REMOVAL & INSTALLATION
8-420 (6.9L), 8-444 (7.3L) Diesel Engines and 8-460 (7.5L) Gasoline Engine
The diesel oil cooler should be disassembled if the cooler O-rings begin to leak.
- Disconnect the batteries' ground cables.
- Remove the radiator fan shroud halves.
- Remove the fan and clutch assembly using tool T83T-6312-A and B, or equivalent.
- Raise and support the front end on jackstands.
- Drain the engine oil and remove the oil filter. Do not install the drain plug.
- Remove the nut attaching the left side engine mount insulator to the frame.
- Slight raise the left side of the engine with a floor jack and place a 1 in. (25mm) wood block between the insulator and the frame. Allow the engine to rest on the block.
- Remove the oil cooler-to-block bolts and lower the cooler from the van.
- Gently rap the front and oil cooler headers to loosen the O-rings. Carefully twist the oil cooler apart.
- Using a suitable solvent, thoroughly clean the oil cooler and the front and filter headers.
- Always use new O-rings when reassembling. Lubricate the new rings and all O-ring mating surfaces with clean engine oil. Install the two narrow O-rings into their respective grooves inside the front and filter headers.
- Place the large O-ring over the oil cooler shell.
- Press the assembly together, making sure the locating clips align with the slots.
- Using new gaskets, install the engine oil cooler.
- Raise the engine, remove the wood block and lower the engine back onto its mount.
- Install the mount washer and nut. Tighten the nut to 80 ft. lbs. (108 Nm).
- Install a new oil filter.
- Install the oil pan drain plug.
- Refill the crankcase and prime the system to fill the cooler.
- Install all other parts in reverse order of removal.