ENGINE OIL COOLER > REMOVAL

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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)

  1. Remove the 4 bolts and under cover.



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

  1. Remove the 2 bolts and under cover.



4. DRAIN ENGINE OIL

  1. Remove the oil filler cap.

  1. 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 ASSEMBLY


6. DRAIN FUEL


7. REMOVE MANIFOLD STAY


G037596E01

  1. Remove the 2 bolts and stay.



8. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

  1. Remove the bolt and gauge.

  1. Remove the O-ring from the gauge.



9. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


G036615E01

  1. Remove the bolt and clamp.

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



    A098969E01

  1. Using SST, loosen the union nuts and remove the fuel inlet pipe.

    SST
    09023-12701  



10. REMOVE INJECTION PIPE


G038585E02

NOTICE:
  1. When replacing the injector, also replace the injection pipe.
  2. Keep the joints of the injection pipe clean.

  1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

  1. Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

    HINT:
    If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.



    A098972E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



    A098893E01

  1. Temporarily install the No. 4 injection pipe with the union nuts.

  1. Install 2 new injection pipe clamps with the 2 bolts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    NOTICE:
    1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
    2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.



    A098973E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



11. REMOVE OIL FILTER SUB-ASSEMBLY

  1. Check and clean the oil filter installation surface.

  1. Apply clean engine oil to the gasket of a new oil filter.

  1. Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.



    A060101E01

  1. Using SST, tighten the oil filter. Depending on the work space available, choose from the following.

    SST
    09228-07501  

    1. If enough space is available, use a torque wrench to tighten the oil filter.

      Torque:
      12 N*m{ 122 kgf*cm , 9 ft.*lbf }

    2. If enough space is not available to use a torque wrench, tighten the oil filter 3/4 turn by hand or with a common wrench.



12. REMOVE STARTER ASSEMBLY


A111850

  1. Disconnect the starter connector.

  1. Remove the nut and disconnect the starter wire.

  1. Remove the clutch release cylinder.



    A111851

  1. Remove the nut, bolt, ground cable and starter.



13. REMOVE FUEL SUPPLY PUMP ASSEMBLY


G036615E01

  1. Remove the bolt and clamp.

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



    A098969E01

  1. Using SST, loosen the union nuts and remove the fuel inlet pipe.

    SST
    09023-12701  



    A098895E01

  1. Disconnect the 2 fuel hoses.



    A098896E01

  1. Disconnect the 2 connectors.



    A070710E01

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

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



    A070711E02

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

    SST
    09213-58013  
    09330-00021  



    A098897E01

  1. Loosen the 2 nuts.



    A070714E01

  1. 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.

  1. Remove the 2 nuts and pump.

    NOTICE:
    1. Do not hold the pump or carry it holding the pipe.
    2. The pump must be kept horizontal.

  1. Remove the O-ring.



14. REMOVE COMMON RAIL ASSEMBLY


A098899E01

  1. Disconnect the fuel pressure sensor connector.

  1. Remove the 2 bolts and common rail.

    NOTICE:
    Do not remove the pressure limiter and pressure sensor.



15. REMOVE OIL COOLER COVER SUB-ASSEMBLY


A038741E01

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

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



16. REMOVE OIL COOLER ASSEMBLY

  1. Loosen the 4 nuts first.

  1. Partially tap out the oil cooler by tapping each nut head with a plastic-faced hammer.

  1. Remove the 4 nuts, oil cooler and 2 gaskets.