ENGINE OIL COOLER (w/ 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. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

    Note

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

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


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

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


    1. Remove the 2 bolts and No. 2 engine under cover.

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir 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. A01DY58E01

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

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  5. DRAIN ENGINE OIL


    1. Remove the oil filler 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.

  6. LOOSEN FUEL TANK CAP ASSEMBLY

  7. DRAIN FUEL

  8. REMOVE EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE


    1. Remove the EGR cooler with electric EGR control valve and No. 2 EGR valve Click here.

  9. REMOVE NO. 4 INJECTION PIPE


    1. A01E10I

      Remove the bolt and disconnect the injection pipe clamp.

    2. A01DVY2E02

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

  10. REMOVE OIL DIPSTICK GUIDE

    A01DZT2

    1. Remove the bolt and injection pipe clamp.

    2. Remove the bolt and guide.

    3. Remove the O-ring from the guide.

  11. REMOVE MANIFOLD STAY


    1. A01DZWT

      Disconnect the 2 connectors.

    2. A01DXHK

      Disconnect the 4 vacuum hoses.

    3. A01DW1B

      Remove the 2 bolts and manifold stay with VSV.

  12. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the 3 fuel hoses.

    2. A01DVSC

      Remove the check valve, 3 bolts, leakage pipe and gasket.

  13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E02G

      Remove the bolt and clamp.

    2. A01E1CP

      Remove the bolt and oil level gauge guide.

    3. A01E0LTE02

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

  14. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

  15. REMOVE COMMON RAIL ASSEMBLY


    1. A01DX72

      Disconnect the 2 connectors.

    2. Remove the 2 bolts, common rail and insulator.

      Note

      Do not remove the pressure discharge valve and pressure sensor.

  16. REMOVE OIL FILTER SUB-ASSEMBLY

    A01DXRME01

    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

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

  17. REMOVE STARTER ASSEMBLY


    1. A01DXR9

      Disconnect the starter connector.

    2. Remove the nut and disconnect the starter wire.

    3. A01DYK6E01

      Remove the 2 bolts and disconnect the ground wire.

    4. Remove the stater.

  18. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01DVYA

      Disconnect the 2 fuel hoses.

    2. A01DZOI

      Disconnect the 2 connectors.

    3. A01E0LPE01

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

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

    5. A01E0MBE02

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

      SST
      09213-58013
      09330-00021
    6. A01DXRJ

      Loosen the 2 nuts.

    7. 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.

    8. Remove the 2 nuts and pump.

      Note


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

      • The pump must be kept horizontal.

    9. Remove the O-ring.

  19. REMOVE OIL COOLER COVER SUB-ASSEMBLY

    A01DZN0

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

    2. Remove the 2 nuts and No. 2 vacuum transmitting pipe.

    3. Remove the 13 bolts and oil cooler cover.

  20. REMOVE OIL COOLER ASSEMBLY


    1. A01DWJT

      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.