ENGINE OIL COOLER REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. DRAIN ENGINE COOLANT

    A01BCB6E01

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator reserve tank 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. Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

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

    4. Tighten the engine drain plug (on the radiator).

    5. Tighten the engine drain plug (on the engine oil cooler cover).

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

  3. 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 }

  4. REMOVE FRONT DOOR SCUFF PLATE RH

  5. REMOVE FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  6. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet, and remove the 5 bolts and engine service hole sub cover sub-assembly.

  7. REMOVE NO. 2 ENGINE SERVICE HOLE COVER

    A01BG4E

    1. Roll up the carpet.

    2. A01BD0S

      Remove the 3 bolts and No. 2 engine service hole cover.

  8. REMOVE FENDER APRON MUDGUARD SEAL LH

    A01BEKQ

    1. Remove the 4 clips and fender apron mudguard seal.

  9. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY

    A01BBMO

    1. Remove the 2 bolts, and separate the vane pump oil reservoir assembly.

  10. REMOVE NO. 4 AIR HOSE

    A01BH66

    1. Loosen the 2 clamps.

    2. Remove the No. 4 air hose.

  11. REMOVE EGR COOLER ASSEMBLY

    A01BH3G

    1. Loosen the clip and disconnect the No. 4 water by-pass hose.

    2. Loosen the clip and disconnect the No. 2 water by-pass hose.

    3. A01BDC3

      Remove the 3 bolts and 2 nuts and remove the EGR cooler assembly.

  12. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    A01BA8Q

    1. Disconnect the 2 throttle body connectors.

    2. A01BEHN

      Remove the 2 bolts, 2 nuts, and the diesel throttle body assembly.

    3. Remove the gasket from the intake air connector.

  13. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01BBVC

      Disconnect the intake air temperature sensor connector.

    2. Remove the vacuum regulating valve.


      1. A01BDUS

        Remove the 2 vacuum hoses and the vacuum regulating valve connector.

      2. A01BH0B

        Remove the 2 bolts and the vacuum regulating valve.

    3. A01BBMB

      Remove the electric EGR control valve with the sensor.


      1. Remove the bolt, and separate the manifold stay.

      2. Disconnect the vacuum hose from the intake air connector.

      3. A01BHKK

        Disconnect the EGR valve position sensor connector.

      4. Disconnect the vacuum hose from the electric EGR control valve.

      5. Remove the bolt, 2 nuts and intake air connector assembly.

      6. A01BACYE02

        Remove the 2 gaskets and electric EGR control valve from the intake air connector.

  14. REMOVE OIL LEVEL GAUGE GUIDE


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

  15. REMOVE INJECTION PIPE SUB-ASSEMBLY

    A01BALH

    1. Disconnect the fuel injector connector and harness clamps.

    2. Remove the 3 bolts.

    3. A01BEJA

      Remove the 2 bolts and remove the 2 No. 2 injection pipe clamps.

    4. A01BFN0

      Using SST, remove the 4 injection pipes.

      SST
      09023-12701

  16. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    A01BC23

    1. Remove the 2 clamp bolts.

    2. A01BDF3

      Using SST, loosen the 2 union nuts and remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  17. REMOVE NO.2 NOZZLE LEAKAGE PIPE ASSEMBLY

    A01BBPS

    1. Disconnect the 4 fuel hoses from the No. 2 nozzle leakage pipe assembly.

    2. A01BGX5

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

  18. REMOVE FUEL COOLER

    A01BGDF

    1. Slide the clip and disconnect the water by-pass hose from the oil cooler cover.

    2. Remove the 2 bolts and fuel cooler.

  19. REMOVE OIL FILTER SUB-ASSEMBLY

    A01BBU2E01

    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Position the drain oil container to collect the oil from the oil filter.

  20. REMOVE OIL COOLER COVER SUB-ASSEMBLY

    A01BABQ

    1. Disconnect the oil pressure switch connector.

    2. Disconnect the 2 oil filter drain hoses.

    3. A01BHZ8

      Remove the 13 bolts, 2 nuts and separate the No. 2 vacuum transmitting pipe.

    4. Remove the oil cooler cover and gasket from the cylinder block.

  21. REMOVE OIL COOLER ASSEMBLY


    1. A01BFXN

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