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
- Install the TOC front pipes to the vehicle (through the top of the vehicle).
Finesse the pipes into position.
- Raise the vehicle.
- Remove the caps from the rear of the TOC front pipes and remove the plugs from the junction fittings at the engine flywheel housing.NOTE: Refer to Fastener Notice in Cautions and Notices.
- ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front upper and lower pipe fittings to the junction fittings at the engine flywheel housing.
Tighten: Tighten the transmission oil cooler front upper and lower pipe fittings to the junction at the engine flywheel housing to 27 N.m (20 lb ft).
- Install the TOC front pipe rear retaining clamp and bolt.
Tighten: Tighten the transmission oil cooler front pipe rear retaining clamp bolt to 2.2 N.m (19 lb in).
- Install the TOC front pipe front retaining clamp and bolt.
Tighten: Tighten the transmission oil cooler front pipe front retaining clamp bolt to 12 N.m (106 lb in).
- Install the TOC front pipe front clip.
- Install the right hand engine mount (and bracket). Refer to Engine Mount Replacement - Right in Engine Mechanical - 5.7L.
- Lower the vehicle; leave the vehicle on the hoist.
- Remove the J 41803 and the J 28467-B .
- Install the generator. Refer to Generator Replacement in Engine Electrical.
- Install the A/C compressor bracket. Refer to Compressor Mounting Bracket Replacement in Heating, Ventilation, and Air Conditioning.
- Position the PS gear and cooler to the front suspension crossmember.
- Install the BPMV bracket. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Antilock Brake System.
- Install the PS gear mounting bolts and nuts.
Tighten: Tighten the power steering gear mounting nuts to 100 N.m (74 lb ft).
- Install the PS cooler retaining bolts.
Tighten: Tighten the power steering cooler retaining bolts to 11 N.m (97 lb in).
- Connect the intermediate shaft lower coupling to the PS gear; be sure that the intermediate shaft and the PS gear steering shaft are orientated as marked prior to disconnecting them.
Slide the intermediate shaft lower coupling onto the PS gear steering shaft.
- Install the intermediate shaft lower coupling bolt.
Tighten: Tighten the steering column intermediate shaft lower coupling bolt to 34 N.m (25 lb ft).
- Install the intermediate shaft lower coupling shield.
- Lower the vehicle.
- Remove the tie-off retainer and carefully pivot the AC condenser and the radiator back into position.
- Install the radiator outlet hose to the radiator outlet.
- Using J 38185 , position the radiator outlet hose clamp onto the radiator outlet.
- Install the radiator inlet hose to the radiator inlet.
- Using J 38185 , position the radiator inlet hose clamp onto the radiator inlet.
- Install the surge tank upper hose to the radiator inlet.
- Using J 38185 , position the coolant surge tank upper hose clamp onto the radiator inlet.
- Install the compressor hose to the condenser.
- Using a back-up wrench on the condenser fitting (2), tighten the compressor hose fitting (1) to the condenser.
Tighten: Tighten the fitting to 24 N.m (17 lb ft).
- Connect the front evaporator tube to the condenser.
- Install the front evaporator tube to condenser bolt.
Tighten: Tighten the front evaporator tube bolt to 27 N.m (20 lb ft).
- Install the upper and lower radiator support. Refer to Radiator Support Replacement in Engine Cooling.
- Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
- Connect the upper TOC line to the oil cooler using the following steps:
- Push the TOC pipe into the quick connect fitting, until a click is heard.
- Tug gently in the TOC line to ensure a proper connection.
- Position the plastic retainer over the connection.
- Raise the vehicle.
- Connect the lower TOC line to the oil cooler using the following steps:
- Push the TOC pipe into the quick connect fitting, until a click is heard.
- Tug gently in the TOC line to ensure a proper connection.
- Position the plastic retainer over the connection.
- Lower the vehicle.
- Connect the negative battery cable.
Tighten: Tighten the negative battery cable bolt to 15 N.m (11 lb ft).
- Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
- Recharge the AC system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
- Check the transmission fluid level. Add if necessary.
NO RELATED
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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.