Special Tools

1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the headlamp harness. Refer to Sealed Beam Headlamp Replacement .
3. Remove the hood. Refer to Hood Layer Removal .
4. Remove the front bumper. Refer to Front Bumper Replacement .
5. Remove the air cleaner. Refer to the appropriate procedure:

•	Air Cleaner Element Replacement

•	Air Cleaner Element Replacement for the 6.6L engine

•	Air Cleaner Replacement for the 7.2L Caterpillar engine

•	Air Cleaner Replacement for the 7.8L engine

•	Air Cleaner Replacement for the 8.1L engine

6. Remove the charged air cooler hoses. Refer to the appropriate procedure:

•	Charge Air Cooler Replacement for the 6.6L engine

•	Charge Air Cooler Replacement for the 7.2L Caterpillar engine

•	Charge Air Cooler Replacement for the 7.8L engine




7. Remove the radiator support brace bolt and nut from the right and left shock bracket.
8. Remove the surge tank. Refer to Radiator Surge Tank Replacement .
9. Remove the surge tank hose from the fan shroud.
10. Remove the outlet heater hose clamp from the radiator using the J 38185 .
11. Remove the outlet heater hose.
12. Remove the clamp at the radiator inlet using the J 38185 .



13. Remove the radiator inlet hose from the radiator.
14. Remove the clamp at the radiator outlet using the J 38185 .
15. Remove the radiator outlet hose retainers from the fan shroud.
16. Remove the radiator outlet hose from the radiator.



17. Disconnect the evaporator hose coupling (3) from (2).
18. Remove the drive belt. Refer to the appropriate procedure:

•	Drive Belt Replacement for the 6.6L engine

•	Drive Belt Replacement for the 7.2L (Caterpillar) engine

•	Drive Belt Replacement for the 7.8L engine

•	Drive Belt Replacement for the 8.1L engine

19. Disconnect the compressor clutch electrical connector.
20. Disconnect the high pressure switch electrical connector.



21. Remove the compressor mounting bolts (1).



22. Remove the A/C coupling (4) from (2).



23. Remove the retaining nuts (3) from the accumulator retaining bracket.
24. Disconnect the low pressure sensor electrical connector.
25. Remove the accumulator (5) from the bracket.
26. Secure the A/C compressor and the accumulator to the radiator support.
27. Disconnect the auxiliary engine oil cooler hoses. Refer to Engine Oil Cooler Hose/Pipe Replacement .
28. Disconnect the transmission oil cooler lines.
29. Disconnect the auxiliary transmission oil cooler lines from the auxiliary cooler.



30. Disconnect the vacuum hose from the vacuum hose connection (1).
31. Disconnect the electrical connector for the cooling layer.
32. Remove the relay mounted on the fan shroud.



33. Remove the lower radiator support nuts (2).



34. Remove the cooling layer using a suitable lifting device.