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WARNING: Do not run the engine while the protective components are removed. Failure to follow these instructions may result in personal injury. All vehicles 1. Remove the air cleaner assembly. 2. Drain the cooling system. Supercharged vehicles 3. Remove the supercharger degas bottle. All vehicles 4. Remove the front air deflector. 1 Remove the pin-type retainers. 2 Remove the front air deflector. 5. Remove the upper hose from the radiator. 1 Release the clamp. 2 Disconnect the hose. 6. Remove the degas bottle hose from the radiator. 1 Release the hose clamp and slide it away from the end of the hose. 2 Slide the overflow hose off the radiator fitting. 7. Remove the fan blade assembly and fan clutch. 1 Use the fan pulley holding wrench to hold the water pump pulley steady. 2 Use the fan clutch nut wrench to remove the fan blade and the fan clutch. 7. Remove the fan blade assembly and fan clutch. 1 Use the fan pulley holding wrench to hold the water pump pulley steady. 2 Use the fan clutch nut wrench to remove the fan blade and the fan clutch. 9. NOTE: If the lead retaining clip is broken, install a new lead retaining clip. If equipped, disconnect the fan clutch electrical connector and lead retaining clip. 10. Remove the fan blade and fan shroud out of the vehicle together. 11. Remove the bolts and separate the fan blade assembly from the fan clutch. 12. NOTE: To avoid stripping the threads, use the correct bolts when installing a new fan clutch. Use’ bolts 575632-S426 for fan clutch F85A-8A616 and bolts N602548-S426 for fan clutch 2L34-8A616 and 2C64-8A616. To install, reverse the removal procedure.

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No. 1/1 2/1 2/2 2/4 2/5 2/6 2/7 2/11 2/15 2/16 2/17 2/20 2/22 2/23 2/28 2/30 2/32 2/35 2/44 2/46 2/53 2/61 2/66 3/1 3/2 3/3 3/4 3/6 3/7 Component Name Battery Headlight relay with bulb failure sensor Foglight relay Intermittent wiper relay, windshield wipers Relay, seat belt reminder/ignition key warning Overload relay 15I Central lock relay, inside lighting, delayed action Relay, engine cooling fan Relay exhaust temperature sensor Intermittent wiper relay, tailgate wiper Horn relay Relay auto down power windows Automatic climate control A/C relay Relay, fuel pump Anti-theft relay Overload relay, +X Main relay, Fuel Injection system Start motor 50 relay Relay rear window/door mirror heating Relay ignition coil Air pump relay Parking lights relay Relay, fog lights, USA Ignition lock High and low beam switch Switch, turnsignal/high-low beam Cruise control operation Switch, hazard warning with flasher relay Foglight switch

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Cooling Fan Control The purpose of the Electro-Viscous (EV) fan clutch is to maintain powertrain cooling requirements. The Powertrain Control Module (PCM) monitors the following sensors to regulate the fan speed; – Engine coolant temperature sensor – A/C refrigerant pressure sensor – Vehicle speed sensor – Intake air temperature sensor – Transmission fluid temperature sensor – Ambient air temperature sensor The PCM controls the electro-viscous fan clutch engagement. The PCM regulates a 12-volt pulse width modulated signal (PWM) to the cooling fan relay. The PWM signal determines the ON time of the relay. As the commanded state of the fan clutch increases, so does the ON time of the relay. This ON time directly effects the amount of time the solenoid, which is internal to the fan clutch, is energized. When the solenoid in the fan clutch is energized, it opens the spring loaded valve and allows fluid to flow from the storage chamber to the fluid coupling of the cooling fan clutch, increasing the fan speed. When the solenoid is de-energized, the spring loaded valve closes, and blocks the path of the fluid to the fluid coupling of the fan clutch, reducing fan speed. The fan has the ability to create a feedback signal, so the PCM has an actual fan speed input. This is done with a hall effect sensor internal to the fan clutch. The PCM supplies a 5-volt reference and a low reference to the hall effect sensor. The hall effect sensor returns a signal pulse through the cooling fan speed signal circuit in response to the reluctor track passing by the magnetic field of the hall effect sensor. The PCM commands the cooling fan to 100% under the following conditions: – Engine coolant temperature exceeds approximately 129°C (264°F). – The transmission oil temperature exceeds approximately 151°C (304°F). – A/C refrigerant pressure exceeds 1655 kPa (240 psi). – When certain DTC’s set. These include P0116, P0117, P0118, P0125, P1481, P1482, and P1484.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. If servicing the radiator lower fan shroud or the radiator, drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 3. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. If servicing the radiator lower fan shroud or the radiator, fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. Item 9: Lower Degas Bottle Hose Removal Note 1. Remove the lower degas bottle hose from the clip on the radiator lower fan shroud. Item 10: A/C Tube Removal Note 1. On 4.6L engines, detach the A/C tube from the retainers. Item 11: Transmission Cooler and A/C Tubes Removal Note 1. Disconnect the transmission cooler tubes. Remove the safety retainers from the transmission cooler tubes. Using the special tool, disconnect the quick coupler. If equipped, loosen and remove the screw clamp from the hose. 2. Remove the A/C tube brackets from the engine front cover. Item 12: Radiator Fan Shroud Screw Removal Note 1. Not all vehicles will have these radiator fan shroud screws. If vehicle is equipped with these screws, please discard them. Item 15: Cooling Fan Removal Note 1. CAUTION: Cardboard must be placed against the radiator when removing the cooling fan. Failure to follow these procedures can result in damage to the vehicle. Place a piece of cardboard against the radiator to prevent damage while removing the cooling fan. 2. Using the special tools, remove the fan blade and the clutch assembly. Item 17: Radiator Lower Fan Shroud Removal Note 1. Remove the power steering tube from the clip on the radiator lower fan shroud. Item 19: Radiator Bracket Bolt Removal Note 1. If necessary, remove the radiator brackets. Item 21: A/C Condenser Support Bracket Bolt Removal Note 1. If necessary, remove the condenser brackets. Item 22: Radiator Removal Note 1. NOTE: It will be necessary to lift the radiator assembly up off the mounts and set it on the frame in order to separate the A/C condenser from the radiator. NOTE: RH side shown, LH side similar. Remove the radiator up off the mounts and set it on the frame. 2. Remove the left inner air deflector from the A/C condenser.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. If servicing the radiator, drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 3. Remove the parts in the order indicated in the following illustrations and tables. 4. To install, reverse the removal procedure. If servicing the radiator, fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. Item 9: Lower Degas Bottle Hose Removal Note 1. Remove the lower degas bottle hose from the clip on the radiator lower fan shroud. Item 10: A/C Tube Removal Note 1. On 4.6L engines, detach the A/C tube from the retainers. Item 11: Transmission Cooler and A/C Tubes Removal Note 1. Disconnect the transmission cooler tubes. Remove the safety retainers from the transmission cooler tubes. Using the special tool, disconnect the quick coupler. If equipped, loosen and remove the screw clamp from the hose. 2. Remove the A/C tube brackets from the engine front cover. Item 12: Radiator Fan Shroud Screw Removal Note 1. Not all vehicles will have these radiator fan shroud screws. If vehicle is equipped with these screws, please discard them. Item 15: Cooling Fan Removal Note 1. CAUTION: Cardboard must be placed against the radiator when removing the cooling fan. Failure to follow these procedures can result in damage to the vehicle. Place a piece of cardboard against the radiator to prevent damage while removing the cooling fan. 2. Using the special tools, remove the fan blade and the clutch assembly. Item 17: Radiator Lower Fan Shroud Removal Note 1. Remove the power steering tube from the clip on the radiator lower fan shroud. Item 19: Radiator Bracket Bolt Removal Note 1. If necessary, remove the radiator brackets. Item 21: A/C Condenser Support Bracket Bolt Removal Note 1. If necessary, remove the condenser brackets. Item 22: Radiator Removal Note 1. NOTE: It will be necessary to lift the radiator assembly up off the mounts and set it on the frame in order to separate the A/C condenser from the radiator. NOTE: RH side shown, LH side similar. Remove the radiator up off the mounts and set it on the frame. 2. Remove the left inner air deflector from the A/C condenser. 3. Remove the right inner air deflector from the A/C condenser.