ENGINE OIL COOLER REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Remove the radiator cap.

    2. Loosen the radiator drain cock plug and a cylinder block drain cock plug. Then drain the coolant.

      A01BC1SE01

  4. REMOVE BATTERY SERVICE HOLE COVER

  5. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)

    Tech Tips

    Use the same procedures described for the LH side. Click here

  6. REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)

    Tech Tips

    Use the same procedures described for the LH side. Click here

  7. REMOVE FRONT DOOR SCUFF PLATE RH

  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


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

  9. REMOVE FAN & GENERATOR V BELT


    1. A01BGLOE03

      Remove the drive belt by rotating the tensioner pulley in clockwise direction to loosen its tension with the pulley set bolt of the tensioner.

  10. REMOVE TIMING BELT COVER NO.1


    1. Remove the wire harness clamp.

    2. A01BHT6

      Remove the 6 bolts and timing belt cover No.1.

  11. REMOVE TIMING BELT


    1. A01BB9ZE01

      Turn the crankshaft in the clockwise direction and align the timing marks as shown in the illustration.

    2. A01BHFH

      Uniformly loosen the 2 bolts, and remove the chain tensioner assembly No.1.

    3. Remove the timing belt.

  12. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBMI

      Remove the 2 bolts. Separate the vane pump oil reservoir assembly.

  13. SEPARATE OIL RETURN HOSE (w/ Intercooler)


    1. A01BFPG

      Loosen the clip.

    2. Disconnect the oil return hose from the intake manifold.

  14. REMOVE EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BGWP

      Disconnect the fuel pressure sensor connector.

    2. A01BD88

      Remove the 2 bolts, 2 nuts, and the EGR pipe sub-assembly.

    3. Remove the 2 gaskets.

  15. REMOVE AIR HOSE NO.4


    1. A01BGX6

      Loosen the 2 clamps.

    2. Remove the air hose No.4.

  16. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01BCMO

      Disconnect the 2 throttle body connectors.

    2. A01BBJH

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

    3. Remove the gasket from intake air connector.

  17. REMOVE ENGINE SERVICE HOLE COVER NO.2


    1. A01BG4E

      Roll up the carpet.

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

  18. REMOVE INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A01BDK1

      Remove the bolt, and separate the manifold stay.

    2. Disconnect the vacuum hose from intake air connector.

    3. A01BEP8E01

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

    4. Remove the 2 gaskets and intake air connector No.2 from the intake air connector.

  19. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Remove the vacuum regulating valve.


      1. A01BHSL

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

      2. Remove the 2 bolts and the vacuum regulating valve.

    2. Remove the EGR valve assembly with the sensor.


      1. A01BCF1

        Remove the bolt, and separate the manifold stay.

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

      3. A01BAPE

        Disconnect the intake air temperature sensor connector.

      4. Disconnect the EGR valve position sensor connector.

      5. A01BACYE01

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

      6. Remove the 2 gaskets and EGR valve assembly from the intake air connector.

  20. REMOVE OIL LEVEL GAUGE GUIDE


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

  21. REMOVE INJECTION PIPE SUB-ASSEMBLY

    SST
    09023-12701

    1. Remove the injection pipe.


      1. A01BC89

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

      2. A01BFG2

        Using SST, remove the 4 injection pipes.

        SST
        09023-12701

  22. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Using SST, remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  23. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. A01BE3U

      Disconnect 3 fuel hoses from nozzle leakage pipe assembly No.2.

    2. A01BEHR

      Remove the union bolt from nozzle leakage pipe No.2.

    3. A01BCQO

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

    4. Remove the gasket from nozzle leakage pipe No.2.

  24. REMOVE INTAKE MANIFOLD


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

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

    3. A01BHYI

      Remove the 4 bolts, 2 nuts, and intake manifold.

    4. Remove the gasket from the cylinder head.

  25. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01BBU2E01

      Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

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

  26. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the fuel pressure sensor connector from the common rail assembly.

    2. Disconnect the fuel hose from the fuel pressure limiter.

    3. A01BC8UE01

      Remove the 2 bolts and common rail assembly.

  27. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY


    1. A01BCD7

      Remove the 4 bolts.

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

    3. A01BFRE

      Using SST, remove the supply pump gear set nut and O-ring while holding the crankshaft pulley.

      SST
      09213-58013
      09330-00021
    4. A01BGD8

      Disconnect the 2 fuel hoses.

    5. Disconnect the 2 connectors and wire harness.

    6. Loosen the 2 nuts as shown in the illustration.

    7. A01BA4CE01

      Using SST, disengage the supply pump from the supply pump gear.

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

    8. Remove the 2 nuts and supply pump from the engine.

    9. Remove the O-ring from the supply pump.

    10. Remove the pulley key from the supply pump.

  28. REMOVE OIL COOLER COVER SUB-ASSEMBLY (w/o EGR Valve)


    1. A01BABQ

      Disconnect the oil pressure switch connector.

    2. Disconnect the oil filter drain hoses.

    3. A01BHZ8

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

  29. REMOVE OIL COOLER COVER SUB-ASSEMBLY (w/ EGR Valve)


    1. A01BDJ0

      Disconnect the oil pressure switch connector.

    2. Disconnect the oil filter drain hoses.

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

    4. A01BB05

      Remove the 13 bolts, oil cooler cover, and gasket.

  30. REMOVE OIL COOLER ASSEMBLY


    1. A01BBX5

      Loosen the 4 nuts until they are flush with the end of the bolts.

    2. Using a plastic hammer, uniformly tap the end of the nuts to separate the oil cooler cover and oil cooler assembly.

    3. A01BE0Y

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