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Removal NOTE: Removal of the vertical EGR cooler is not required to service the thermostats. 1. Remove the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section. 2. Remove the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 3. Using a mirror, find the end of the upper radiator hose spring clip. Remove the spring clip, disconnect the upper radiator hose from the thermostat housing and position the upper radiator hose aside. 4. Remove and discard the nut and the vertical EGR cooler lower clamp. 5. Remove the bolt and the vertical EGR cooler lower bracket. 6. NOTE: Vertical EGR cooler removed from art for clarity. Disconnect the wiring from the heater return tube. 7. Remove the 2 bolts and position out the LH heater return tube. • Remove and discard the O-ring seal. 8. NOTE: The 6.4L diesel engine uses 2 thermostats. Remove the 4 bolts, the collar and the thermostat housing. • Lift the bottom of the collar up and rotate toward the engine to remove. 9. NOTICE: If the thermostats are contaminated with engine oil, new thermostats must be installed. Reusing a thermostat that has been exposed to engine oil may result in engine overheating. Remove the thermostats and the gasket from the thermostat housing. • Discard the gasket. Installation 1. Install a new gasket and the thermostats into the thermostat housing. 2. Install the thermostat housing, the collar and the 4 bolts. • Tighten to 13 Nm (115 lb-in). 3. NOTE: Vertical EGR cooler removed from art for clarity. NOTE: Install a new O-ring seal. Install the LH heater return tube and the 2 bolts. • Tighten to 13 Nm (115 lb-in). 4. Connect the wiring to the heater return tube. 5. Position the lower vertical EGR cooler bracket and loosely install the bolt. 6. Install a new vertical EGR cooler lower clamp. Tighten the clamp nut in 3 stages. • Stage 1: Tighten the nut to 10 Nm (89 lb-in). • Stage 2: Loosen the nut 720 degrees (2 complete turns). • Stage 3: Tighten the nut to 8 Nm (71 lb-in). 7. Tighten the lower EGR cooler bracket bolt. • Tighten to 62 Nm (46 lb-ft). 8. Connect the upper radiator hose to the thermostat housing. Install the spring clip. • Verify the spring clip is correctly seated. 9. Install the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 10. Install the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section.

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1. Place the transaxle range selector lever in the PARK position. 2. Remove the engine air cleaner assembly. For additional information, refer to Section 303-12. 3. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Disconnect the battery. For additional information, refer to Section 414-01. 4. Disconnect the electrical connectors. 1. Disconnect the digital transmission range (TR) sensor electrical connector. 2. Disconnect the transaxle electrical connector. 3. Disconnect the wire harness from the bracket. 5. Remove the wiper arm and pivot assembly. For additional information, refer to Section 501-16.6. Remove the front upper radiator shield. 7. Install the special tool. 8. Install the special tool. 9. Install the special tools. 10. Install the special tool. 11. Remove the upper main control cover bolts. 12. Raise and support the vehicle. For additional information, refer to Section 100-02. 13. Remove the LH wheel and tire. For additional information, refer to Section 204-04. 14. Remove the LH transaxle support and insulator. For additional information, refer to Transaxle Support Insulator in this section. 15. Position a drain pan under the transaxle side pan. 16. NOTE: It will be necessary to lower the left side of the subframe to remove the main control cover through the wheel well. Remove the remaining bolts, and remove the main control cover. 17. CAUTION: Do not pull on the wires or the electrical connectors. Damage to the connectors will result. Lift the locking tab and disconnect the electrical connectors. 18. Position the transaxle wiring harness out of the way. 19. CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body and become damaged. CAUTION: Only four of the six bolts need to be removed. Remove the bolts. Note the size and location of the bolts. 20. Disconnect the manual linkage. 21. Remove the main pump assembly and the main control valve body by carefully sliding it off the pump shaft. Installation 1. Install the pump assembly and main control valve body onto the pump shaft. 2. Rotate the pump assembly and main control valve body to connect the manual valve link with the manual valve. 3. CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur. Using the Valve Body Aligner, install the pump assembly and main control valve body. Install the retaining bolt. 4. Install the transaxle wire harness and retaining clip into the separator plate. 5. Connect the electrical connectors.

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Headlamp Assembly NOTE: Make sure the headlamp switch and ignition switch are in the OFF position. 1. To remove individual components, only carry out the following steps. Component Radiator grille opening cover Radiator sight shield Headlamp assembly 2. View 1 of 2. Remove the components in the order indicated in the following illustration and table. 3. View 2 of 2. Remove the components in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. Item 2: Radiator Grille Opening Cover Removal Note 1. Position the ambient air temperature sensor aside. Item 6: Standard Headlamp Disassembly Note 1. To remove individual components, only carry out the following steps. Component Low beam bulb High beam bulb Side marker module 2. Disassemble the components in the order indicated in the following illustration and table. Steps 1-2, 4-5 6-7, 9-10 11-14 3. To assemble, reverse the disassembly procedure. Items 5 and 10: Low and High Beam Bulb Removal Note WARNING: The headlamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. 1. The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp with the bulb removed from the leadlamp. Item 6: HID Headlamp Disassembly Note 1. To remove individual components, only carry out the following steps. Component HID ballast and bulb 1-2, 4-7, 9-11 High beam bulb Side marker module 2. Disassemble the components in the order indicated in the following illustration and table. Steps 12-13, 15-16 17-20

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Installation of this kit requires modifications to the front bumper and removal of the bumper reinforcement. Please check with the owner of the vehicle before installing this kit.2. Removal of Stock Parts Please refer to the factory service manual for the proper removal of stock parts. 2-1 Disconnect the negative terminal of the battery. 2-2 Remove the under carriage cover. 2-3 Remove the front bumper. 2-4 Remove the bumper reinforcement (this will not be reinstalled). 2-5 Remove the stock Intercooler piping. 2-6 Remove the power steering oil cooler. 3. KIT INSTALLATION 3-1 Mount the Intercooler (1) Mount the top bracket of the Intercooler to the horn bracket using the stock bolt. (Parts used #1) (2) Mount the bottom bracket to the radiator core support lower. (Parts used #17) 3-2 Intake Pipe installation (1) Install the intake pipes I-1, I-2 from the turbo outlet side stock piping to the Intercooler. (Parts used #2, 6, 11)

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1/Place vehicle on ramp or axle stands. Open Bonnet/Hood. Remove the 4xT20 torx screws from the top edge of the bumper. Remove the T20 torx screw within each wheelarch. Remove the 2×10mm bolts and the 4 plastic clips that retain the lower edge of the bumper. Remove the front sections of both front wheelarch liners by removing the plastic retaining clips. Once the arch liners are loose you can gain access to the 2×10mm bolts each side that retain the bumper to the front wing/fender. Disconnect the fog light connections either side and lift the whole front bumper section clear. See pictures below. 2/ Remove the plastic grille on the upper right of the engine bay by turning the 2 slots through 90 degrees to the right. Remove both complete headlamps, these are retained by 3×10mm screws and the single electrical connection to each headlight. 3/ Remove the 2×13mm bolts at the top of the radiator panel as shown below. Loosen the 2x hose clips at the top of the convoluted hoses from the intercooler. Completely remove the 2 plastic air pipes located on top of the engine (the 2 leading to the intercooler hoses) by removing the 2×10mm bolts that retain each pipe. Remove the single air conditioning pipe bracket on the lower left as you look at the front of the car (see picture below). Push the top intercooler retaining clip through the radiator panel so the top edge of the intercooler is free. Disconnect the single electrical connection to the intercooler fan system. Remove the crash bar by removing the 6×13mm bolts. Lift the radiator panel slightly upwards and forwards so it is free from the locators. Now lift the intercooler upwards and o ut from the engine bay (you may need help here to lift both the radiator panel and the intercooler from its location at the same time) Be careful not to damage the small bore water overflow pipes that run just behind the intercooler.