ENGINE OIL COOLER REMOVAL

Note


  • 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.

  • 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.


  1. REMOVE NO. 1 ENGINE COVER


    1. A003DQW

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  2. REMOVE ENGINE ROOM SIDE COVER


    1. A003B3G

      Remove the clip and engine room side cover.

  3. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A003AXU

      Remove the 8 clips and radiator support opening cover.

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

    • w/ Navigation System (for HDD):

      After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.

  5. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A003EIP

      Remove the 4 screws and 2 bolts.

    2. A003ALH

      Remove the 8 bolts and 3 screws.

    3. Detach the 2 hooks of the front lower bumper absorber from the installation holes on the body and remove the front lower bumper absorber.

  6. REMOVE ENGINE UNDER COVER


    1. A003BQH

      Remove the 11 clips and engine under cover.

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

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  8. DRAIN ENGINE COOLANT


    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. Remove the radiator reservoir cap.

      CAUTION:

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

    3. Loosen the cylinder block drain cock plug. Then drain the coolant from the engine.

      Tech Tips

      The plug is on the backside of the generator on the EGR cooler side.

      A00OSDBE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Cylinder Block Drain Cock Plug (Type A) *4 Cylinder Block Drain Cock Plug (Type B)
      *5 Radiator Drain Cock Plug - -

  9. REMOVE NO. 3 AIR HOSE


    1. A003DCT

      Loosen the 2 hose clamps.

    2. Remove the No. 3 air hose from the No. 2 air tube and diesel throttle body.

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A003B2E

      Disconnect the No. 7 water by-pass hose from the throttle body.

    2. Disconnect the No. 6 water by-pass hose from the throttle body.

    3. Disconnect the throttle position sensor and throttle motor connector.

    4. A003C3E

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

  11. DISCONNECT ENGINE WIRE

    A003BMP

    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the grommet and nut, and disconnect the glow plug wire harness.

    4. Detach the 2 wire harness clamps.

    5. Remove the bolt and wire harness bracket.

    6. Remove the bolt and 3 nuts, and disconnect the engine wire.

  12. REMOVE EGR VALVE BRACKET


    1. A003E6M

      Disconnect the 2 connectors and detach the 2 wire harness clamps.

    2. A003E5Y

      Remove the 3 bolts and 2 EGR valve brackets.

  13. REMOVE NO. 7 WATER BY-PASS HOSE

    A003C0A

  14. DISCONNECT NO. 8 WATER BY-PASS HOSE

    A003C1D

  15. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A003BVE

      Disconnect the electric EGR control valve connector.

    2. A003CDBE01
      Text in Illustration
      *1 Nut

      Remove the 3 bolts, 2 nuts and No. 2 EGR pipe.

    3. Remove the 2 gaskets.

  16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A003AHE

      Remove the electric EGR control valve and gasket.

  17. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note

    After removing the fuel inlet pipe, cover the common rail and supply pump with electrical tape to prevent dirt from entering them.


    1. A003AJA

      Remove the nut and 2 clamps.

    2. Using a 14 mm union nut wrench, remove the fuel inlet pipe.

  18. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A003DL2

      Remove the 2 bolts and 4 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

    4. Remove the 4 injection pipes.

  19. REMOVE COMMON RAIL ASSEMBLY


    1. A003B5S

      Using pliers, grip the claws of the clip and slide the clip to disconnect the fuel hose.

    2. Remove the 2 bolts and common rail.

  20. REMOVE INTAKE MANIFOLD INSULATOR


    1. A003CC9

      Remove the intake manifold insulator from the intake manifold.

  21. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A003E7T

      Disconnect the connector and detach the wire harness clamp from the engine oil level dipstick guide.

    3. Remove the 2 bolts and engine oil level dipstick guide.

    4. Remove the O-ring from the engine oil level dipstick guide.

  22. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A003BFA

      Disconnect the vacuum hose.

    2. Disconnect the sensor connector.

    3. Remove the bolt and sensor.

  23. REMOVE NO. 1 GAS FILTER


    1. A003BBJ

      Disconnect the vacuum hose.

    2. Remove the No. 1 gas filter from the gas filter bracket.

  24. REMOVE GAS FILTER BRACKET


    1. A003AWW

      Remove the 2 bolts and gas filter bracket.

  25. REMOVE ENGINE COVER BRACKET


    1. A003EJ9

      Remove the bolt and engine cover bracket.

  26. REMOVE NO. 2 INTAKE MANIFOLD


    1. A003DE3

      Remove the bolt, 2 nuts, No. 2 intake manifold and gasket.

  27. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE


    1. A003BTF

      Disconnect the No. 2 vacuum transmitting hose from the intake manifold.

  28. REMOVE INTAKE MANIFOLD


    1. A003DELE01
      Text in Illustration
      *1 Nut

      Remove the 7 bolts, 2 nuts, intake manifold and gasket.

    2. Remove the gasket from the cylinder head.

  29. REMOVE WATER BY-PASS HOSE

    A003CG4

  30. REMOVE OIL COOLER ASSEMBLY


    1. A003DKC

      Remove the 5 bolts and oil cooler.

    2. Remove the 3 O-rings from the oil cooler bracket.