Engine Mount Replacement - Right Side

Single Use Fasteners and Components Air Conditioning Compressor and Condenser Hose Seal [2x] Air Conditioning Evaporator Thermal Expansion Valve Seal - Small Air Conditioning Evaporator Thermal Expansion Valve Seal - Large Catalytic Converter Clamp Catalytic Converter Gasket Emission Reduction Fluid Injector Clamp Engine Mount Engine Side Bolt [2x] Engine Mount Frame Side Bolt [3x] Exhaust Gas Recirculation Cooler Inlet Pipe Gasket - Lower Exhaust Gas Recirculation Cooler Inlet Pipe Gasket - Upper Exhaust Gas Recirculation Outlet Pipe Gasket Exhaust Gas Recirculation Valve Cooler Gasket Exhaust Gas Recirculation Valve Inlet Gasket Exhaust System Front Gasket [2x] Turbocharger Coolant Feed and Return Pipe Gasket Special Tools Engine Mechanical - 3.0L (LM2) EN-36857 Engine Lift Bracket EN-51768 Engine Support Fixture Adaptor Bolt - M8 Equivalent regional tools: Special Tools

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. Removal Procedure

1. Recover the refrigerant. Refrigerant Recovery and Recharging

Engine Mount Replacement - Right Side — figure 1

2. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation
3. Oil Filler Cap » Remove

Engine Mount Replacement - Right Side — figure 2

4. Intake Manifold Cover Bolt (1) » Remove
5. Intake Manifold Cover (2) » Remove
6. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.

Engine Mount Replacement - Right Side — figure 3

7. Battery Hold Down Strap Bolt (1) » Remove [2x]
8. Battery Hold Down Strap (2) » Reposition

Engine Mount Replacement - Right Side — figure 4

9. Retaining Tab (1) » Disengage [2x]
10. Front Compartment Fuse Block Cover (2) » Remove

Engine Mount Replacement - Right Side — figure 5

11. Battery Positive Post Clamp Nut (1) » Loosen

Engine Mount Replacement - Right Side — figure 6

12. Electrical Connector (1) » Disconnect

Engine Mount Replacement - Right Side — figure 7

13. Retaining Tab (1) » Disengage [3x]
14. Battery Distribution Engine Compartment Fuse Block (2) » Reposition

Engine Mount Replacement - Right Side — figure 8

15. Battery Hold Down Retainer Bolt (1) » Remove
16. Battery Hold Down Retainer (2) » Remove

Engine Mount Replacement - Right Side — figure 9

17. Battery (1) » Remove

Engine Mount Replacement - Right Side — figure 10

18. Retaining Tab (1) » Disengage [2x]
19. Engine Wiring Harness Junction Block Cover (2) » Remove
20. Battery Positive Cable Nut (3) » Remove
21. Starter Solenoid Cable (4) » Remove

Engine Mount Replacement - Right Side — figure 11

22. Engine Wiring Harness Junction Block Bolt (2) » Loosen [4x]
23. Retaining Tab (1) » Disengage [4x]
24. Engine Wiring Harness Junction Block (3) » Remove

Engine Mount Replacement - Right Side — figure 12

25. Electrical Connector (1) » Remove [4x]

Engine Mount Replacement - Right Side — figure 13

26. Engine Wiring Harness Fuse Block Bracket Bolt (2) » Remove [2x]
27. Retaining Tab (1) » Disengage
28. Engine Wiring Harness Fuse Block Bracket (3) » Remove

Engine Mount Replacement - Right Side — figure 14

29. Air Conditioning Compressor and Condenser Hose Nut (2) @ Air Conditioning Refrigerant Heat Exchanger » Remove
30. Air Conditioning Compressor and Condenser Hose (3) @ Air Conditioning Refrigerant Heat Exchanger » Remove
31. Air Conditioning Compressor and Condenser Hose Seal (4) » Remove and DISCARD
32. Air Conditioning Condenser and Evaporator Hose Clip (6) » Remove
33. Air Conditioning Condenser and Evaporator Hose (1) » Remove
34. Air Conditioning Compressor and Condenser Hose Seal (5) » Remove and DISCARD

Engine Mount Replacement - Right Side — figure 15

35. Air Conditioning Refrigerant Heat Exchanger Nut (1) @ Battery Tray » Remove

Engine Mount Replacement - Right Side — figure 16

36. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Remove
37. Air Conditioning Refrigerant Heat Exchanger (2) » Remove
38. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Remove and DISCARD
39. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Remove and DISCARD
40. Remove retainers as needed.

Engine Mount Replacement - Right Side — figure 17

41. Battery Tray Bolt (1) » Remove [7x]

Engine Mount Replacement - Right Side — figure 18

42. Battery Tray (1) » Remove

Engine Mount Replacement - Right Side — figure 19

43. Exhaust Gas Recirculation Temperature Sensor (2) » Remove and position aside

Engine Mount Replacement - Right Side — figure 20

44. Turbocharger Heat Shield Bolt (1) » Remove [2x]
45. Turbocharger Heat Shield Nut (2) » Remove

Engine Mount Replacement - Right Side — figure 21

46. Turbocharger Heat Shield (1) » Remove

Engine Mount Replacement - Right Side — figure 22

47. Catalytic Converter Clamp (1) » Loosen
48. Nitrogen Oxides Sensor » Remove and position aside

Engine Mount Replacement - Right Side — figure 23

49. Exhaust Temperature Sensor - Position 1 (1) » Remove and position aside

Engine Mount Replacement - Right Side — figure 24

50. Exhaust Temperature Sensor - Position 2 (1) » Remove and position aside

Engine Mount Replacement - Right Side — figure 25

51. Emission Reduction Fluid Exhaust Front Pipe Injector Supply Pipe Insulator (1) » Remove

Engine Mount Replacement - Right Side — figure 26

52. Emission Reduction Fluid Injector Clamp (1) » Remove and DISCARD

Note

Do not use a prying tool to remove the injector.

53. Reductant Fluid Injector (2) » Reposition

Note

After removing the injector, wipe any residual DEF with a clean towel to avoid urea crystal build up at the connection during installation. Urea crystal build-up can result in a future leak.

54. Exhaust System Front Gasket (3) » Remove and DISCARD
55. Clean the exhaust mounting flange and injector mounting surfaces to remove any soot or emission reduction fluid deposits.
56. Front Wheelhouse Liner - Right Side (3) » Remove — Front Wheelhouse Liner Replacement
57. Drain the cooling system. Cooling System Draining and Filling

Engine Mount Replacement - Right Side — figure 27

58. Exhaust Temperature Sensor - Position 3 (1) » Remove and position aside

Engine Mount Replacement - Right Side — figure 28

59. Using a suitable tool, remove the position 2 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.

Engine Mount Replacement - Right Side — figure 29

60. Using a suitable tool, remove the position 3 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.

Engine Mount Replacement - Right Side — figure 30

61. Using a suitable tool, remove the exhaust particulate sensor (1) from the nitrogen oxides catalytic converter.

Engine Mount Replacement - Right Side — figure 31

62. Exhaust Pipe Clamp (1) » Loosen

Engine Mount Replacement - Right Side — figure 32

63. Exhaust Front Pipe Nut (1) » Remove [2x]

Engine Mount Replacement - Right Side — figure 33

64. Catalytic Converter Brace Bracket Nut (1) » Remove [2x]
65. Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) » Remove
66. Catalytic Converter Brace Bracket (3) » Remove

Engine Mount Replacement - Right Side — figure 34

67. Exhaust Front Pipe Nut (1) » Remove [2x]

Engine Mount Replacement - Right Side — figure 35

68. Nitrogen Oxides Catalytic Converter (1) » Remove
69. Exhaust System Front Gasket (2) » Remove and DISCARD

Engine Mount Replacement - Right Side — figure 36

70. Electrical Connector (1) @ Exhaust Back Pressure Valve » Disconnect
71. Disconnect wiring harness retainers, as required.

Engine Mount Replacement - Right Side — figure 37

72. Exhaust Gas Recirculation Valve Cooling Return Pipe Bolt (1) » Remove [2x]
73. Exhaust Gas Recirculation Valve Cooling Return Pipe (2) » Remove
74. Turbocharger Coolant Feed and Return Pipe Gasket (3) » Remove and DISCARD

Engine Mount Replacement - Right Side — figure 38

75. Catalytic Converter Nut (1) » Remove [3x]

Engine Mount Replacement - Right Side — figure 39

76. Exhaust Back Pressure Valve (1) » Remove
77. Exhaust Gas Recirculation Valve Inlet Gasket (2) » Remove and DISCARD

Engine Mount Replacement - Right Side — figure 40

78. Air Cleaner Outlet Duct Clamp (1) » Loosen [2x]
79. Air Cleaner Outlet Front Duct (2) » Remove

Engine Mount Replacement - Right Side — figure 41

80. Air Cleaner Outlet Duct Clamp (1) » Loosen
81. Air Cleaner Outlet Duct (2) » Remove

Engine Mount Replacement - Right Side — figure 42

82. Hose Clamp (1) » Disengage [4x] — Hose Clamp Replacement Guidelines - Spring Type
83. Exhaust Gas Recirculation Coolant Return Pipe (2) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
84. Heater Inlet Hose (3) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
85. Exhaust Gas Recirculation Cooler Outlet Pipe (4) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
86. Exhaust Gas Recirculation Cooler Inlet Pipe (5) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove

Engine Mount Replacement - Right Side — figure 43

87. Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
88. Thermostat Bypass Hose (2) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove

Engine Mount Replacement - Right Side — figure 44

89. Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines - Spring Type
90. Exhaust Gas Recirculation Valve Cooling Return Hose (3) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
91. Turbocharger Coolant Feed and Return Pipe (4) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove

Engine Mount Replacement - Right Side — figure 45

92. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Remove [2x]

Engine Mount Replacement - Right Side — figure 46

93. Exhaust Gas Recirculation Cooler Inlet Pipe (1) » Remove

Engine Mount Replacement - Right Side — figure 47

94. Remove the 3 rear engine wiring harness channel nuts (1).
95. Position the rear engine wiring harness channel (2) out of the way.

Engine Mount Replacement - Right Side — figure 48

96. Remove the 2 exhaust pressure differential sensor bracket studs (1) and reposition the exhaust pressure differential bracket (2).

Engine Mount Replacement - Right Side — figure 49

97. Disengage the exhaust pressure differential sensor hose clamp (1) and remove the exhaust pressure differential sensor from the exhaust gas recirculation valve hose. Hose Clamp Replacement Guidelines - Spring Type

Engine Mount Replacement - Right Side — figure 50

98. Disengage the exhaust pressure differential sensor hose clamp (1) and remove the exhaust pressure differential sensor at the exhaust gas recirculation cooler. Hose Clamp Replacement Guidelines - Spring Type

Engine Mount Replacement - Right Side — figure 51

99. Disengage the 2 exhaust pressure differential sensor hose clamp (1) and remove the 2 exhaust pressure differential sensor hoses at the exhaust gas recirculation cooler. Hose Clamp Replacement Guidelines - Spring Type

Engine Mount Replacement - Right Side — figure 52

100. Exhaust Gas Recirculation Pipe Nut (1) » Remove

Engine Mount Replacement - Right Side — figure 53

101. Exhaust Gas Recirculation Pipe Nut (1) » Remove

Engine Mount Replacement - Right Side — figure 54

102. Exhaust Gas Recirculation Pipe (1) » Reposition
103. Exhaust Gas Recirculation Outlet Pipe Gasket (2) » Remove and DISCARD

Engine Mount Replacement - Right Side — figure 55

104. Disconnect the electrical connector (1).
105. Exhaust Gas Recirculation Pipe Bolt (2) » Remove [2x]

Engine Mount Replacement - Right Side — figure 56

106. Exhaust Gas Recirculation Valve Bracket Nut (1) » Remove
107. Heater Inlet Hose Bracket (2) » Reposition

Engine Mount Replacement - Right Side — figure 57

108. Exhaust Gas Recirculation Pipe Bolt (1) » Remove [2x]

Engine Mount Replacement - Right Side — figure 58

109. Remove the exhaust gas recirculation valve (1) with the exhaust gas recirculation valve hose.
110. Exhaust Gas Recirculation Valve Cooler Gasket (2) » Remove and DISCARD

Engine Mount Replacement - Right Side — figure 59

111. Exhaust Gas Recirculation Cooler Inlet Pipe Bolt (1) » Remove [4x]
112. Exhaust Gas Recirculation Pipe (2) » Remove
113. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket - Lower (3) Remove and DISCARD
114. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket - Upper (4) Remove and DISCARD

Engine Mount Replacement - Right Side — figure 60

115. Disconnect the electrical connector at exhaust gas recirculation cooler.
116. Remove the 4 exhaust gas recirculation cooler nuts (1).

Engine Mount Replacement - Right Side — figure 61

117. Remove the exhaust gas recirculation cooler (1).

Engine Mount Replacement - Right Side — figure 62

118. { If equipped } Catalytic Converter Brace Bracket Nut (2) » Remove
119. { If equipped } Battery Negative Cable Extension Cable Strap (1) @ Catalytic Converter Brace Bracket » Remove

Engine Mount Replacement - Right Side — figure 63

Note

Quantity of fasteners may vary based on option content.

120. Catalytic Converter Brace Bracket Nut (1) » Remove [2x]

Engine Mount Replacement - Right Side — figure 64

121. Catalytic Converter Brace Bracket Nut (1) » Loosen [2x]

Engine Mount Replacement - Right Side — figure 65

122. Fuel Heater Inlet and Outlet Nut (1) » Remove
123. Fuel Cooler Coolant Cooler Inlet Hose » Reposition

Engine Mount Replacement - Right Side — figure 66

124. Catalytic Converter Brace Bracket Nut (1) » Loosen [2x]
125. Reposition hoses and wiring harness as needed.

Engine Mount Replacement - Right Side — figure 67

126. Nitrogen Oxides Catalytic Converter (1) » Remove
127. Catalytic Converter Clamp (2) » Remove and DISCARD
128. Catalytic Converter Gasket (3) » Remove and DISCARD

Engine Mount Replacement - Right Side — figure 68

129. Catalytic Converter Brace Bracket Bolt (2) » Remove [2x]
130. Catalytic Converter Brace Bracket (1) » Remove

Engine Mount Replacement - Right Side — figure 69

Note

Some components not shown for graphic clarity.

131. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
132. Engine Wiring Harness Bracket Bolt (2) » Remove
133. Reposition the engine wiring harness channel (3) away from the front of the engine.

Engine Mount Replacement - Right Side — figure 70

134. Remove the fuel injector wiring harness connector (1) from the engine coolant air bleed bracket.

Engine Mount Replacement - Right Side — figure 71

Note

Some components not shown for graphic clarity. It is not necessary to remove both bolts.

135. Engine Coolant Air Bleed Pipe Bolt - Right Side Upper (1) » Remove

Engine Mount Replacement - Right Side — figure 72

Note

It is not necessary to remove both gaskets.

136. Turbocharger Coolant Feed and Return Pipe Gasket - Right Side Upper (1) » Remove and DISCARD

Engine Mount Replacement - Right Side — figure 73

137. { If equipped } Engine Wiring Harness Ground Bolt (1) » Remove
138. { If equipped } Ground Cable (2) » Position aside

Engine Mount Replacement - Right Side — figure 74

139. Install the EN-36857 Engine Lift Bracket (1) to the front left side of the cylinder head as shown using the EN-51768 Engine Support Fixture Adaptor Bolt - M8 (2).

Engine Mount Replacement - Right Side — figure 75

140. Chassis Front Wiring Harness Bracket Bolt - Rear (1) » Remove
141. Chassis Wiring Harness Front Bracket Retainer (2) » Remove [2x]
142. Chassis Front Wiring Harness Bracket Bolt - Front (3) » Remove
143. Remove the positive battery cable retainers from the chassis wiring harness front bracket.
144. Chassis Wiring Harness (4) » Reposition

Engine Mount Replacement - Right Side — figure 76

145. Working through the wheelhouse opening, remove and DISCARD the 3 engine mount frame side bolts (1).

Caution

When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage.

Note

When raising the engine only raise enough to separate the engine mount from the engine mount bracket. Raising any further will require removal of the fan shroud or the exhaust pipe.

146. Raise the engine with a suitable lifting device to remove the engine mount.

Engine Mount Replacement - Right Side — figure 77

147. Remove and DISCARD the 2 engine mount engine side bolts (1).
148. Disconnect electrical connector at the rear of engine mount.

Engine Mount Replacement - Right Side — figure 78

149. Engine Mount (1) » Remove Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Engine Mount Replacement - Right Side — figure 79

1. Clean the exhaust gas recirculation valve (1).

2. Inspect the exhaust gas recirculation valve (1).

3. Replace the exhaust gas recirculation valve (1) if any damage is found. Installation Procedure

4. Engine Mount (1) » Install

5. Connect electrical connector at the rear of engine mount.

6. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 3.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 3.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 3.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 3.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution

Refer to Fastener Caution.

4. Install and tighten the 2 NEW engine mount engine side bolts (1). Fastener Specifications

5. Lower the engine.

6. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 6.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 6.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 6.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 6.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

7. Install and tighten the 3 NEW engine mount frame side bolts (1). Fastener Specifications

8. Chassis Wiring Harness (4) » Install

9. Install the positive battery cable retainers to the chassis wiring harness front bracket.

10. Chassis Front Wiring Harness Bracket Bolt - Front (3) » Install and tighten — Fastener Specifications

11. Chassis Front Wiring Harness Bracket Bolt - Rear (1) » Install and tighten — Fastener Specifications

12. Chassis Wiring Harness Front Bracket Retainer (2) » Install [2x]

13. Remove the EN-51768 Engine Support Fixture Adaptor Bolt - M8 and the EN-36857 Engine Lift Bracket (1) from the front of the left side cylinder head.

14. Turbocharger Coolant Feed and Return Pipe Gasket - Right Side Upper (1) » Install NEW

Note

Some components not shown for graphic clarity.

15. Engine Coolant Air Bleed Pipe Bolt - Right Side Upper (1) » Install and tighten — Fastener Specifications

16. { If equipped } Ground Cable (2) » Install

17. { If equipped } Engine Wiring Harness Ground Bolt (1) » Install and tighten — Ground Repair

18. Install the fuel injector wiring harness connector (1) to the engine coolant air bleed bracket.

Note

Some components not shown for graphic clarity.

19. Position the engine wiring harness channel (3) to the front of the engine.

20. Engine Wiring Harness Bracket Bolt (2) » Install and tighten — Fastener Specifications

21. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

22. Catalytic Converter Brace Bracket (1) » Install

23. Catalytic Converter Brace Bracket Bolt (2) » Install and tighten [2x] — Fastener Specifications

24. Catalytic Converter Gasket (3) » Install NEW

25. Catalytic Converter Clamp (2) » Install NEW

26. Nitrogen Oxides Catalytic Converter (1) » Install

27. Install hoses and wiring harness as needed.

28. Catalytic Converter Brace Bracket Nut (1) » Tighten [2x] — Fastener Specifications

29. Fuel Cooler Coolant Cooler Inlet Hose » Install

30. Fuel Heater Inlet and Outlet Nut (1) » Install and tighten — Fastener Specifications

31. Catalytic Converter Brace Bracket Nut (1) » Tighten [2x] — Fastener Specifications

Note

Quantity of fasteners may vary based on option content.

32. Catalytic Converter Brace Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

33. { If equipped } Battery Negative Cable Extension Cable Strap (1) @ Catalytic Converter Brace Bracket » Install

34. { If equipped } Catalytic Converter Brace Bracket Nut (2) » Install and tighten — Fastener Specifications

35. Install the exhaust gas recirculation cooler (1).

36. Exhaust Gas Recirculation Cooler Nut (1) » Install and tighten [4x] — Fastener Specifications

37. Connect the electrical connector at exhaust gas recirculation cooler.

38. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket - Upper (4) » Install NEW

39. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket - Lower (3) » Install NEW

40. Exhaust Gas Recirculation Pipe (2) » Install

41. Exhaust Gas Recirculation Cooler Inlet Pipe Bolt (1) » Install and tighten [4x] — Fastener Specifications

42. Exhaust Gas Recirculation Valve Cooler Gasket (2) » Install NEW

43. Install the exhaust gas recirculation valve (1) with the exhaust gas recirculation valve hose.

44. Exhaust Gas Recirculation Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications

45. Heater Inlet Hose Bracket (2) » Install

46. Exhaust Gas Recirculation Valve Bracket Nut (1) » Install and tighten — Fastener Specifications

47. Exhaust Gas Recirculation Pipe Bolt (2) » Install and tighten [2x] — Fastener Specifications

48. Connect the electrical connector (1).

49. Exhaust Gas Recirculation Outlet Pipe Gasket (2) » Install NEW

50. Exhaust Gas Recirculation Pipe (1) » Install

51. Exhaust Gas Recirculation Pipe Nut (1) » Install and tighten — Fastener Specifications

52. Exhaust Gas Recirculation Pipe Nut (1) » Install and tighten — Fastener Specifications

53. Position the exhaust pressure differential sensor bracket (2) into place.

54. Exhaust Pressure Differential Sensor Bracket Stud (1) » Install and tighten [2x] — Fastener Specifications

55. Install the rear engine wiring harness channel (2).

56. Install the 3 rear engine wiring harness channel nuts (1).

Engine Mount Replacement - Right Side — figure 80

57. Exhaust Pressure Differential Sensor (1) » Install

58. Install the exhaust pressure differential sensor (2) to the exhaust gas recirculation cooler by engaging the hose clamp (1). Hose Clamp Replacement Guidelines - Spring Type

59. Install the exhaust pressure differential sensor to the exhaust gas recirculation valve hose by engaging the hose clamp (1). Hose Clamp Replacement Guidelines - Spring Type

Engine Mount Replacement - Right Side — figure 81

60. Exhaust Pressure Differential Sensor (1) » Install

61. Exhaust Pressure Sensor Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

62. Exhaust Gas Recirculation Cooler Inlet Pipe (1) » Install

63. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Install and tighten [2x] — Fastener Specifications

64. Turbocharger Coolant Feed and Return Pipe (4) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

65. Exhaust Gas Recirculation Valve Cooling Return Hose (3) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

66. Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

67. Thermostat Bypass Hose (2) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

68. Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

69. Exhaust Gas Recirculation Cooler Inlet Pipe (5) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

70. Exhaust Gas Recirculation Cooler Outlet Pipe (4) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

71. Heater Inlet Hose (3) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

72. Exhaust Gas Recirculation Coolant Return Pipe (2) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

73. Hose Clamp (1) » Engage [4x] — Hose Clamp Replacement Guidelines - Spring Type

74. Exhaust Gas Recirculation Valve Inlet Gasket (2) » Install NEW

75. Exhaust Back Pressure Valve (1) » Install

76. Catalytic Converter Nut (1) » Install and tighten [3x] — Fastener Specifications

77. Turbocharger Coolant Feed and Return Pipe Gasket (3) » Install NEW

78. Exhaust Gas Recirculation Valve Cooling Return Pipe (2) » Install

79. Exhaust Gas Recirculation Valve Cooling Return Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications

80. Electrical Connector (1) @ Exhaust Back Pressure Valve » Connect

81. Connect wiring harness retainers, as required.

82. Exhaust System Front Gasket (2) » Install NEW

83. Nitrogen Oxides Catalytic Converter (1) » Install

84. Exhaust Front Pipe Nut (1) » Install and tighten [2x] — Fastener Specifications

85. Catalytic Converter Brace Bracket (3) » Install

86. Catalytic Converter Brace Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

87. Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) » Install

88. Exhaust Front Pipe Nut (1) » Install and tighten [2x] — Fastener Specifications

89. Exhaust Pipe Clamp (1) » Tighten — Fastener Specifications

90. Coat the threads of the exhaust particulate sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

Caution

Refer to Component Fastener Tightening Caution.

91. Exhaust Particulate Sensor (1) » Install and tighten — Fastener Specifications

92. Coat the threads with of the nitrogen oxides sensor – position 3 (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

93. Nitrogen Oxides Sensor - Position 3 (1) » Install and tighten — Fastener Specifications

94. Coat the threads with of the nitrogen oxides sensor – position 2 (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

95. Nitrogen Oxides Sensor - Position 2 (1) » Install and tighten — Fastener Specifications

96. Exhaust Gas Temperature Sensor(1) » Install and tighten — Fastener Specifications

97. Front Wheelhouse Liner - Right Side (3) » Install — Front Wheelhouse Liner Replacement

98. Exhaust System Front Gasket (3) » Install NEW

99. Reductant Fluid Injector (2) » Install

100. Emission Reduction Fluid Injector Clamp (1) » Install NEW — Fastener Specifications

101. Exhaust Temperature Sensor - Position 2 (1) » Install — Fastener Specifications

102. Exhaust Temperature Sensor - Position 1 (1) » Install — Fastener Specifications

Engine Mount Replacement - Right Side — figure 82

103. Coat the threads of the nitrogen oxides sensor (2) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

104. Nitrogen Oxides Sensor (2) » Install and tighten — Fastener Specifications

105. Catalytic Converter Clamp (1) » Tighten — Fastener Specifications

106. Turbocharger Heat Shield (1) » Install

107. Turbocharger Heat Shield Nut (2) » Install and tighten — Fastener Specifications

108. Turbocharger Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

109. Exhaust Gas Recirculation Temperature Sensor (2) » Install and tighten — Fastener Specifications

110. Battery Tray (1) » Install

111. Engage all wire harness retainers to the battery tray.

112. Battery Tray Bolt (1) » Install and tighten [7x] — Fastener Specifications

113. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Install NEW

114. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Install NEW

115. Air Conditioning Refrigerant Heat Exchanger (2) » Install

116. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Install and tighten — Fastener Specifications

Engine Mount Replacement - Right Side — figure 83

117. Air Conditioning Refrigerant Heat Exchanger Nut (1) @ Battery Tray » Install and tighten — Fastener Specifications

Engine Mount Replacement - Right Side — figure 84

118. Air Conditioning Compressor and Condenser Hose Seal (5) » Install NEW

119. Air Conditioning Condenser and Evaporator Hose (1) » Install

120. Air Conditioning Condenser and Evaporator Hose Clip (6) » Install

121. Air Conditioning Compressor and Condenser Hose Seal (4) » Install NEW

122. Air Conditioning Compressor and Condenser Hose (3) @ Air Conditioning Refrigerant Heat Exchanger » Install

123. Air Conditioning Compressor and Condenser Hose Nut (2) @ Air Conditioning Refrigerant Heat Exchanger » Install and tighten — Fastener Specifications

124. Engine Wiring Harness Fuse Block Bracket (3) » Install

125. Retaining Tab (1) » Engage

126. Engine Wiring Harness Fuse Block Bracket Bolt (2) » Install and tighten [2x] — Fastener Specifications

127. Electrical Connector (1) » Install [4x]

128. Engine Wiring Harness Junction Block (3) » Install

129. Retaining Tab (1) » Engage [4x]

130. Engine Wiring Harness Junction Block Bolt (2) » Tighten [4x] — Fastener Specifications

131. Starter Solenoid Cable (4) » Install

132. Battery Positive Cable Nut (3) » Install and tighten — Fastener Specifications

133. Engine Wiring Harness Junction Block Cover (2) » Install

134. Retaining Tab (1) » Engage [2x]

135. Battery (1) » Install

136. Battery Hold Down Retainer (2) » Install

137. Battery Hold Down Retainer Bolt (1) » Install and tighten — Fastener Specifications

138. Battery Distribution Engine Compartment Fuse Block (2) » Install

139. Retaining Tab (1) » Engage [3x]

140. Battery Positive Post Clamp Nut (1) » Tighten — Fastener Specifications

141. Electrical Connector (1) » Connect

142. Front Compartment Fuse Block Cover (2) » Install

143. Retaining Tab (1) » Engage [2x]

144. Battery Hold Down Strap (2) » Install

145. 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: 145.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 145.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 145.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 145.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

146. Battery Hold Down Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications

147. Air Cleaner Outlet Duct (2) » Install

148. Air Cleaner Outlet Duct Clamp (1) » Tighten [2x] — Fastener Specifications

149. Air Cleaner Outlet Front Duct (2) » Install

150. Air Cleaner Outlet Duct Clamp (1) » Tighten [2x] — Fastener Specifications

151. Oil Filler Cap » Remove

152. Intake Manifold Cover (2) » Install

153. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

154. Oil Filler Cap » Install

155. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

156. Fill the cooling system to the proper level. Cooling System Draining and Filling

157. Recharge the refrigerant. Refrigerant Recovery and Recharging

158. Inspect the exhaust system for leaks.