FUEL COOLER (for Engine Room Side) REMOVAL


  1. REMOVE COMMON RAIL ASSEMBLY LH AND RH

    Click here

  2. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

    A0155ZV

  3. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

    A01565Y

  4. REMOVE INTAKE PIPE


    1. A01580H

      w/ EGR System:

      Remove the 2 nuts, 6 bolts, intake pipe and 2 gaskets.

    2. A015CFP

      w/o EGR System:

      Remove the 2 nuts, 4 bolts, intake pipe and gasket.

  5. DISCONNECT NO. 2 ENGINE WIRE


    1. A0156MM

      Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

  6. REMOVE NO. 3 INTAKE MANIFOLD


    1. A0158GX

      Remove the 16 bolts, No. 3 intake manifold and 2 gaskets.

  7. REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR System)

    A0159XK

  8. REMOVE EGR PIPE INSULATOR (w/ EGR System)


    1. A015B26

      Remove the 2 bolts and EGR pipe insulator.

  9. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)


    1. A01584Z

      Remove the 10 bolts, EGR valve with EGR cooler and 2 gaskets.

    2. A015AI2

      Disconnect the No. 5 water by-pass hose from the water by-pass outlet.

  10. REMOVE EGR COOLER INSULATOR (w/ EGR System)

    A015CP9

  11. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A015AB8

      Disconnect the No. 1 fuel hose from the fuel cooler.

    2. Remove the union bolt, bolt, No. 3 nozzle leakage pipe and gasket.

      Note

      After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

  12. REMOVE NO. 4 NOZZLE LEAKAGE PIPE


    1. A015AQI

      Disconnect the No. 2 fuel hose from the fuel cooler.

    2. Remove the union bolt, bolt, No. 4 nozzle leakage pipe and gasket.

      Note

      After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

  13. DISCONNECT NO. 6 WATER BY-PASS HOSE

    A015A9V

  14. DISCONNECT NO. 3 FUEL HOSE


    1. A01576Z

      Disconnect the fuel hose from the fuel cooler.

  15. REMOVE FUEL COOLER ASSEMBLY


    1. A0159DJ

      Remove the 2 bolts and fuel cooler.

  16. DISCONNECT NO. 7 WATER BY-PASS HOSE


    1. A015AAS

      Disconnect the water by-pass hose from the fuel cooler.