ENGINE OIL COOLER REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail assembly, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail assembly, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.


  1. REMOVE NO. 1 ENGINE COVER


    1. A01INMI

      Hold the rear of the No. 1 engine cover and slowly raise it to detach the clip on the rear of the No. 1 engine cover. Continue to raise the No. 1 engine cover to detach the 3 clips on the front and side of the No. 1 engine cover and remove the No. 1 engine cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover to break.

  2. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A01IS0M

      Remove the 3 clips.

    2. Detach the 4 hooks and remove the radiator support opening cover.

  3. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  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.

  5. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01IUIX

      Remove the 6 bolts and 10 clips.

    2. Remove the No. 1 engine under cover.

  6. DRAIN ENGINE OIL


    1. Remove the oil filler cap sub-assembly.

    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 }

  7. 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.

      A01IUC4E01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Radiator Drain Cock Plug - -

  8. REMOVE NO. 3 AIR HOSE


    1. A01ISZ1

      Loosen the 2 hose clamps.

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

  9. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01IS7W

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

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

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

    4. A01IS0N

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

  10. DISCONNECT ENGINE WIRE

    A01IRBA

    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the screw 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.

  11. REMOVE EGR VALVE BRACKET


    1. A01IPQ0

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

    2. A01IPI2

      Remove the 3 bolts and 2 EGR valve brackets.

  12. REMOVE NO. 7 WATER BY-PASS HOSE

    A01IUFE

  13. DISCONNECT NO. 8 WATER BY-PASS HOSE


    1. A01INDM

      Slide the clamp and disconnect the No. 8 water by-pass hose from the electric EGR control valve assembly.

  14. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A01IOQA

      Disconnect the electric EGR control valve connector.

    2. A01IPRKE01
      Text in Illustration
      *1 Nut

      Remove the 3 bolts, 2 nuts, No. 2 EGR pipe sub-assembly and 2 gaskets.

  15. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IQP8

      Remove the electric EGR control valve assembly and gasket.

  16. 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. A01ITN1

      Remove the nut and 2 No. 2 injection pipe clamps.

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

  17. 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. A01IO2G

      Remove the 2 bolts and 4 No. 2 injection pipe clamps.

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

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

    4. Remove the 4 injection pipes.

  18. REMOVE COMMON RAIL ASSEMBLY


    1. A01IUFT

      Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 4 fuel hose from the common rail assembly.

    2. Remove the 2 bolts and common rail assembly.

  19. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01IQK4

      Remove the intake manifold insulator from the intake manifold.

  20. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01IMYE

      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.

  21. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A01IQ0K

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  22. REMOVE NO. 1 GAS FILTER


    1. A01IQMA

      Disconnect the vacuum hose.

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

  23. REMOVE GAS FILTER BRACKET


    1. A01ITRH

      Remove the 2 bolts and gas filter bracket.

  24. REMOVE ENGINE COVER BRACKET


    1. A01INXS

      Remove the bolt and engine cover bracket.

  25. REMOVE NO. 2 INTAKE MANIFOLD


    1. A01IPPN

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

  26. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE


    1. A01IPLK

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

  27. REMOVE INTAKE MANIFOLD


    1. A01IOHHE01
      Text in Illustration
      *1 Nut

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

  28. REMOVE WATER BY-PASS HOSE


    1. A01IQEK

      Slide the 2 clamps and remove the water by-pass hose from the water outlet and oil cooler assembly.

  29. REMOVE OIL COOLER ASSEMBLY


    1. A01IRXA

      Remove the 5 bolts and oil cooler assembly.

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