ENGINE OIL COOLER (w/ DPF) 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.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. PRECAUTION

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. DRAIN ENGINE COOLANT

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. A01KFNQE02
      Text in Illustration
      *1 Radiator Cap
      *2 Engine Drain Plug
      *3 Radiator Drain Plug

      Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

    3. Loosen the engine drain plug (on the oil cooler cover), and drain the coolant.

    4. Drain the coolant from the reservoir tank.

    5. Tighten the engine drain plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  4. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the drain plug from the oil pan and drain the engine oil into a container.

    3. Clean the drain plug.

    4. Install the drain plug with a new gasket.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  5. REMOVE EGR COOLER ASSEMBLY

    Click here

  6. REMOVE STARTER ASSEMBLY


    1. A01KGB5

      Disconnect the connector.

    2. Open the terminal cap.

    3. Remove the nut and disconnect the wire harness.

    4. A01KG0T

      Remove the bolt and nut and remove the starter.

  7. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01KHEI

      Disconnect the 3 fuel hoses.

    2. Remove the fuel check valve and gasket from the No. 3 nozzle leakage pipe.

      Text in Illustration
      A01KGZT Fuel Check Valve

    3. Remove the bolt and No. 2 injection pipe clamp from the No. 3 nozzle leakage pipe and No. 3 fuel pipe.

    4. Remove the bolt and No. 3 nozzle leakage pipe.

  8. REMOVE NO. 3 FUEL PIPE

    A01KHV0
    Text in Illustration
    A01KGZT Union Bolt A01KF96 Fuel Check Valve
    A01KFFI Bolt - -

    1. Remove the 2 union bolts and gasket from the No. 3 fuel pipe.

    2. Remove the fuel check valve and gasket from the No. 3 fuel pipe.

    3. Remove the 3 bolts and No. 3 fuel pipe.

  9. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01KIIV

      Remove the union bolt and gasket from the No. 2 nozzle leakage pipe assembly.

      Text in Illustration
      A01KGZT Union Bolt

    2. Remove the 3 bolts and No. 2 nozzle leakage pipe assembly.

  10. REMOVE NO. 3 WATER BY-PASS HOSE

    A01KGDA

    1. Remove the No. 3 water by-pass hose.

  11. REMOVE NO. 2 WATER BY-PASS HOSE

    A01KH2W

    1. Remove the No. 2 water by-pass hose.

  12. REMOVE OIL FILTER SUB-ASSEMBLY


    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Because the oil in the filter flows out through the vinyl tube, place the drain oil container under the vinyl tube.

  13. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. Disconnect the engine oil pressure switch connector.

    2. Remove the drain cock plug.

    3. Disconnect the vinyl tube from the oil cooler cover.

    4. A01KI56

      Remove the 2 nuts and bolt and disconnect the No. 2 vacuum transmitting pipe from the oil cooler cover.

    5. A01KHCA

      Remove the 12 bolts and oil cooler cover and gasket.

  14. REMOVE ENGINE OIL COOLER ASSEMBLY

    A01KIGR

    1. Remove the 4 nuts, engine oil cooler and 2 gaskets from the oil cooler cover.