Generator Cooler Lines Replacement Outlet

1. Partially drain the engine coolant. Refer to Cooling System Draining and Filling .



2. Remove the two nuts (2) from the intake manifold sight shield (1).
3. Remove the sight shield (1) from the engine.



4. Remove the PCV fresh air tube (1).



5. Disconnect the generator cooler outlet hose from the pipe (1).



6. Disconnect the generator cooler hose (2) from the heater pipe (3).
7. Remove the two push nuts (1) attaching the generator cooler pipe assembly to the engine.
8. Remove the generator cooler pipe assembly from the engine.
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
10. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.



11. Disconnect the generator cooler outlet hose (1) from the generator (3).
12. Remove the generator cooler outlet hose retaining bolt (2).
13. Remove the generator cooler outlet hose (1) from the vehicle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the generator cooler outlet hose retaining bolt (2) to the generator (3).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

2. Connect the generator cooler outlet hose (1) to the generator (3).
3. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
4. Lower the vehicle.



5. Install the generator cooler pipe assembly to the engine.
6. Install the two push nuts (1) attaching the generator cooler pipe assembly to the engine.
7. Connect the generator cooler hose (2) to the heater pipe (3).



8. Connect the generator cooler outlet hose to the pipe (1).



9. Install the PCV fresh air tube (1).



10. Position the intake manifold sight shield (1) to the engine.
11. Install the two intake manifold sight shield nuts (2).

Tighten
Tighten the nuts to 3 N·m (27 lb in).

12. Fill the cooling system. Refer to Cooling System Draining and Filling .

Generator Cooler Lines Replacement Inlet

Tools Required

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



4. Separate the radiator half of the generator cooler inlet hose (2) from the generator half of the generator cooler inlet hose (3).



5. Position the J 38185  (3) to the clamp in order to remove the generator cooler inlet hose (2) from the radiator (1).



6. Disconnect the generator cooler inlet hose (2) from the generator (1).
7. Remove both hoses from the vehicle.

1. Connect the generator cooler inlet hose (2) to the generator (1).



2. Position the J 38185  (3) to the clamp in order to connect the generator cooler inlet hose (2) to the radiator (1).



3. Connect the radiator half of the generator cooler inlet hose (2) to the generator half of the generator cooler inlet hose (3).
4. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
5. Lower the vehicle.
6. Fill the cooling system. Refer to Cooling System Draining and Filling .