ENGINE OIL COOLER (w/o EGR Cooler) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)


    1. Remove the 4 bolts and under cover.

  2. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)


    1. Remove the 2 bolts and under cover.

  3. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil drain plug, and drain the engine oil from the oil pan.

      Note

      Collect the oil in an oil disposal container.

  4. LOOSEN FUEL TANK ASSEMBLY

  5. DRAIN FUEL

  6. REMOVE MANIFOLD STAY

    A01E1L4E01

    1. Remove the 2 bolts and stay.

  7. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY


    1. Remove the bolt and gauge.

    2. Remove the O-ring from the gauge.

  8. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Remove the engine oil level dipstick.

    2. A01DW6AE01

      Remove the bolt and clamp.

    3. Remove the bolt and engine oil level dipstick guide.

    4. Remove the O-ring engine oil level dipstick guide.

    5. A01E03WE03

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  9. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A01E30RE05

      Remove the bolt and No. 2 injection pipe clamp.

    2. Remove the 2 nuts and No. 3 injection pipe clamp.

    3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  10. REMOVE NO. 4 INJECTION PIPE


    1. A01E0ZRE01

      Remove the 2 bolts.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01E2XGE01

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  11. REMOVE OIL FILTER SUB-ASSEMBLY


    1. Check and clean the oil filter installation surface.

    2. Apply clean engine oil to the gasket of a new oil filter.

    3. Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.

    4. A01DY82E01

      Using SST, tighten the oil filter. Depending on the work space available, choose from the following.

      SST
      09228-07501

      1. If enough space is available, use a torque wrench to tighten the oil filter.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      2. If enough space is not available to use a torque wrench, tighten the oil filter 3/4 turn by hand or with a common wrench.

  12. REMOVE STARTER ASSEMBLY


    1. A01DYLE

      Disconnect the starter connector.

    2. Remove the nut and disconnect the starter wire.

    3. A01DXY7

      Remove the nut, bolt, and disconnect the ground cable.

    4. Remove the starter.

  13. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    A01DW6AE01

    1. Remove the bolt and clamp.

    2. Remove the 2 bolts and oil level gauge guide.

    3. A01E03WE07

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

    4. A01DYSWE01

      Disconnect the 2 fuel hoses.

    5. A01DXJEE01

      Disconnect the 2 connectors.

    6. A01E0LPE01

      Remove the 4 bolts indicated by the arrows in the illustration.

    7. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    8. A01E0MBE02

      Remove the set nut and O-ring while holding the crankshaft pulley by using SST.

      SST
      09213-58013
      09330-00021
    9. A01E141E01

      Loosen the 2 nuts.

    10. A01DVLSE01

      Using SST, disconnect the pump from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    11. Remove the 2 nuts and pump.

      Note


      • Do not hold the pump or carry it holding the pipe.

      • The pump must be kept horizontal.

    12. Remove the O-ring.

  14. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the fuel pressure sensor connector and pressure discharge valve connector.

    2. A01E2QU

      Remove the 2 bolts and common rail.

      Note

      Do not remove the fuel pressure sensor and pressure discharge valve.

  15. REMOVE OIL COOLER COVER SUB-ASSEMBLY

    A01E05LE01

    1. Disconnect the oil pressure switch connector and wire harness.

    2. Remove the 13 bolts, 2 nuts and oil cooler cover.

  16. REMOVE OIL COOLER ASSEMBLY


    1. Loosen the 4 nuts first.

    2. Partially tap out the oil cooler by tapping each nut head with a plastic-faced hammer.

    3. Remove the 4 nuts, oil cooler and 2 gaskets.