GSIC - Global Service Information Center

# ENGINE OIL COOLER > INSTALLATION

## for Preparation Click here

1. INSTALL OIL COOLER ASSEMBLY

1. Install 2 new gaskets to the oil cooler.

1. Install the oil cooler to the oil cooler cover with the 4 nuts.

   Torque:
     16 N*m{ 163 kgf*cm , 12 ft.*lbf }

2. INSTALL OIL COOLER COVER SUB-ASSEMBLY

1. Install a new gasket and the oil cooler cover with the 13 bolts and 2 nuts.

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

1. Connect the oil pressure connector and install the wire harness.

3. INSTALL COMMON RAIL ASSEMBLY

NOTICE:

  When replacing the common rail, do not remove the foreign object mixing prevention caps of the common rail until just before the fuel inlet pipe and injection pipe are connected to the common rail.

1. Install the common rail with the 2 bolts.

   Torque:
     38 N*m{ 387 kgf*cm , 28 ft.*lbf }

1. Connect the fuel pressure sensor connector.

4. INSTALL FUEL SUPPLY PUMP ASSEMBLY

1. Check that the supply pump gear in the timing gear case moves back and forth smoothly.

1. Install a new O-ring to the pump.

1. Apply a light coat of engine oil to the O-ring.

1. Align the set key on the drive shaft with the groove of the injection gear.

1. Install the pump with the 2 nuts.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf }

1. Set a new O-ring before tightening the set nut.

1. Using SST, hold the crankshaft pulley and install the set nut.

   SST
     09213-58013
     09330-00021

   Torque:
     64 N*m{ 653 kgf*cm , 47 ft.*lbf }

1. Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.

   Thrust clearance:
     0.15 to 0.55 mm (0.0059 to 0.0217 in.)
   If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat the step above.

1. Connect the 2 connectors.

1. Connect the 2 fuel hoses.

1. Temporarily install the fuel inlet pipe with the union nuts.

   NOTICE:
   1. If the supply pump is replaced, the fuel inlet pipe must be replaced.
   2. Keep the fuel inlet pipe free of foreign matter.

1. Using SST, tighten the injection pipe union nut 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 nut on the supply pump side.

   SST
     09023-12701

   Torque:
     32 N*m{ 326 kgf*cm , 24 in.*lbf } for use with SST
     35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST
   Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Install the oil level gauge guide with the 2 bolts.

   Torque:
     8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

1. Install the clamp with the bolt.

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

5. INSTALL STARTER ASSEMBLY

1. A/T:
   Install the starter and ground cable with the 2 nuts and bolt.

1. M/T:
   Install the starter and ground cable with the nut and bolt.

   Torque:
     68 N*m{ 693 kgf*cm , 50 ft.*lbf }

1. Install the starter wire to terminal 30 with the nut.

   Torque:
     9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }

1. Connect the starter connector.

1. A/T:
   Install the A/T oil dipstick with the 2 bolts.

1. M/T:
   Install the clutch release cylinder.

6. INSTALL 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.

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.

7. INSTALL INJECTION PIPE

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.

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.).

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.

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.).

8. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

1. Temporarily install the fuel inlet pipe with the union nuts.

   NOTICE:
   1. If the supply pump is replaced, the fuel inlet pipe must be replaced.
   2. Be careful that dust, dirt or any other foreign matter does not contact the joint area of the fuel inlet pipe.

1. Using SST, tighten the inlet pipe union nut 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

1. Using SST, tighten the inlet pipe union nut on the supply pump 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

1. Install the oil level gauge guide with the 2 bolts.

   Torque:
     8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

1. Install the clamp with the bolt.

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

9. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

1. Apply clean engine oil to a new O-ring.

1. Install the O-ring to the dipstick.

1. Install the level gauge with the bolt.

   Torque:
     8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

10. INSTALL MANIFOLD STAY

1. Install the stay with the 2 bolts.

   Torque:
     19 N*m{ 194 kgf*cm , 14 ft.*lbf }

11. ADD FUEL

12. TIGHTEN FUEL TANK CAP ASSEMBLY

13. ADD ENGINE OIL

14. BLEED AIR FROM FUEL SYSTEM

1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

16. PERFORM INITIALIZE

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

17. CHECK FOR FUEL LEAKS

18. CHECK FOR ENGINE OIL LEAKS

19. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD)

1. Install the under cover with the 2 bolts.

   Torque:
     28 N*m{ 286 kgf*cm , 21 ft.*lbf }

20. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)

1. Install the under cover with the 4 bolts.

   Torque:
     28 N*m{ 286 kgf*cm , 21 ft.*lbf }