Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Installation Procedure
Water Outlet Seal (1) - Install NEW
Engine Coolant Flow Control Valve (1) - Install
- CAUTION:
Refer to Fastener Caution .
Engine Coolant Flow Control Valve Bolt (1) - Tighten [3x] - Fastener Specifications
Engine Coolant Flow Control Valve Bolt (1) - Tighten [2x] - Fastener Specifications
Connect the electrical connectors and install the wiring harness retainers as necessary. (1)
Engine Oil Cooler Coolant Inlet Hose (1) - Install
- Hose Clamp (2) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose (2) - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Heater Inlet Pipe (2) - Install
- Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Radiator Inlet Hose (2) - Install
Connect the electrical connectors and install the wiring harness retainers as necessary. (1)
Intake Manifold Gasket @ Intake Manifold (1) - Install NEW
Intake Manifold (1) - Install
- Intake Manifold Bolt (2) - Install and hand tighten [5x]
- Intake Manifold Bolt (1) - Tighten in sequence [5x] - Fastener Specifications
Intake Manifold Cover (1) - Install
- Connect the electrical connectors and install the wiring harness retainers as necessary.
Oil Level Indicator - Install
- Oil Level Indicator Tube Bracket Bolt (2) Install and tighten - Fastener Specifications
- Intake Manifold Cover Bolt (1) - Install and tighten [3x] - Fastener Specifications
Install the Hose retainers as necessary (1).
Install the Hose retainers as necessary (1).
Charge Air Cooler Coolant Hose (2) - Install
- Charge Air Cooler Inlet Air Hose Clamp Nut (1) - Install and tighten - Fastener Specifications
Charge Air Cooler Bracket (1) - Install
Charge Air Cooler Bracket Bolt (1) - Install and tighten [4x] - Fastener Specifications
Charge Air Cooler (1) - Install
Charge Air Cooler Coolant Hose Clamp (4) - Tighten - Fastener Specifications
- Charge Air Cooler Coolant Hose (3) - Install [2x]
- Charge Air Cooler Coolant Hose Retainer (2) - Engage [2x]
- Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
- Connect the electrical connector. (5)
Charge Air Cooler Bolt (1) - Install and tighten [4x] - Fastener Specifications
Air Cleaner Outlet Duct (4) - Install
- Air Cleaner Outlet Duct Nut (3) - Install and tighten - Fastener Specifications
- Air Cleaner Outlet Duct Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Air Cleaner Outlet Duct Clamp (5) - Tighten - Fastener Specifications
- Turbocharger Outlet Duct Front Clamp (1) - Tighten - Fastener Specifications
Positive Crankcase Ventilation Fresh Air Tube (1) @Air Cleaner Outlet Duct - Connect - Plastic Collar Quick Connect Fitting Service
Oil Filler Cap (1) - Remove
Intake Manifold Cover (1) - Install
Oil Filler Cap - Install
- Fill the cooling system to the proper level. Cooling System Draining and Filling (GE 47716)
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Perform the Engine Coolant Control Valve Learn. Engine Coolant Control Valve Learn
- Perform the Engine Coolant Bypass - Oil Heat Exchanger Valve Learn. Engine Coolant Bypass - Oil Heat Exchanger Valve Learn
- Perform the Engine Block Coolant Control Valve Position Learn. Engine Block Coolant Control Valve Position Learn
- Perform the engine coolant pump data reset. Engine Coolant Pump Data Reset
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.