Removal

Removal

Warning: Risk of injury to skin and eyes from scalding with hot coolant. Risk of poisoning from swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C (194°F)). Open cap slowly to release pressure. store coolant in suitable and appropriately marked container. Wear protective gloves, clothes and eye wear.

Note: Inspect condition of all clamps and hoses, replace as necessary.

1. Disconnect the negative battery cable.
2. Disconnect the AGM starter negative battery cable located inside the vehicle under the instrument panel near the accelerator pedal.

WARNING: The Absorbent Glass Mat (AGM) starter battery should only be charged and tested with the OTC One Step Battery Analyzer and Charger or equivalent. Never test the AGM battery with a Midtronics Micro 420 battery tester.

3. Remove the air box assembly.
4. Remove the engine cover.
5. Drain the cooling system. Service and Repair






6. Remove the fan and shroud. Service and Repair

Note:The radiator fan assembly is attached (threaded) to the fan pulley (1). Remove the fan blade/viscous fan drive assembly from the fan pulley by turning the mounting nut clockwise as viewed from the front. Threads on the radiator cooling fan are REVERSE THREADED (LEFT-HAND THREAD).

7. Remove the fan drive belt (2). Service and Repair






8. Remove the serpentine belt (1). Service and Repair
9. Remove the oil dipstick retaining bolt.
10. Remove the generator.
11. Remove the lower charge air cooler hose.






12. Remove the EGR airflow valve assembly.
13. Remove water pump retaining bolts, water pump and gasket.