ENGINE OIL COOLER (w/o EGR Cooler) REMOVAL

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)


    1. Remove the 4 bolts and under cover.

  2. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)


    1. Remove the 2 bolts and under cover.

  3. DRAIN ENGINE OIL


    1. Remove the oil filter cap.

    2. Remove the oil drain plug, and drain the engine oil from the oil pan.

      Note

      Collect the oil in an oil disposal container.

  4. LOOSEN FUEL TANK CAP ASSEMBLY

  5. DRAIN FUEL

  6. REMOVE MANIFOLD STAY

    A01E1L4E01

    1. Remove the 2 bolts and stay.

  7. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY


    1. Remove the bolt and gauge.

    2. Remove the O-ring from the gauge.

  8. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Remove the engine oil level dipstick.

    2. A01DW6AE01

      Remove the bolt and clamp.

    3. Remove the bolt and engine oil level dipstick guide.

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

    5. A01E03WE03

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  9. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A01DXPXE01

      Remove the bolt and No. 2 injection pipe clamp.

    2. Remove the 2 nuts and No. 3 injection pipe clamp.

    3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  10. REMOVE NO. 4 INJECTION PIPE


    1. A01E0ZRE01

      Remove the 2 bolts and disconnect the 2 injection pipe clamps.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01E2XGE01

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  11. REMOVE OIL FILTER SUB-ASSEMBLY

    A01DVQRE01

    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Insert the drain hose in the oil filter. Put the drain oil container beneath the drain hose to collect the oil from the oil filter.

  12. REMOVE STARTER ASSEMBLY


    1. for A340F A340E:

      Remove transmission oil filler tube sub-assembly.


      1. Remove the oil level dipstick.

      2. Remove the 2 bolts and transmission oil filler tube sub-assembly.

      3. Remove the O-ring from the transmission oil filler tube sub-assembly.

    2. A01E32S

      Disconnect the starter connector.

    3. Remove the nut and disconnect the starter wire.

    4. A01E0N6

      A/T:

      Remove the 2 nuts, bolt, and disconnect the ground cable.

    5. A01DXFN

      M/T:

      Remove the nut, bolt, and disconnect the ground cable.

    6. Remove the starter.

  13. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    A01DW6AE01

    1. Remove the bolt and clamp.

    2. Remove the 2 bolts and oil level gauge guide.

    3. A01E03WE05

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

    4. A01DYSWE01

      Disconnect the 2 fuel hoses.

    5. A01DXJEE01

      Disconnect the 2 connectors.

    6. A01E0LPE01

      Remove the 4 bolts indicated by the arrows in the illustration.

    7. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    8. A01E0MBE02

      Remove the set nut and O-ring while holding the crankshaft pulley by using SST.

      SST
      09213-58013
      09330-00021
    9. A01E141E01

      Loosen the 2 nuts.

    10. A01DVLSE01

      Using SST, disconnect the pump from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    11. Remove the 2 nuts and pump.

      Note


      • Do not hold the pump or carry it holding the pipe.

      • The pump must be kept horizontal.

    12. Remove the O-ring.

  14. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the 2 connectors.

    2. A01DVT1

      Remove the 2 bolts, common rail and No. 2 intake manifold insulator.

      Note

      Do not remove the pressure discharge valve and fuel pressure sensor.

  15. REMOVE OIL COOLER COVER SUB-ASSEMBLY

    A01E05LE01

    1. Disconnect the oil pressure switch connector and wire harness.

    2. Remove the 13 bolts, 2 nuts and oil cooler cover.

  16. REMOVE OIL COOLER ASSEMBLY


    1. Loosen the 4 nuts first.

    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.