ENGINE OIL COOLER (w/o DPF) REMOVAL


  1. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  2. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Remove the 4 bolts and No. 1 engine under cover.

  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. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A00JWDE

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A00JVX9E01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  4. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

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

  5. REMOVE STARTER ASSEMBLY


    1. for 2.2 kW Type:

      Remove the starter Click here.

    2. for 2.7 kW Type:

      Remove the starter Click here.

    3. for 3.0 kW Type:

      Remove the starter Click here.

  6. REMOVE COMMON RAIL ASSEMBLY


    1. Remove the common rail Click here.

  7. REMOVE SUPPLY PUMP ASSEMBLY


    1. Remove the supply pump Click here.

  8. REMOVE VACUUM CONTROL VALVE SET


    1. A00O7ZB

      Disconnect the 2 VSV connectors and 3 vacuum hoses.

    2. Remove the 2 bolts and vacuum control valve set.

  9. DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR Cooler)


    1. A00JVYB

      Disconnect the No. 3 water by-pass hose.

  10. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A00JZXEE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  11. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. Disconnect the oil pressure switch connector.

    2. Disconnect the vinyl tube.

    3. A00JZ9L

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

    4. A00K0S0

      Remove the 13 bolts and oil cooler cover.

  12. REMOVE OIL COOLER ASSEMBLY


    1. A00JXC9

      Loosen the 4 nuts.

    2. Partially tap out the oil cooler by tapping each nut head with a plastic-faced hammer.

    3. Remove the 4 nuts, oil cooler and 2 gaskets.