Installation Procedure
Engine Radiator (4) - Install
- Radiator Lower Insulator - Left and Right (3) - Install [2x]
- Radiator Air Lower Baffle (2) - Install
- Radiator Air Side Seal - Left and Right (1) - Install [2x]
Air Conditioning Condenser (3) - Install
- Air Conditioning Condenser Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Radiator Air Upper Seal (1) - Install
Charge Air Cooler (2) - Install
- Charge Air Cooler Bolt (1) - Install and tighten [2x] - Fastener Specifications
Engine Coolant Fan (2) @ Radiator Assembly - Install
- Engine Coolant Fan Bolt (1) - Install and tighten - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
Engine Coolant Fan Module Radiator Assembly (1) - Install
- NOTE:
Left side shown, right side similar.
Radiator Upper Bracket - Left and Right (3) - Install [2x]
- Radiator Air Upper Baffle Retainer - Left and Right (2) - Install [2x]
- Radiator Upper Bracket Bolt - Left and Right (1) - Install and tighten [4x] - Fastener Specifications
Transmission Fluid Cooler Pipe (3) - Install
- Transmission Fluid Cooler Pipe Fitting Retainer (2) - Install - Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
- Transmission Fluid Cooler Pipe Bolt - Install and tighten Fastener Specifications
Transmission Fluid Cooler Pipe (3) - Install
- Transmission Fluid Cooler Pipe Fitting Retainer (2) - Install - Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
- Transmission Fluid Cooler Pipe Bolt - Install and tighten Fastener Specifications
Transmission Fluid Cooler Pipe Clip (1) - Install
Check the rubber seal (1) is inside the inlet and outlet air hose.
- NOTE:
DO NOT insert fingers inside quick connect to manipulate duct during disassembly/assembly. Rubber pad gloves increase risk to dislodge seal.
Charge Air Cooler Outlet Air Hose (2) - Install
- Charge Air Cooler Outlet Air Hose Retainer Spring (1) - Engage
- Verify connection is properly made by pulling and pushing on the duct at the quick connector location.
- NOTE:
DO NOT insert fingers inside quick connect to manipulate duct during disassembly/assembly. Rubber pad gloves increase risk to dislodge seal.
Charge Air Cooler Inlet Air Hose (2) - Install
- Charge Air Cooler Inlet Air Hose Retainer Spring (1) - Engage
- Verify connection is properly made by pulling and pushing on the duct at the quick connector location.
Radiator Outlet Hose (2) @ Radiator - Install
- Radiator Outlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Radiator Inlet Hose @ Radiator (3) - Install
- Radiator Inlet Hose Clamp @ Radiator (2) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Engine Coolant Air Bleed Hose (1) - Install
- CAUTION:
Refer to Air Conditioning Sealing Washers Oil or Lubricant Exposure Caution .
Air Conditioning Compressor and Condenser Hose Seal (3) - Install NEW Air Conditioning System Seal Replacement
- Air Conditioning Compressor Hose (2) - Install
- Air Conditioning Compressor Tube Nut (1) - Install and tighten - Fastener Specifications
Air Conditioning Condenser Hose Seal (3) - Install NEW Air Conditioning System Seal Replacement
- Air Conditioning Refrigerant Heat Exchanger (2) - Install
- Air Conditioning Condenser Tube Nut (1) - Install and tighten - Fastener Specifications
Radiator Air Lower Baffle (2) - Install
- Radiator Air Lower Baffle Retainer (1) - Install [2x]
Ensure that the locking tab is engaged and install the radiator air lower baffle (1).
Front Bumper Impact Bar (1) - Install
Front Bumper Impact Bar Bolt - Left Side (1) - Install and tighten [4x] - Fastener Specifications
Front Bumper Impact Bar Bolt - Right Side (1) - Install and tighten [4x] - Fastener Specifications
- Body Wiring Harness Clip (2) - Install
Radiator Air Upper Baffle (1) - Install
Radiator Air Upper Baffle Retainer (1) - Install [2x]
Radiator Air Upper Baffle Retainer (1) - Install [2x]
Intake Air Duct (1) - Install
Intake Air Duct Retainer (1) - Install [2x]
Hood Front Bumper Bracket Support (2) - Install [3x]
- Hood Front Bumper Bracket Support Bolt (1) - Install and tighten [6x] - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Connect the electrical connectors.
- Front Headlamp - Left and Right (3) - Install [2x]
- Secure the front headlamp guide pin (1) to the front bumper fascia guide (2).
- NOTE:
Left side shown, right side similar.
Headlamp Bolt - Left and Right (1) - Install and tighten [10x] - Fastener Specifications
Front Bumper Fascia (1) - Install - Front Bumper Fascia Removal and Installation
- After installation, aim the front headlamps. Front Headlamp Aiming (with Horizontal Adjustment) , or Front Headlamp Aiming (without Horizontal Adjustment)
- Fill the cooling system. Cooling System Draining and Filling (GE 47716) , or Cooling System Draining and Filling (Static)
- Recharge the refrigerant. Refrigerant Recovery and Recharging
- Fill and inspect the transmission fluid level. Transmission Fluid Level and Condition Check
- Inspect for refrigerant leaks. Leak Testing
- Remove the drain pan.
- Start vehicle and listen for whistling at the charge air cooler inlet/outlet tube quick connect located at the charge air cooler. Leak Testing
Handle the charge air cooler inlet and outlet air tubes only by the outside surface, making sure to avoid touching the internal seals. Touching the internal seals can dislodge them from their intended location and lead to seal damage and leaks during tube installation.
Verify the charge air cooler inlet and outlet air tube quick connect seal condition and location prior to installation. Seal must be evenly seated in the quick connector body and sealing surface must be free of deformation and damage. Deformed or damaged seals can lead to reduced engine power and/or engine stalling.