ENGINE OIL COOLER INSTALLATION
CAUTION / NOTICE / HINT
Note
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When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.
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When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.
PROCEDURE
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INSTALL OIL COOLER ASSEMBLY
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Apply engine oil to the 2 new O-rings labeled B in the illustration.
Note
Do not apply engine oil to the new O-ring labeled A in the illustration.
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Install the 3 new O-rings to the No. 1 oil cooler bracket.
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Install the oil cooler assembly with the 5 bolts.
- Torque:
- 10 N*m { 102 kgf*cm, 7 ft.*lbf }
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INSTALL WATER BY-PASS HOSE
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*1 Paint Mark *a Upper Side Install the water by-pass hose to the water outlet and oil cooler assembly, and slide the 2 clamps to secure the hose.
Tech Tips
Make sure the claws of hose clamp A are positioned above the paint mark as shown in the illustration.
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INSTALL INTAKE MANIFOLD
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CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY
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INSTALL NO. 2 INTAKE MANIFOLD
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INSTALL ENGINE COVER BRACKET
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INSTALL GAS FILTER BRACKET
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INSTALL NO. 1 GAS FILTER
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INSTALL DIESEL TURBO PRESSURE SENSOR
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INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
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INSTALL INTAKE MANIFOLD INSULATOR
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INSTALL COMMON RAIL ASSEMBLY
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INSTALL INJECTION PIPE SUB-ASSEMBLY
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INSTALL FUEL INLET PIPE SUB-ASSEMBLY
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INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
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INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY
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CONNECT NO. 8 WATER BY-PASS HOSE
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INSTALL NO. 7 WATER BY-PASS HOSE
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INSTALL EGR VALVE BRACKET
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CONNECT ENGINE WIRE
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INSTALL DIESEL THROTTLE BODY ASSEMBLY
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ADD ENGINE OIL
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CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
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ADD ENGINE COOLANT
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BLEED AIR FROM FUEL SYSTEM
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INSPECT FOR COOLANT LEAK
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INSPECT FOR OIL LEAK
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INSPECT FOR FUEL LEAK
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INSPECT ENGINE OIL LEVEL