Engine Auxiliary Radiator Replacement (LM2)
Removal Procedure
  1. Drain the charge air cooling system.Charge Air Cooling System Draining and Filling

    2. Object ID: 5537676
  2. Front Bumper Fascia(2)»Remove—Front Bumper Fascia Removal and Installation

    3. Object ID: 5607471
  3. Radiator Inlet Hose Clamp(1)»Disengage—Hose Clamp Replacement Guidelines - Spring Type
  4. Auxiliary Radiator Inlet Hose(2)@Engine Auxiliary Radiator»Remove

    5. Object ID: 5520779

    Note: Left side shown, right side similar.

  5. Remove the 6 right and left side headlamp bolts (1).

    6. Object ID: 5520782

    Note: Left side shown, right side similar.

  6. Remove the 6 right and left side headlamp bolts (1).

    7. Object ID: 5520784

    Note: Left side shown, right side similar.

  7. Release the front headlamp guide pins from the front bumper fascia guides (1).
  8. Remove the right and left side headlamps (2).
  9. Release the wiring harness retaining tabs.
  10. Disconnect all electrical connectors.

    11. Object ID: 5544167
  11. Loosen the left and right side front bumper fascia upper stiffener nut (1).
  12. Remove the left and right side front bumper fascia upper stiffener bolt (2).

    13. Object ID: 5544169
  13. Pull the front bumper fascia upper stiffener (1) up and out over the stud.
  14. Disconnect the electrical connector and reposition wiring harness.

    15. Object ID: 5548894
  15. Front Bumper Shutter Bolt(1)»Remove[9x]
  16. Front Bumper Shutter(2)»Remove

    17. Object ID: 5517058
  17. Radiator Air Side Baffle Retainer(1)»Remove[2x]
  18. Radiator Air Side Baffle(2)»Reposition

    19. Object ID: 5157388
  19. Charge Air Cooler Coolant Hose Clamp(1)»Disengage—Hose Clamp Replacement Guidelines - Spring Type
  20. Charge Air Cooler Coolant Hose(2)@Engine Auxiliary Radiator»Remove

    21. Object ID: 5160909
  21. Auxiliary Radiator Bracket Bolt(1)»Remove[4x]
  22. Auxiliary Radiator Bracket- Right Side(2)»Remove

    23. Object ID: 5160910
  23. Auxiliary Radiator Bracket Bolt(1)»Remove[4x]
  24. Auxiliary Radiator Bracket- Left Side(2)»Remove

    25. Object ID: 5517051
  25. Front Bumper Shutter Bolt(1)»Remove
  26. Front Bumper Shutter Bracket(2)»Remove

    27. Object ID: 5572426

    Note: Some components not shown for graphic clarity.

  27. Front End Sheet Metal Diagonal Brace Bolt- Left Side and Right Side(1)»Remove[4x]
  28. Front End Sheet Metal Diagonal Brace- Left Side and Right Side(2)»Remove[2x]

    29. Object ID: 5788027
  29. Disconnect the electrical connector.
  30. Horn Nut(1)»Remove
  31. Horn(2)»Remove

    32. Object ID: 5160911
  32. Engine Auxiliary Radiator(1)»Remove
Installation Procedure

    Object ID: 5160911
  1. Engine Auxiliary Radiator(1)»Install

    2. Object ID: 5788027
  2. Horn(2)»Install

    3. Caution: Refer to Fastener Caution.

  3. Horn Nut(1)»Install and tighten—Fastener Specifications
  4. Connect the electrical connector.

    5. Object ID: 5572426
  5. Front End Sheet Metal Diagonal Brace- Left Side and Right Side(2)»Install[2x]
  6. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  7. Front End Sheet Metal Diagonal Brace Bolt- Left Side and Right Side(1)»Install and tighten[4x]—Fastener Specifications

    8. Object ID: 5517051
  8. Front Bumper Shutter Bracket(2)»Install
  9. Front Bumper Shutter Bolt(1)»Install and tighten—Fastener Specifications

    10. Object ID: 5160910
  10. Auxiliary Radiator Bracket- Left Side(2)»Install
  11. Auxiliary Radiator Bracket Bolt(1)»Install and tighten[4x]—Fastener Specifications

    12. Object ID: 5160909
  12. Auxiliary Radiator Bracket- Right Side(2)»Install
  13. Auxiliary Radiator Bracket Bolt(1)»Install and tighten[4x]—Fastener Specifications

    14. Object ID: 5157388
  14. Charge Air Cooler Coolant Hose(2)@Engine Auxiliary Radiator»Install
  15. Charge Air Cooler Coolant Hose Clamp(1)»Engage—Hose Clamp Replacement Guidelines - Spring Type

    16. Object ID: 5517058
  16. Radiator Air Side Baffle(2)»Install
  17. Radiator Air Side Baffle Retainer(1)»Install[2x]

    18. Object ID: 5548894
  18. Front Bumper Shutter(2)»Install
  19. Front Bumper Shutter Bolt(1)»Install and tighten[9x]—Fastener Specifications
  20. Connect the electrical connectors and install wiring harness.

    21. Object ID: 5544169
  21. Front Bumper Fascia Upper Stiffener(1)»Install

    22. Object ID: 5544167
  22. Install and tighten the left and right side front bumper fascia upper stiffener bolt (2). Fastener Specifications
  23. Tighten the left and right side front bumper fascia upper stiffener nut (1).Fastener Specifications

    24. Object ID: 5520784

    Note: Left side shown, right side similar.

  24. Connect all electrical connectors.
  25. Secure the wiring harness retaining tabs.
  26. Install the right and left side headlamps (2).
  27. Secure the front headlamp guide pins to the front bumper fascia guides (1).

    28. Object ID: 5520782

    Note: Left side shown, right side similar.

  28. Install the 6 right and left side headlamp bolts (1). Fastener Specifications

    29. Object ID: 5520779

    Note: Left side shown, right side similar.

  29. Install the 6 right and left side headlamp bolts (1). Fastener Specifications

    30. Object ID: 5607471
  30. Auxiliary Radiator Inlet Hose(2)@Engine Auxiliary Radiator»Install
  31. Radiator Inlet Hose Clamp(1)»Engage—Hose Clamp Replacement Guidelines - Spring Type

    32. Object ID: 5537676
  32. Front Bumper Fascia(2)»Install—Front Bumper Fascia Removal and Installation
  33. Fill the charge air cooling system.Charge Air Cooling System Draining and Filling
  34. Start the engine and check for coolant leaks.