Engine Oil Cooler -- Removal |
- NOTICE:
- 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.
| 2. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD) |
Remove the 4 bolts and under cover.
| 3. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD) |
Remove the 2 bolts and under cover.
| 4. DRAIN ENGINE OIL |
Remove the oil filler cap.
Remove the oil drain plug, and drain the engine oil from the oil pan.
- NOTICE:
- Collect the oil in an oil disposal container.
| 5. LOOSEN FUEL TANK CAP ASSEMBLY |
| 6. DRAIN FUEL |
| 7. REMOVE MANIFOLD STAY |
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Remove the 2 bolts and stay.
| 8. REMOVE OIL DIPSTICK GUIDE |
Remove the bolt and guide.
Remove the O-ring from the guide.
| 9. REMOVE FUEL INLET PIPE SUB-ASSEMBLY |
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Remove the bolt and clamp.
Remove the bolt and oil dipstick guide.
Using union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
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| 10. REMOVE INJECTION PIPE |
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- NOTICE:
- 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.
Remove the 2 nuts and No. 3 injection pipe clamp.
Remove the bolt and No. 2 injection pipe clamp.
Using union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Remove the 2 bolts and disconnect the 2 injection pipe clamps.
Using union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
| 11. REMOVE OIL FILTER SUB-ASSEMBLY |
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Using SST, remove the oil filter.
- SST
- 09228-07501
- HINT:
- Insert the drain hose in the oil filter. Put the disposal container beneath the drain hose to collect the oil from the oil filter.
| 12. REMOVE STARTER ASSEMBLY |
Disconnect the starter connector.
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Remove the nut and disconnect the starter wire.
Remove the 2 bolts and starter.
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| 13. REMOVE FUEL SUPPLY PUMP ASSEMBLY |
Remove the bolt and clamp.
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Remove the bolt and oil dipstick guide.
Using union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
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Disconnect the 2 fuel hoses.
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Disconnect the 2 connectors.
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Remove the 4 bolts indicated by the arrows in the illustration.
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Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.
Remove the set nut and O-ring while holding the crankshaft pulley using SST.
- SST
- 09213-58013
09330-00021
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Loosen the 2 nuts.
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Using SST, disconnect the pump from the injection gear.
- SST
- 09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)
- NOTICE:
- Apply lubricant to the threads and tip of SST (center bolt) before using it.
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Remove the 2 nuts and pump.
- NOTICE:
- Do not hold or carry the pump by holding the pipe.
- The pump must be kept horizontal.
Remove the O-ring.
| 14. REMOVE COMMON RAIL ASSEMBLY |
Disconnect the fuel pressure sensor connector.
Remove the 2 bolts and common rail.
- NOTICE:
- Do not remove the pressure limiter and pressure sensor.
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| 15. REMOVE OIL COOLER COVER SUB-ASSEMBLY |
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Disconnect the oil pressure switch connector and wire harness.
Remove the 13 bolts, 2 nuts and oil cooler cover.
| 16. REMOVE OIL COOLER ASSEMBLY |
Loosen the 4 nuts first.
Partially tap out the oil cooler by tapping each nut head with a plastic-faced hammer.
Remove the 4 nuts, oil cooler and 2 gaskets.