1-21

Oil Pan





Special Tool(s)





Material

Removal

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Maintenance/Service and Repair.
2. Disconnect the negative battery cable. Refer to Battery.

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. If equipped, disconnect the coolant return hose at the fluid cooler.
4. Remove the fill cap from the degas bottle.





5. Remove the oil pan drain plug and drain the engine oil.





6. Loosen the exhaust pipe retaining nuts.





7. NOTE: LH shown, RH similar.

Remove the motor mount retaining nuts.





8. Open the radiator draincock. Disconnect the lower radiator hose.





9. Disconnect the transmission cooler tubes.
10. Remove the air cleaner assembly. Refer to Fuel Delivery and Air Induction.

Vehicles with metal ducts





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

Remove the charge air cooler duct.

Vehicles with blow molded ducts





12. NOTE: Engine side shown, charger air cooler side similar.

Loosen the clamps and remove the charge air cooler duct.

All vehicles





13. Remove the radiator support brackets.





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





15. 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.





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





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





19. 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.





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

Vehicles with dual generators





21. Remove the secondary accessory drive belt.