Removal

Oil Pan-Lower





Special Tool(s)





Material

Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the LH and RH battery ground cables.





3. WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or result in personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When certain all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions can result in personal Injury.
CAUTION: The coolant must be removed in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly and the system filled with new coolant.

NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement.

Place a suitable container below the radiator draincock and drain the cooling system.
4. Remove the fill cap from the degas bottle.
5. Remove the oil pan drain plug and drain the engine on.





6. Loosen the exhaust pipe retaining nuts.





7. NOTE: RH shown, LH similar.

Remove the motor mount retaining nuts.





8. Disconnect the lower radiator hose.





9. Disconnect the transmission cooler tubes.
10. Remove the air cleaner assembly.





11. NOTE: Charge air cooler (CAC) side shown, engine side similar.

Loosen the clamps and remove the CAC ducts.





12. Remove the radiator support brackets.





13. Remove the 4 pin-type retainers and pull back the sight shield.





14. With the sight shield pulled back, remove the 3 pin-type retainers and the 2 wiring retainers and position the harness rearward out of the way.





15. Disconnect the upper radiator hose and the radiator overflow hose.
16. Remove the radiator and shroud as an assembly.





17. Disconnect the cooling fan electrical connector. Unclip and position the fan and wiring aside.





18. NOTE: Use a hole in the fan hub to prevent the fan from turning.

Using the special tool, loosen the fan clutch. Remove the cooling fan.





19. Remove the bolts from the stator, remove the stator.

Vehicles with dual generators





20. Remove the secondary accessory drive belt.





21. Remove the bolt and the secondary accessory drive belt tensioner.





22. Remove the primary accessory drive belt.





23. Remove the bolts, bracket and secondary accessory drive belt idler pulley.





24. Remove the bolts and the primary accessory drive belt tensioner.





25. Disconnect the wire retainer, secondary generator electrical connector and B+ wire.





26. Remove the bolts and the secondary generator with mounting bracket.

Vehicles with single generator





27. Remove the primary accessory drive belt.





28. Remove the bolts and the primary accessory drive belt tensioner.

All vehicles





29. Remove the bolts and position the generator back.





30. Support the hood and disconnect the hood lift assemblies.





31. Install two lifting eyes on the RH cylinder head.





32. Remove the retaining bolt for the fuel lines.





33. Disconnect the heater hose from the front cover and position aside.





34. Install one lifting eye on the LH cylinder head.





35. CAUTION: Do not use the special tool to raise the engine. Damage to the special tool or vehicle may occur.

NOTE: The ball studs may have to be removed.

NOTE: This procedure requires a second bolt hook assembly. The tools are available through Rotunda tools with the following numbers: bolt hook 303-F070-6, handle 303-F070-8, bracket 303-F070-7 and washer 303-F070-12004.

Install the special tool.

36. NOTE: The engine must be raised evenly.

Using a lifting crane, raise the engine until the turbocharger is almost touching the cowl. Secure the engine with the special tool.





37. Remove the transmission cooler line bracket.





38. NOTE: The oil pan bolts must be reinstalled in their original positions. Mark the location of the longer bolts to aid in installation.

Remove the bolts and position back the oil pan until the oil pickup tube bolts are accessible.





39. Remove the bolts and let the oil pickup tube go into the oil pan. Remove the oil pan.





40. Remove the press-in-place gasket and discard.
^ Clean and inspect the sealing surfaces.





41. Remove and discard the oil pickup tube O-ring seal.