22-42

Oil Pan con't





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





23. Remove the primary accessory drive belt.





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





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





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





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

Vehicles with single generator





28. Remove the primary accessory drive belt.

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 at the coolant pump.





34. Remove the fan shroud mounting stud.





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





36. 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-FO70-6, handle 303-FO70-8, bracket 303-FO70-7 and washer 303-FO70-12004.

Install the special tool.

37. NOTE: The engine must be raised evenly.

Using a lifting crane, raise the engine until the turbo charger is about to touch the cowl. Secure the engine with the special tool.





38. Remove the transmission cooler line bracket.





39. Remove the bolts and position back the oil pan until the oil pick-up tube bolts are accessible.





40. Remove the bolts and let the oil pick-up tube go into the oil pan. Remove the oil pan.





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





42. Remove and discard the oil pick-up tube O-ring.

Installation

All vehicles





1. Install a new O-ring on the oil pick-up tube and position the oil pick-up tube in the oil pan.





2. Install a new press-in-place gasket into the upper oil pan.
3. Position the oil pan in the vehicle.





4. Install the oil pick-up tube and bolts.





5. Position the oil pan and install the bolts.





6. Install the transmission cooler tube bracket and nut.





7. Using the special tool, lower the engine.





8. NOTE: RH side shown, LH similar.

Remove the lifting eyes and the special tool.





9. Install the fan shroud mounting stud.





10. Connect the heater hose at the coolant pump.





11. Install the retaining bolt for the fuel lines.





12. If removed, install the ball studs. Connect the hood lifts and remove the hood support.





13. Position the primary generator and install the bolts.

Vehicle with single generator





14. Install the primary accessory drive belt.

Vehicle with dual generators





15. Install the secondary generator with mounting bracket and bolts.





16. Connect the B+ wire, secondary generator electrical connector and wire retainer.





17. Install the primary accessory drive belt tensioner and bolts.





18. Position the secondary accessory drive belt idler pulley. Install the bracket and bolts.





19. Install the primary accessory drive belt.





20. Install the secondary accessory drive belt tensioner and bolt.





21. Install the secondary accessory drive belt.

All vehicles





22. Install the stator and stator bolts.





23. Install the cooling fan clutch. Use the special tool to tighten the cooling fan clutch.





24. Position and clip the cooling fan wiring. Connect the cooling fan electrical connector.
25. Install the radiator and shroud as an assembly.





26. Connect the upper radiator hose and the radiator overflow hose.





27. Position the harness wiring, install the 2 wiring retainers and 3 pin-type retainers.





28. Position the sight shield and install the 4 pin-type retainers.





29. Install the radiator support brackets.

Vehicles with metal ducts





30. Install the charge air cooler duct and tighten the clamps.

Vehicles with blow molded ducts





31. Install the charge air cooler duct and tighten the clamps.

All vehicles
32. Install the air cleaner assembly. Refer to Fuel Delivery and Air Induction.





33. Connect the transmission cooler tubes.





34. Close the radiator draincock. Connect the lower radiator hose.





35. NOTE: LH side shown, RH side similar.

Install the motor mount retaining nuts.





36. Tighten the exhaust pipe retaining nuts.





37. Clean and inspect the oil pan drain plug and gasket, install new if necessary.





38. Install the oil pan drain plug.
39. Connect the LH and RH negative battery cable.
40. Fill the engine with clean engine oil.
41. Fill the coolant system.
42. Run the engine and check for leaks.