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56. Install the new alternator belt tensioner
#510991. Secure with one (1) screw #5001799
on which blue Loctite is applied on the threads.

FIGURE 66: TENSIONER MOUNTING SCREW TORQUE : 48
lb-ft

57. 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 67

FIGURE 68

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

FIGURE 69

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

FIGURE 70

59. 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 71

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60. Install the alternator drive belt #506026.
NOTE: Use belt #506080 instead if the
original crank pulley is still in place (vehicle
equipped with a trailer hitch).

FIGURE 72

61. Remove former belt routing decal and replace
with decal #010060.

FIGURE 73

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

FIGURE 74

63. Perform the “Multiplex Modules Disconnection
Procedure Prior to Welding” found in your
vehicle Maintenance Manual, Section 00:
General.
64. Weld the new coolant filter support #050265 on
the engine cradle.
23 1/2 inches (597 mm) from the end of the cradle

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FIGURE 75

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FIGURE 76

FIGURE 77

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65. As a preparation for welding, use a grinder
with abrasive disc to remove some paint to
reach bare metal. Weld the ground stud
#380360 centered on the beam, at 16 inches
(406 mm) from the vertical member beam end.

FIGURE 78

FIGURE 79

66. 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 80: GROUND STUD #380360

FIGURE 81: GROUND STUD #380360

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

FIGURE 82

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

FIGURE 83

70. 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 84

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

FIGURE 85

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72. Install the new coolant filter included in the kit
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.
73. 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

74. Install the new radiator outlet pipe #050331.
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 86

B: drain plug
C: coolant extractor quick connect valve
D: # 053617 silicone hose
75. Connect the elbow between the copper heater
line and the new radiator outlet pipe.
A: #992086 hose clamp (1x)
For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 14.

FIGURE 87

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76. Using blue flexible hose #052366, prepare two
new short hoses for the coolant filter.
a) Cut two sections of blue flexible hose, one 13
inches long and a second one, 27 inches
long.
b) Use the banjo fittings recovered from the
previous installation.
A : hose clamp #992081 (4x)
B: banjo fitting copper washer #507657 (6x)

FIGURE 88

hose clamp torque: 30 lbf-in

FIGURE 89

77. Install the” 13″ and 27″ long hoses prepared at
the previous step as shown on the images.

FIGURE 90

FIGURE 91

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78. Secure the 24″ long hose as shown on the
image.
A : nylon tie # 509491

FIGURE 92

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

FIGURE 93: DEF INJECTOR COOLANT LINE RETURN HOSE

80. Connect the coolant line that comes from the
surge tank to the radiator outlet pipe. Use one
(1) hose clamp #992086.

TORQUES:
Caillau clamps : 30 lbf-in

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FIGURE 94

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81. Secure the coolant hoses together using the
following hardware.
A : nylon tie # 509491 (2x)
B:swivel mount #504751 (1x)

FIGURE 95

82. Secure the coolant hoses together using nylon
ties.
A: « handcuff » nylon tie #N37749 (2x)

FIGURE 96

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83. Hang the engine intake pipe #050308 in place.

FIGURE 97

FIGURE 98: ENGINE INTAKE PIPE SUPPORT

FIGURE 99: PIPE SUPPORT

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84. Reinstall the intake elbow and adapter. Use the
following hardware:
A: V-band clamp #20592783 (2x)
B: Gasket #1675066 (2x)

FIGURE 100: ENGINE INTAKE PIPE SUPPORT

FIGURE 101

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85. Connect the new CAC outlet pipe #050308 to
the engine intake elbow.
A: #030096 hose (1x)
B: #21490630 spring loaded clamp (2X)

FIGURE 102

Constant Torque hose clamp 4.25″ - charge air
cooler (CAC)
4.5-5.5 lbf-ft

FIGURE 103: CONNECTION AT THE ENGINE INTAKE
ELBOW

86. Reinstall the pipe (item A) section located
downstream the engine air filter. Connect the
air compressor fresh-air inlet pipe (item B)
connected to pipe A.

FIGURE 104

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87. Reinstall the exhaust pipe section located
between the DPF and the flexible section. Use
the following hardware:
•

V-band clamp #21021850 (2x)

•

Gasket #21095726 (2x)

FIGURE 105: REINSTALL THIS EXHAUST PIPE SECTION

88. Pre-install the new radiator inlet pipe #050309.
A: #052889 silicone hose
B: # 992089 hose clamp (4x); final torque: 30
lbf-in

FIGURE 106

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89. Install seven (7) nylon tie mounts centered
on the beam, as shown in the picture. Drill Ø
¼″. Use the following hardware:
•

Tie mount #509490 (7x)

•

Rivet #504610 (7x)

Spacing between each tie mount: around 6 ½″

FIGURE 107

FIGURE 108

FIGURE 109

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90. Install five (5) nylon tie mounts as shown in
the picture. Drill Ø ¼″. Use the following
hardware:
Tie mount #509490 (5x)
Rivet #504610 (5x)

•
•

FIGURE 110

FIGURE 111

FIGURE 112: TIE MOUNT 3 & 4 SHALL NOT BE PLACED
BETWEEN THE BULKHEAD AND THE VALVE COVER.

91. On the bracket shown on the image, drill a hole
of Ø 11/32″ and then install a nylon tie with fir
tree mount #504750.

FIGURE 113: BRACKET ON THE ENGINE HOT SIDE

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92. Hook up the “L.H. alternator power cable»
#060682 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)

FIGURE 114

FIGURE 115

93. Secure the alternator power cable to the tie
mounts previously installed using nylon ties:
nylon tie #509491 (7x)

•

FIGURE 116

FIGURE 117

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94. On the diagonal member located under the
previously welded ground stud, install a nylon tie
mount. Use:
Tie mount #509490 (1x)
Rivet #504610 (1x)

•
•

FIGURE 118

95. Partially install the “fan drive power cable”
#0610563. Secure to the tie mount using a nylon
tie. Keep the nylon tie loose.
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
A: nylon tie #509491 (1x)
B: fan drive power cable #0610563

FIGURE 119

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96. Install the “fan drive ground cable” #069246 and
connect to the ground stud previously welded to
the chassis.
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
A: fan drive ground cable #069246
B: fan drive power cable #0610563

FIGURE 120

C: split lock washer #500482 + brass nut #500998
D: tie mount #509490 (1x) + rivet #504610 (1x) +
nylon tie #509491 (1x)
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT

FIGURE 121

A: fan drive ground cable #069246
B: fan drive power cable #0610563