Cooling System - Removal, Replacement and Installation: Other Volvo S60 I

Radiator/charge air cooler (CAC), replacing

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Drain the A/C system. See Refrigerant, draining .

Scheme 13

Remove

1. the engine cooling fan (FC). See «Engine cooling fan (FC), replacing»(ref-415515-S20927006412011081500000)
2. the screws for the air conditioning aggregate on the front cover plate
3. the expansion tank cap.

Removing the front bumper cover

Remove the front bumper cover. See Bumper front, replacing (-2004) or Bumper front, replacing (2005-).

Scheme 14

Remove

1. the air baffle
2. the lower oil cooler hose from the air conditioning aggregate (automatics transmissions only).

Note. Collect the oil from the oil cooler in a container.

Remove the screw for the mounting for the cable duct for engine wiring at the front edge of the sub-frame.

Installing the radiator and the charge air cooler (CAC)

Install

1. the charge air cooler (CAC)
2. radiator
3. the 4 M6 screws
4. the hose for the additional charge air cooler (CAC).

Installing the cooler unit

Place the air conditioning aggregate on the transmission jack and raise it carefully.

Note. Ensure that no cable harnesses or hoses are trapped.

Raise until it is approximately 20 cm from the installed position. Connect the connector to the dryer.

Raise fully and install the 2 M8 screws.

Right-hand side

Install the pipe on the dryer bottle using an M6 screw. Use a new O-ring.

Left side

Install the pipe on the condenser using an M8 screw. Use a new O-ring.

Install

1. the hose on the additional charge air cooler (CAC)
2. the lower radiator hose
3. the lower oil cooler hose (automatics only).

Install

1. the air baffle
2. the air hose between the air cleaner (ACL) housing and the front cover plate
3. the air cleaner (ACL) housing.

Installing the front bumper cover

Install the front bumper cover. See Bumper front, replacing (-2004) or Bumper front, replacing (2005-).

Installing the engine cooling fan (FC)

Install

1. the engine cooling fan (FC). See «Engine cooling fan (FC), replacing»(ref-415515-S20927006412011081500000)
2. the 2 M6 screws for the air conditioning aggregate on the front cover plate.

Finishing

Fill with coolant and run the engine until the thermostat opens. Top up as necessary.

Check the transmission oil level (automatic transmissions only). Top up if necessary.

Filling with refrigerant

Lower the car.

Vacuum pump. See Vacuum pumping .

Fill the A/C system. See Refrigerant, filling .

Check for leaks. See Leak tracing, fluorescent tracing agent / UV lamp or Leak tracing, electronic leak tracer .

Removing the radiator unit

1. Remove the engine cooling fan (FC) according to «Engine cooling fan (FC), replacing»(ref-415515-S40075774602011081500000) .

1. Disconnect the charge air pipe from the charge air cooler (CAC) on the left-hand side (turbocharged engines only). If necessary, use a hot air gun to make removal easier
2. Remove the screws for the radiator unit on the front cover plate.

Scheme 15

Remove

1. the two upper screws holding the radiator unit together
2. the expansion tank cap.

Scheme 16

Block the upper radiator hose with lock grip pliers

Work under the car

Remove

1. the air baffles
2. the lower oil cooler hose from the radiator unit (automatics only)
3. NOTE: Collect the oil from the oil cooler in a container.
4. the screw for the mounting for the cable duct for engine wiring at the front edge of the sub-frame.

Work from above

1. Remove the upper radiator hose. Place it to one side. Seal the openings.

Scheme 17

1. Disconnect the connector from the receiver drier and the cable from the holder
2. Hang up the condenser using tie straps on the right-hand side in the pipe for the receiver drier and on the left-hand side in the pipe for the condenser
3. Remove the lower screws holding the radiator unit.

1. The following requires two people: Disconnect the radiator and the charge air cooler (CAC) firstly from the left and then from the right-hand side by removing the two screws
2. On the right-hand side, press the cable duct and the compressor hose towards the engine. At the same time release the radiator and charge air cooler (CAC) downwards on the right-hand side. Then release the radiator and charge air cooler (CAC) on the left-hand side. Ensure that the mounting for the radiator and charge air cooler (CAC) passes the AC pipe
3. Disconnect the hose from the radiator to the expansion tank
4. Replace the radiator / charge air cooler (CAC).

Installing the radiator and charge air cooler (CAC)

1. Hold the radiator unit and secure the hose from the expansion tank to the radiator
2. Install the connector from the receiver drier and the cable from the holder.

1. Lift up the radiator and charge air cooler (CAC) on the left-hand side. Ensure that the mounting for the charge air cooler (CAC) passes above the AC pipe. Lift the right-hand side while pressing the cable duct and the compressor hose towards the engine
2. Thread the screws for the radiator and charge air cooler (CAC) into the member.

1. Install the lower screws to assemble the radiator unit. Tighten the screws. Tighten to 10 Nm
2. Remove the tie straps
3. Check that the radiator unit is against the rubber seal
4. Tighten the radiator unit to the member. Tighten to 25 Nm .

1. Install the lower radiator hose
2. Remove the lock grip pliers
3. Install the screw for the mounting for the engine wiring cable duct at the front edge of the sub-frame
4. Install the lower oil cooler hose on the radiator unit (automatic gear boxes only).

Install

1. the upper radiator hose. Remove the lock grip pliers
2. the charge air pipe to the charge air cooler (CAC) on the left-hand side (turbocharged engines only).

1. Install the upper screws to assemble the radiator unit. Tighten the screws
2. Tighten to 10 Nm .

1. Install the screws for the radiator unit on the front cover plate
2. Tighten to 10 Nm

To install the engine cooling fan (FC), see Engine cooling fan (FC), replacing .

Topping up the coolant

1. Install the cap on the expansion tank
2. Run the engine until the thermostat has opened
3. Stop the engine. Top up if necessary.

Replacing the radiator / charge air cooler (CAC)

Special tools

9995972

Remove the engine cooling fan (FC) according to Removing the engine cooling fan (FC) .

Disconnect the charge air pipe for the charge air cooler (CAC) on the left-hand and right-hand sides. Fold the hoses out of the way.

Remove the screws for the cooler unit on the front cover plate

Remove

1. the two upper screws holding the air conditioning aggregate together
2. the expansion tank cap.

Block the upper radiator hose with lock grip pliers.

Disconnect the hose from the radiator. Collect the coolant that flows out.

Remove

1. the air baffles
2. the lower oil cooler hose from the cooler unit (automatics only). Protect the hose opening
3. NOTE: Collect the oil from the oil cooler in a container.
4. the screw (1) for the cable harness on the front edge of the sub-frame.

Disconnect the connector from the condenser on the right side. Press the spring to disconnect the connector.

Hang up the condenser using tie straps on the right-hand side in the pipe for the receiver drier and on the left-hand side in the pipe for the condenser.

Remove the lower screws holding the air conditioning aggregate.

HINT: The following procedure requires two people.

Disconnect the radiator and the charge air cooler (CAC) firstly from the left and then from the right-hand side by removing the two screws.

On the right-hand side, press the cable duct and the compressor hose towards the engine. At the same time release the radiator and charge air cooler (CAC) downwards on the right-hand side. Then release the radiator and charge air cooler (CAC) on the left-hand side. Ensure that the mounting for the radiator and charge air cooler (CAC) passes the AC pipe.

Disconnect the hose from the radiator to the expansion tank.

Remove the radiator / charge air cooler (CAC).

Hold the radiator unit. Secure the hose from the expansion tank to the radiator. Use a new clamp.

Check that the 2 plastic nuts are in position on the radiator.

Lift up the radiator and charge air cooler (CAC) on the left-hand side. Ensure that the mounting for the charge air cooler (CAC) passes above the AC pipe. Lift the right-hand side while pressing the cable duct and the compressor hose towards the engine.

Thread the screws for the radiator and charge air cooler (CAC) into the member.

Connect the connector to the right-hand side of the condenser.

Install the lower screws to assemble the air conditioning aggregate. Tighten the screws. Tighten to 10 Nm .

Remove the tie straps.

Check that the air conditioning aggregate is against the rubber seal. Secure.

Tighten the air conditioning aggregate to the member. Tighten to 25 Nm .

Install the lower radiator hose.

Remove the lock grip pliers.

Install the screw for the mounting for the engine wiring cable duct at the front edge of the sub-frame.

Install the lower oil cooler hose on the air conditioning aggregate (automatic transmissions only).

Lower the car.

Installing the screws for the air conditioning aggregate

Install the upper screws to assemble the air conditioning aggregate. Tighten the screws. Tighten to 10 Nm .

Install the screws for the air conditioning aggregate on the front cover plate. Tighten to 10 Nm .

Install

1. the charge air pipe on the left and right-hand sides of the radiator
2. the upper radiator hose.

To install the engine cooling fan (FC), see Installation .

1. Install the cap on the expansion tank
2. Run the engine until the thermostat has opened
3. Stop the engine. Top up if necessary.

See Replacing the radiator / charge air cooler (CAC)

See Replacing the radiator / charge air cooler (CAC)

See Replacing the radiator / charge air cooler (CAC)

See Replacing the radiator / charge air cooler (CAC)

See Replacing the radiator / charge air cooler (CAC)

See Replacing the radiator / charge air cooler (CAC)

Coolant pump, replacing

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Scheme 18

1. Remove the expansion tank cap.

1. Remove the splash guard under the engine
2. Position a container under the engine drain cock. Drain the engine coolant. Avoid skin contact with the coolant.
3. Transfer the container to the radiator draining tap. Drain off the remaining coolant
4. Close the nipples
5. Install the splashguard under the engine.

Scheme 19

Remove

1. the cross stay between the suspension turrets
2. the servo reservoir and the expansion tank and place them on top of the engine. WARNING: Ensure that no power steering fluid is spilled. Extremely flammable.
3. the auxiliaries belt
4. the front timing belt cover.

Raise the car.

1. the right front wheel
2. the nut for the cover in the right fender liner.

Install the upper timing belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.

Turn the crankshaft a further 1/4 of a turn clockwise, then back counter-clockwise until the markings correspond.

Remove the upper timing belt cover.

Scheme 20

Slacken off the belt tensioner.

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw in place. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key.

Unhook the timing belt.

Scheme 21

Remove the screws

1. Tap the pump wheel with the shaft of a hammer and remove the pump
2. Clean the gasket faces thoroughly.

Scheme 22

Install

1. a new gasket
2. a new pump.

Tighten the screws crosswise. Tighten to 17 Nm .

Scheme 23

Install the belt in the following order

1. crankshaft
2. the idler pulley
3. intake camshaft pulley
4. exhaust camshaft pulley
5. water pump
6. belt tensioner.

Scheme 24

This adjustment is carried out on a cold engine. A suitable temperature is approximately 20°C/68°F.

At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The illustration shows the needle position when adjusting the timing belt tensioner at different engine temperatures.

Scheme 25

Tension the timing belt as follows

1. Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
2. Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window
3. Hold the eccentric secure and tighten the center screw. Tighten to 20 Nm .

Check that the indicator is in the correct position.

Scheme 26

Checking markings

1. press the belt to check that the indicator on the tensioner moves easily
2. install the upper timing belt cover
3. turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond
4. also check that the indicator on the belt tensioner is within the marked area.

Reinstall

Reinstall the removed components

1. the upper timing belt cover
2. the front timing belt cover. Tighten to 12 Nm
3. install the auxiliaries belt
4. reinstall the servo reservoir and the expansion tank. Ensure that the hoses are correctly positioned
5. the engine stabilizer brace. Tighten the screws at the suspension turrets. Tighten to 50 Nm . Tighten the screw for the engine bracket. Tighten to 80 Nm
6. the cover in the fender liner
7. the wheel. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Fill the cooling system with Volvo original coolant.

Wipe clean and check the engine compartment.

Checking work

Function test

1. Warm up the engine until the thermostat opens
2. Top up the cooling system if necessary.

Check for leaks.

Replacing the thermostat and/or engine coolant temperature sensor

Special tools

9512885

Removing the engine coolant temperature (ECT) sensor

Remove

1. the upper timing belt cover
2. cable from the sensor
3. the sensor from the thermostat housing. Use socket «9512885»(ref-403953-S00557342822011061000000) .

Note. Put paper underneath the sensor to prevent coolant spillage.

Installing the engine coolant temperature (ECT) sensor

Install

1. the sensor with a new seal
2. Tighten to 22 Nm , use socket «9512885»(ref-403953-S00557342822011061000000)
3. the upper camshaft cover.

Preparation

Remove the cap from the expansion tank.

Install a hose clamp on the upper coolant hose.

Raise the car. Remove the lower splashguard.

Position a container under the engine drain cock. Drain 2 liters of engine coolant.

Close the cock. Install the lower splash guard. Lower the car.

Disconnect the sensor cable connector.

Remove the upper timing belt cover.

Removing the thermostat

Remove

1. the upper timing belt cover
2. the auxiliaries belt.

Remove the delivery pipe from the power steering pump.

Note. Put paper under the generator (GEN) to avoid oil spillage.

Remove

1. the servo pump
2. the connector from the sensor
3. the thermostat housing from the cylinder head.

Replacing the thermostat

Remove the cover and the thermostat.

Install a new thermostat with a new gasket.

Note. Ensure that the thermostat is positioned correctly in the thermostat housing.

Installing the thermostat

Install

1. the thermostat housing. Use a new gasket
2. the connector for the sensor
3. the servo pump
4. the delivery line for the power steering pump
5. the upper timing belt cover.

Remove the hose clip.

Fill with coolant.

Install the cap on the expansion tank.

Test drive the engine until the thermostat has opened.

Check for leakage.

Top up the coolant and oil if necessary.

See Coolant pump, replacing

Thermostat / temperature sensor, engine coolant, replacing

Special tools

9512885

9995722

9997109

9512953

9512957

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 27

Remove

1. the upper timing belt cover. Disconnect the connector for the temperature sensor
2. the temperature sensor from the thermostat housing. Use «9512885»(ref-403953-S00557342822011061000000) .

Note. Put paper underneath the sensor to prevent coolant spillage.

Install

1. the sensor with a new seal. Tighten. See: «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) . Use: «9512885»(ref-403953-S00557342822011061000000)
2. the upper timing belt cover.

Scheme 28

Remove the cap from the expansion tank. Install a hose clamp on the upper coolant hose.

The vehicle must be raised for this work. See: Jacking points, body . Remove the lower cover plate.

Position a container under the engine drain cock. Drain 2 liters of engine coolant.

Close the cock. Install the lower protective panel.

Lower the vehicle.

Scheme 29

Ignition off. Wait for 2 minutes.

Remove the cover over the control module box. Put the cover to one side.

Insert tool 9995722 around the control module.

Move the upper section of the tool backwards as far as it will go. Pull up the tool. Carefully pull up the control module.

For vehicles with automatic transmissions repeat the above work.

Remove the surround from around the control module box.

Scheme 30

Note. Make a note of the routing of the belt.

Remove

1. the auxiliaries belt. Use «9997109»(ref-403953-S16738480202011061000000)
2. the upper timing belt cover.

Scheme 31

Remove the 3 x screws for the power steering pump. Place the power steering pump to one side.

Scheme 32

Remove

1. the hose clamp to the upper radiator hose. Disconnect the hose from the thermostat housing
2. the connector from the temperature sensor
3. the 2 x screws for the thermostat housing at the section against the cylinder head
4. the thermostat housing from the cylinder head
5. the hose clamp for the water hose for heating crankcase ventilation.

Transfer the temperature sensor to the new thermostat housing.

Note. For tightening torques, see: Tightening torque .

Installing the thermostat housing

Install

1. the hose for the water heated crankcase ventilation. Before installing the thermostat housing, use a new hose clamp
2. a new gasket
3. the thermostat housing assembly. Tighten the screws
4. the upper radiator hose. Tighten the hose clamp.

Connect the connector for the temperature sensor.

Note. Ensure that the auxiliaries belt is correctly positioned on all the pulleys.

Install

1. the power steering pump. Tighten the 3 x screws
2. the auxiliaries belt. Use «9997109»(ref-403953-S16738480202011061000000)
3. the upper camshaft cover.

Scheme 33

Install the surround for the control module box.

Carefully press the control module down into the grooves on the inside of the control module box. Press to the limit position

Insert tool 9995722 around the control module.

Move the upper section of the tool forwards as far as it will go. Pull up the tool.

Press the cover into place over the control modules. Check that the air ducts are correctly positioned.

Remove the hose clip. Refill with coolant. Use filling equipment 9512957 and cover 9512953 . Install the cap on the expansion tank.

Test drive the engine until the thermostat has opened. Check for leakage. Top-up the coolant.

See Coolant pump, replacing

See Replacing the thermostat and/or engine coolant temperature sensor

See Coolant pump, replacing

Remove the cap from the expansion tank.

Install a hose clamp on the upper coolant hose.

Raise the car. Remove the lower splashguard.

Position a container under the engine drain cock. Drain 2 liters of engine coolant.

Close the cock. Install the lower splash guard. Lower the car.

Disconnect the sensor cable connector.

Remove the upper timing belt cover.

Remove

1. the thermostat housing cover
2. the thermostat.

Remove the thermostat housing cover.

Clean the thermostat housing mating surfaces. Ensure that there is no dirt left in the thermostat housing.

Remove the sensor.

Install

1. the new thermostat
2. Install the thermostat housing cover. Use a new gasket . Tighten to 17 Nm .

Install

1. the new sensor. Use a new gasket . Tighten to 20 Nm
2. the thermostat housing. Use a new gasket . Tighten to 17 Nm . Connect the sensor cable connector.

Install the upper camshaft cover. Remove the hose clamp.

Fill with coolant.

Install the cap on the expansion tank.

Removing the timing belt

Slacken off the belt tensioner.

Slacken off the belt tensioner center screw slightly.

Hold the center screw secure and turn the eccentric on the tensioner with a 6 mm (0.24") Allen key clockwise to the 10 o'clock position.

Remove the camshaft belt.

Installing the camshaft belt

Install the belt in the following order

1. crankshaft
2. idler pulley
3. intake camshaft pulley
4. exhaust camshaft pulley
5. water pump
6. belt tensioner.

Tension the timing belt

This adjustment is to be made with a cold engine. A suitable temperature is approximately 20°C/68°F.

At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.

The position of the needle when aligning the camshaft belt tensioner at different engine temperatures is shown in the illustration.

Tension the timing belt as follows

1. Carefully turn the crankshaft clockwise until the camshaft belt is tensioned. The belt should be tight between the intake camshaft pulley, idler pulley and crankshaft.
2. Hold the belt tensioner center screw secure and turn the eccentric on the belt tensioner counter-clockwise until the tensioner needle passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
3. Secure the eccentric and tighten the center screw to 20 Nm (14.8 lb.ft) .

Check that the needle is in the correct position.

Check

Checking markings

1. press the belt to check that the indicator on the tensioner moves easily.
2. install the upper timing belt cover.
3. turn the crankshaft 2 turns and check that the markings on the crankshaft and camshaft pulley correspond.
4. also check that the indicator on the belt tensioner is within the marked area.

Reinstall the removed components

1. the upper camshaft belt cover
2. the front camshaft belt cover. Tighten to 12 Nm (8.9 lb.ft)
3. install the auxiliaries belt
4. reinstall the servo reservoir and expansion tank. Ensure that the hoses are correctly positioned
5. the cross member. Tighten the screws at the suspension turret to 50 Nm (36.9 lb.ft) and the screw for the engine bracket to 80 Nm (59.0 lb.ft)
6. the cover in the fender liner
7. the wheel according to «Installing wheels»(ref-445657-S35771726922012010600000) .

Fill the cooling system with Volvo original coolant.

Wipe clean and check the engine compartment.

Function test

1. Warm up the engine so that the thermostat opens.
2. Top up the cooling system if necessary.

Check for leaks.

See Thermostat / temperature sensor, engine coolant, replacing

Replacing the coolant pump

See Replacing the coolant pump

See Replacing the thermostat and/or engine coolant temperature sensor

See Replacing the coolant pump

See Replacing the thermostat and/or engine coolant temperature sensor

See Coolant pump, replacing

See Replacing the thermostat and/or engine coolant temperature sensor

See Coolant pump, replacing

See Thermostat / temperature sensor, engine coolant, replacing

See Coolant pump, replacing

See Replacing the thermostat and/or engine coolant temperature sensor

See Coolant pump, replacing

See Replacing the thermostat and/or engine coolant temperature sensor

Scheme 34

Remove the intake pipe for the air cleaner housing (ACL). Disconnect both the connectors for the engine cooling fan (FC).

Remove

1. The evaporative emission system (EVAP) valve from the engine cooling fan (FC) shroud
2. the hose clamps and charge air pipe/hose on the right-hand side (turbo charged engines only).

Scheme 35

Remove the four tie straps that hold the cable harness secure at the fan shroud.

Note. Certain vehicles have three tie straps and a clip holding the cable harness at the fan shroud.

Lift out the hose for the expansion tank from the holders on top of the fan shroud

Remove

1. the cool box plastic hose from the fan shroud.
2. both the screws holding the fan shroud.

Release the hose for the coolant reservoir from the fan shroud.

Scheme 36

Carefully lower the fan shroud and align with the holders. Route the cable harness behind the holder (3).

Tighten both the mounting screws

Press the hose down from the expansion tank into the holder on the fan shroud

Transfer the clips from two tie-straps to the tie straps that have two catches (1).

Secure the cable harness by the fan shroud using tie straps (1) and (2).

Install

1. the canister purge (CP) valve
2. the hose clamp and charge air pipe/hose on the right-hand side (turbo charged engines only)
3. the intake manifold to the air cleaner (ACL) housing.

Connect the engine cooling fan (FC) connectors.

Scheme 37

Transfer the bracket (1) to the new fan shroud.

Install the connectors for the fan on the bracket using the holder from the service kit (2).

Scheme 38

For vehicles with chassis number according to the table: Replace the cover on the cool box (Engine control module (ECM), Transmission control module (TCM)).

Scheme 39

Apply the decal to the cover of the cool box.

Engine cooling fan (FC), replacing

See Engine cooling fan (FC), replacing

See Engine cooling fan (FC), replacing

See Engine cooling fan (FC), replacing

See Engine cooling fan (FC), replacing

See Engine cooling fan (FC), replacing

See Engine cooling fan (FC), replacing

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Remove

1. the air hose between the air cleaner (ACL) housing and the front cover plate
2. the air cleaner (ACL) housing
3. the charge air pipe over the engine
4. the dip stick.

Scheme 40

Remove the tie straps holding the cables to the fan shroud.

Remove the wiring from the holder on the fan shroud, right-hand side.

Lift out the hose for the expansion tank from the holders on top of the fan shroud.

Disconnect both the engine cooling fan (FC) connectors.

Remove both the screws holding the fan shroud.

Carefully lift up the engine cooling fan (FC).

Scheme 41

Place the engine cooling fan (FC) on a flat surface with the fan pulley downwards.

Remove the three screws.

Expose the cable harness and disconnect the connector.

Lift off the fan shroud.

Note. For tightening torques, see Tightening torque .

Installing the fan shroud

Install

1. the fan shroud
2. the 3 M5 screws for the blower fan motor.

Secure the cable harness with tie straps. Install the connector in the holder on the fan shroud.

Installing the engine coolant fan (FC)

Carefully lower the fan shroud and align it with the holes at the sides of the radiator.

Tighten the 2 M6 mounting screws.

Install the upper oil cooler hose at the radiator unit (automatic transmissions only).

Connect the engine cooling fan (FC) connectors.

Press the hose down from the expansion tank into the holder on the fan shroud.

Secure the wiring to the holder. Use tie straps.

Install

1. the air hose between the air cleaner (ACL) housing and the front cover plate
2. the air cleaner (ACL) housing
3. the charge air pipe over the engine
4. the dip stick.

See Replacing the radiator / charge air cooler (CAC)

See Radiator/charge air cooler (CAC), replacing