electrical connector. (1)
Connect the electrical connectors. (1)
- NOTE:
The proper position of the underbody skid shield is between the front bumper fascia extension and the front frame.
Underbody Skid Shield (2) - Install
- Underbody Splash Shield Bolt (1) - Install and tighten [ 4x ] - Fastener Specifications
With the aid of an assistant, install the fascia. (2)
- Install the 7 grille clips (1).
- { If equipped } 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.
- CAUTION:
Refer to Fastener Caution .
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 bolt (1). Fastener Specifications
Front Bumper Fascia Skid Plate Bolt (1) - Install and tighten [ 4x ] - 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 bolt (2). Fastener Specifications
- Front Wheelhouse Liner- Left Side and Right Side - Install [ 2x ] - Front Wheelhouse Liner Replacement
- NOTE:
Left side shown, right side similar.
Install and tighten the left and right side front bumper fascia bolts (1) to the wheelhouse liner. Fastener Specifications
- Lower the vehicle.
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
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (KL9)
- Recharge the refrigerant. Refrigerant Recovery and Recharging
- Inspect for refrigerant leaks.
- Prelube is necessary if the engine is replaced or overhauled. Engine Prelubing
- Using the GE-47716
Vac-N-Fill Coolant Refill Tool procedure only, fill the coolant system.
Cooling System Draining and Filling (GE 47716 L84, L87) , or
- Install the oil fill cap.
- 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.
- Perform a final inspection for the proper engine oil and coolant levels.
- Perform the throttle body idle air flow compensation reset procedure. Throttle Body Idle Air Flow Compensation Reset
- Perform the crankshaft position variation learn. Crankshaft Position Variation Learn
- If any of the heated oxygen sensors are replaced, perform the heated oxygen sensor heater resistance learned values reset. Heated Oxygen Sensor Heater Resistance Learned Values Reset
- After installation, aim the front headlamps. Front Headlamp Aiming
The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.
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 ONLY GE-47716 for Cooling System Draining and Filling. DO NOT USE Static Fill as it will result in damage to the engine.
Refer to Heated Oxygen Sensor Resistance Learn Reset Caution .