32. Reinstall idler/tensioner assembly as a unit on
the new L.H. engine mount #012942.
Mount the idler/tensioner assembly using
three (3) cap screws #5001643

Tighten to 14-17 lb-ft

FIGURE 36

33. Install the new engine mount #012942 using
seven (7) M14 screws saved from the former
engine support with this exception of:
•

Ground stud #012921 (1x) and nylon
insert NYRT nut #5001665 (1X)

•
•

Isolator cap screw #5001940 (2X)
Nut #5001761 (2X)

FIGURE 37

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FIGURE 38: FOUR (4) SCREWS UNDER THE
REINFORCEMENT CHANNEL

FIGURE 39: REAR VIEW – GROUND STUD

FIGURE 40

FIGURE 41

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34. Install the new crank pulley using six new bolts
#5001296. Use blue Loctite on the bolt threads.
Torque to 26 lb-ft in the numerical order 1, 2,
3, 4, 5, 6, 1
Once done perform a final tightening to the
value of 66 lbf-ft.

FIGURE 42

35. Reinstall the water pump drive belt.

FIGURE 43: WATER PUMP DRIVEBELT

36. Reinstall the AC compressor drive belts.
37. Install the idler support #011213 using three (3)
screws #5001799. At the same time, install the
alternator lower bracket #060102.
screws #5001799 prescribed torque:48 lbf-ft

FIGURE 44: BRACKET #060102

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38. Make a smooth round clearance in the engine
cradle to allow required space for the alternator
lower bracket #060102 installed at the previous
step. Carefully work the edge to achieve a
smooth finish and contour.
Measurements: ↔ 2″, ↕¾″
Apply paint to protect the metal against
corrosion

FIGURE 45

39. Install the new idler #012349 with screw
#5001786 and washer #5002008.
Tighten to 59 lb-ft

FIGURE 46

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40. Install the dust cap #453076.

FIGURE 47

FIGURE 48

41. Install the new alternator belt tensioner
#510991. Secure with one screw #5001799 on
which blue Loctite is applied on the threads.

FIGURE 49: TENSIONER MOUNTING SCREW TORQUE : 48
lb-ft

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42. Apply anti-seize compound (Prevost p/n:
680335) inside the alternator mounting ears and
inside the sleeves found on the support attached
to the engine.

FIGURE 50

FIGURE 51

43. Install the alternator.
A: screw #502950 & nut #5001728 (torque: 82 lbfft)
B: screw #5001800 & nut #5001930 (torque:
48lbf-ft)
C: apply blue Loctite and then torque to 48 lbf-ft

FIGURE 52

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Simultaneously, install the alternator “power
cable” support #050266 to the alternator as
shown on the picture.

FIGURE 53

44. Install the alternator pulley #0600265 (for further
details, refer to Maintenance Information IM1617).
Use washer #500449 and flanged nut #21429955
torque: 75 lbf-ft

FIGURE 54

45. Install the alternator drive belt #506026.

FIGURE 55

46. On the alternator, install the stud adapter
#060297 at B1+ stud terminal.
torque: 11 lbf-ft

FIGURE 56

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47. Perform the “Multiplex Modules Disconnection
Procedure Prior to Welding” found in your
vehicle Maintenance Manual, Section 00:
General.
48. Weld the new coolant filter support #050265 on
the engine cradle.
23 ½ inches from the end of the cradle

FIGURE 57

FIGURE 58

FIGURE 59

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FIGURE 60

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49. As a preparation to welding, use a grinder with
abrasive disc to remove some paint to reach
bare metal. Weld the ground stud #380360
centered in the beam and at 14 inches from the
beam end.

FIGURE 61

50. Apply black paint to the area surrounding the
ground stud and the ground stud circular base.
DO NOT apply paint on the electrical contact
surfaces.

FIGURE 62: GROUND STUD #380360

FIGURE 63: GROUND STUD #380360

51. Install a tie mount #509490 with one screw
#502686 at the back of the L.H. engine mount.

FIGURE 64

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52. Install the alternator ground cable #069504.
Secure to the ground stud on the alternator
using washer #502573 and nut #5001182.
torque: 6 lbf-ft
53. Secure the alternator ground cable to the
previously installed tie mount using one nylon tie
#509491.

FIGURE 65

54. Secure the alternator ground cable #069504 to
the previously installed ground stud on the L.H.
engine mount.
Use screw #502719 & washer #5001935
torque: 20 lbf-ft
Protection against corrosion. Apply Color Guard
rubber coating on the ground stud once the
ground cable is hooked up.
FIGURE 66

55. To the previously installed coolant filter support,
install the filter holder recovered from the former
installation.

FIGURE 67

56. Install a new coolant filter onto the filter holder.
Check the clearance between the filter and the
near hose clamps of the coolant pipe leading to
the transmission oil cooler.

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57. Transfer the drain plug and the coolant extractor
quick connect fitting saved from the old radiator
outlet pipe.
Apply Loctite 567 Thread
installation of the fittings

Sealant

prior

58. Install the new radiator outlet pipe #050288.
Reinstall with the flexible hose #053617 and four
(4) hose clamps #992089. Use steel wire to hold
the end of the pipe until the radiator is installed
if required.
A: # 992089 hose clamp (4x); torque: 30 lbf-in

FIGURE 68

B: drain plug
C: coolant extractor quick connect valve
D: # 053617 silicone hose
59. Reinstall the elbow between the copper heater
line and the new radiator outlet pipe.
For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 12.

FIGURE 69

60. Using blue flexible hose #052366, prepare two
new short hoses for the coolant filter.
a) Cut two sections of blue flexible hose, one 22
inches long and a second one, 38 inches long.
A : hose clamp #992081 (4x)
B: banjo fitting copper washer #507657 (6x)
FIGURE 70

b) Use the banjo fittings recovered from the
previous installation.
hose clamp torque: 30 lbf-in

FIGURE 71

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61. Install the 22″ long and 38″ long hoses prepared
at the previous step as shown on the images.

FIGURE 72

FIGURE 73

62. Connect the DEF injector coolant line return
hose to the radiator outlet pipe.
Use two (2) new banjo fitting copper washer
#507657

FIGURE 74: DEF INJECTOR COOLANT LINE RETURN HOSE

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63. Connect the coolant line that comes from the
surge tank to the radiator outlet pipe.

TORQUES:
Constant-Torque with spring washers clamps :
90-100 lbf-in
Oetiker clamps – green spring : 12-18 lbf-in

FIGURE 75

Oetiker clamps – unpainted spring : 8-9 lbf-in
Caillau clamps : 30 lbf-in
64. Secure the coolant hoses together using nylon
ties.

A : nylon tie (handcuff type) #N37749 (about 3 to
6, as required)

FIGURE 76

FIGURE 77

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65. Secure the coolant hose near the engine block
«push-lok» fitting as shown.
B : nylon tie #504016 (1x)

FIGURE 78

66. Hook up the “L.H. alternator power cable”
#23498785 to the alternator (+) terminal which
is the stud adapter.
A: nut M8 #5001983

torque: 11 lbf-ft

B: flat washer #5001341
C: nylon tie #504016 (2x)
D: tie mount #504013 (2x)
E: rivet #504379 (2x)(hole diameter: Ø 13/64)

FIGURE 79

FIGURE 80

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67. Connect the “fan drive ground cable” #069246
to the ground stud previously welded to the
chassis.
A: split lock washer #500482
B: brass nut #500998
C: fan drive ground cable #069246

FIGURE 81

FIGURE 82

68. Apply Color Guard rubber coating on the ground
stud connection.

FIGURE 83: GROUND STUD WITH RUBBER COATING

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69. Apply Color Guard rubber coating at the
alternator ground
connections.

(

)

and

positive

(+)

FIGURE 84: GROUND CONNECTION ON THE ALTERNATOR

FIGURE 85: POSITIVE (+) CONNECTION ON THE
ALTERNATOR

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70. Install a tie mount #509490 at the location
shown on the picture. Secure the tie mount with
a rivet.
A: tie mount #509490
B: rivet #504610 (hole diameter: Ø 17/64)
C: nylon tie #509491
D: fan drive power cable #23498721

71. Secure the “fan drive power cable” #23498721
onto the tie mount using a nylon tie. Make sure
to leave 26 inches long from the tie mount up
to the end of the “fan drive power cable” red
connector.

FIGURE 86

FIGURE 87

FIGURE 88

FIGURE 89

72. Install six (6) tie mounts to secure the “fan drive
power cable” and the “L.H. alternator power
cable” as shown on the picture.

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FIGURE 90
A: tie mount #509490
B: rivet #504610 (hole diameter: Ø 17/64)