Tools Required

J 38185 Hose Clamp Pliers

1. Install the cooling layer using a suitable lifting device.

Notice: Refer to Fastener Notice in the Preface section.




2. Install the lower radiator support nuts (2).

Tighten
Tighten the nuts to 60 N·m (44 lb ft).




3. Connect the vacuum hose to the vacuum connection (1).
4. Connect the transmission oil cooler lines.
5. Connect the auxiliary transmission oil cooler lines to the auxiliary transmission oil cooler.
6. Connect the auxiliary transmission oil cooler line retaining nuts.

Tighten
Tighten the nuts to 18 N·m (13 lb ft).

7. Connect the auxiliary engine oil cooler hoses. Refer to Engine Oil Cooler Hose/Pipe Replacement .
8. Install the front bumper. Refer to Front Bumper Replacement .



9. Install the accumulator (5) to the bracket.
10. Install the nuts (3) to the accumulator retaining bracket.

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




11. Install the A/C coupling (4) to (2).

Tighten
Tighten the fitting to 45 N·m (33 lb ft).




12. Install the A/C coupling (3) to (2).

Tighten
Tighten the fitting to 35 N·m (26 lb ft).

13. Connect the low pressure sensor electrical connector.



14. Install the compressor (2).
15. Install the compressor mounting bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

16. Connect the compressor clutch electrical connector.
17. Connect the high pressure switch electrical connector.
18. Install the drive belt to the A/C compressor pulley. Refer to the appropriate procedure:

•	Drive Belt Replacement for the 6.6L engine

•	Drive Belt Replacement for the 7.2L (Caterpillar) engine

•	Drive Belt Replacement for the 7.8L engine

•	Drive Belt Replacement for the 8.1L engine




19. Install the radiator inlet hose to the radiator.
20. Install the hose clamp at the radiator inlet housing using the J 38185 .
21. Install the radiator outlet hose to the radiator.



22. Install the radiator hose (2) to the surge tank.
23. Install the radiator hose retainers to the fan shroud.
24. Install the radiator outlet hose clamp to the surge tank using the J 38185 .
25. Install the radiator outlet clamp to the radiator outlet using the J 38185 .
26. Install the outlet heater hose.
27. Install the outlet heater hose clamp using the J 38185 .
28. Connect the surge tank level sensor electrical connector.
29. Fill the cooling system. Refer to Cooling System Draining and Filling .
30. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities .
31. Inspect the engine oil level. Refer to Approximate Fluid Capacities .



32. Install the right and left radiator support brace bolt and nut to the shock bracket.

Tighten
Tighten the bolts to 30 N·m (22 lb ft).

33. Install the charged air cooler hoses. Refer to the appropriate procedure:

•	Charge Air Cooler Replacement

•	Charge Air Cooler Replacement for the 6.6L (LLY) engine

•	Charge Air Cooler Replacement for the 7.2L (Caterpillar) engine

•	Charge Air Cooler Replacement for the 7.8L engine

34. Install the Hood. Refer to Hood Layer Installation .
35. Install the air cleaner. Refer to the appropriate procedure:

•	Air Cleaner Assembly Replacement

•	Air Cleaner Replacement for the 6.6L (LLY) engine

•	Air Cleaner Replacement for the 7.2L (Caterpillar) engine

•	Air Cleaner Replacement for the 8.1L engine

•	Air Cleaner Replacement for the 7.8L engine

36. Install the headlight harness. Refer to Sealed Beam Headlamp Replacement .