Steps 101-164

Engine - Body On













Installation

101. NOTICE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the fuel system.

NOTICE: Make sure that the fuel tubes are not rubbing against the turbocharger actuator cooler or damage to the fuel tubes may occur.

Install new sealing washers and 2 banjo bolts on the fuel cooler.

- Tighten to 25 Nm (18 lb-ft).





102. Connect the fuel supply hose.





103. Position back the engine wiring harness and install the bolt. Connect the fuel temperature sensor electrical connector.





104. Connect the fuel charging harness electrical connector and pushpin retainer.





105. NOTICE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the high-pressure fuel injection pump.

NOTE: Remove the protective plugs as needed.

Install the new sealing washers and 2 banjo bolts at the fuel filter module.

- For M14 banjo bolt with Viton(R) sealing washers, tighten to 28 Nm (21 lb-ft).

- For M14 banjo bolt with copper sealing washer, tighten to 47 Nm (35 lb-ft).

- For M12 banjo bolt with Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).

- For M12 banjo bolt with copper sealing washer, tighten to 38 Nm (28 lb-ft).





106. Connect the heater hose and the engine fill hose. Connect the vacuum tube to the engine fill hose.





107. Install a new press-in place gasket. Install the intake throttle adapter and loosely install the 4 bolts.





108. Connect the EGR valve and Throttle Body (TB) electrical connectors.





109. Install the Air Cleaner (ACL) outlet pipe and tighten the clamp. Install a new clamp on the crankcase vent oil separator hose.
- Tighten to 5 Nm (44 lb-in).





110. Position the auxiliary air intake in the vehicle.





111. Install the ACL assembly and tighten the clamp.
- Tighten to 5 Nm (44 lb-in).





112. Connect the wire retainer to the air cleaner assembly. Connect the filter minder and the Mass Air Flow (MAF) sensor electrical connectors.





113. NOTE: Upper radiator hose shown, lower radiator similar.

Install the upper and lower radiator hoses. Install the clips.





114. Connect the retainers for the lower radiator hoses.





115. NOTE: Install a new horizontal EGR cooler gasket prior to installing the vertical EGR cooler.

Position the vertical EGR cooler assembly and loosely install the 5 bolts.





116. Install a new vertical EGR cooler gasket and the stud.
- Tighten to 17 Nm (150 lb-in).





117. Install the nut and bolt for the vertical EGR cooler.
- Tighten to 31 Nm (23 lb-ft).





118. Connect the EGRT sensor electrical connector.





119. Connect the coolant hose at the vertical EGR cooler.





120. NOTICE: Do not bend or twist the Exhaust Gas Recirculation (EGR) cooler bellows or damage to the EGR cooler may occur.

Install the 2 nuts for the vertical EGR cooler.

- Tighten to 31 Nm (23 lb-ft).

- Inspect the corrugation of the EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.





121. NOTICE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.

NOTE: Install a new clamp on the EGR cooler hose.

Connect the EGR cooler hose and tighten the clamp.

- Tighten to 4 Nm (35 lb-in).





122. NOTE: Carry out this step only if the horizontal EGR cooler was replaced.

Tighten the 2 clamps for the horizontal EGR cooler.

- Tighten to 10 Nm (89 lb-in).

- Loosen the clamps 720 degrees.

- Tighten to 8 Nm (71 lb-in).





123. NOTE: Carry out this step only if the vertical EGR cooler was replaced.

Tighten the 3 clamps for the vertical EGR cooler.

- Tighten to 8 Nm (71 lb-in).

- Loosen the clamps 720 degrees.

- Tighten to 6 Nm (53 lb-in).





124. Tighten the 5 vertical EGR cooler mounting bracket bolts.
- Tighten the M8 bolts to 31 Nm (23 lb-ft).

- Tighten the M10 bolt to 62 Nm (46 lb-ft).





125. NOTE: Vertical EGR cooler removed from art for clarity.

Tighten the 4 bolts for the intake throttle adapter.

- Tighten to 10 Nm (89 lb-in).





126. NOTE: Install a new O-ring seal.

Install the vertical EGR cooler tube and bolt.

- Tighten to 10 Nm (89 lb-in).





127. Install the degas bottle module and 4 bolts.
- Tighten to 19 Nm (168 lb-in).





128. Connect the engine fill hose and install the clip.





129. Connect the EGR cooler to the degas bottle hose. If equipped, connect the vacuum hose.





130. Install the LH battery and hold-down bolt.





131. NOTE: Cover positioned aside for clarity.

Position back the battery cable and connect the retainers. Install the retaining nut.

- Tighten to 10 Nm (89 lb-in).





132. Connect the transmission cooler tubes. Install the retaining nut.
- Tighten to 9 Nm (80 lb-in).





Vehicles with A/C

133. Position the A/C tube in the retaining clip. Connect the A/C pressure switch electrical connector.





134. Install the A/C compressor and 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





135. Install new O-ring seals and gaskets on the A/C hoses. Position the A/C hoses and install the 2 retaining nuts for the A/C hoses.
- Tighten to 15 Nm (133 lb-in).





136. Connect the A/C clutch electrical connector and wire retainer.





All vehicles

137. Install the 2 stator stand offs. Position the ground cable and install the bolt.
- Tighten the stand offs and the bolt to 47 Nm (35 lb-ft).





138. Install the Front End Accessory Drive (FEAD) assembly, 2 nuts and 2 bolts.
- Tighten to 47 Nm (35 lb-ft).





139. Install the accessory drive belt idler pulley and bolt.
- Tighten to 47 Nm (35 lb-ft).





140. Position the generator wiring and connect the pushpin retainer.





141. Position the generator wiring and connect the generator electrical connector. Install the nut and position back the boot.
- Tighten to 8 Nm (71 lb-in).





142. If equipped with dual generators, position the harness and connect the generator electrical connector. Install the nut and position back the boot.
- Tighten to 8 Nm (71 lb-in).





143. Position the power steering pump and install the retaining nut for the power steering hose and tube.
- Tighten to 25 Nm (18 lb-ft).





144. Install the 3 bolts for the power steering pump.
- Tighten to 25 Nm (18 lb-ft).





Vehicles with A/C

145. Install the A/C drive belt.





All vehicles

146. NOTE: Single generator shown, dual generator similar.

Install the accessory drive belt.





147. Install the cooling fan stator, 2 nuts and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





148. NOTE: The cooling fan has LH threads.

Using the Fan Clutch Nut Wrench and Fan Hub Nut Wrench, install the cooling fan assembly.

- Tighten to 150 Nm (111 lb-ft).





149. Install the cooling fan electrical connector into the stator. Connect the cooling fan electrical connector.





150. NOTICE: Do not use air tools to tighten or engine damage may occur.

Tighten the LH Charge Air Cooler (CAC) pipe.

- Tighten to 12 Nm (106 lb-in).





151. Position the front impact severity sensor and install the bolt. Connect the electrical connector.
- Tighten to 12 Nm (106 lb-in).





152. Position the lower cooling fan shroud and wiring. Connect the 7 pushpin retainers around the wiring harness. Connect the remaining pushpin retainers.





153. Install the 2 bolts for the fuel cooling pump.
- Tighten to 3 Nm (27 lb-in).





154. Tighten the 2 bolts for the exhaust downpipe.
- Tighten to 40 Nm (30 lb-ft).





155. NOTE: RH side shown, LH side similar.

Install the front bumper and the 6 bolts.

- Tighten to 47 Nm (35 lb-ft).





156. Connect the fog light electrical connector and pin-type retainer.





157. Install the cooling module. For additional information, refer to Cooling System &/or Engine Block Heater.

Vehicles with manual transmission

158. Install the clutch disc and pressure plate. For additional information, refer to Clutch, M/T.

159. Install the transmission. For additional information, refer to Manual Transmission/Transaxle.

All vehicles

160. Fill the engine with the correct motor oil for the climate. For additional information, refer to the Engine Engine.

161. Connect the LH and RH battery cables. For additional information, refer to Battery.

162. Bleed the high-pressure and low-pressure fuel system. For additional information, refer to Fuel Delivery and Air Induction.

163. NOTE: Clearing the DTCs or Keep Alive Memory (KAM) does not reset the adaptive values in the PCM.

If the high-pressure fuel injection pump or fuel injector(s) were replaced, clear the fuel injector adaptive tables from the PCM, using the scan tool. For additional information, refer to Computers and Control Systems Information.

164. NOTE: Clearing the DTCs or KAM does not reset the adaptive values in the PCM.

If the EGR valve was replaced, clear the EGR adaptive tables from the PCM, using the scan tool. For additional information, refer to Computers and Control Systems Information.