GSIC - Global Service Information Center

# 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 and seat belt pretensioner 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 filter 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 CAP ASSEMBLY

6. DRAIN FUEL

7. REMOVE MANIFOLD STAY

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

1. Remove the bolt and clamp.

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

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

   SST
     09023-12701

10. REMOVE INJECTION PIPE

NOTICE:

1. After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
2. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

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

1. Remove the bolt and No. 2 injection pipe clamp.

1. Using SST, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

   SST
     09023-12701

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

   2. Using SST, loosen the union nuts and remove the No. 4 injection pipe.

      SST
        09023-12701

11. REMOVE OIL FILTER SUB-ASSEMBLY

1. Using SST, remove the oil filter.

   SST
     09228-07501

   HINT:
     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. Disconnect the starter connector.

1. Remove the nut and disconnect the starter wire.

1. A/T:
   Remove the 2 bolts and A/T dipstick.

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

1. A/T:
   Remove the 2 nuts, bolt, ground cable and starter.

1. M/T:
   Remove the nut, bolt, ground cable and starter.

13. REMOVE FUEL SUPPLY PUMP ASSEMBLY

1. Remove the bolt and clamp.

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

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

   SST
     09023-12701

1. Disconnect the 2 fuel hoses.

1. Disconnect the 2 connectors.

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.

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

   SST
     09213-58013
     09330-00021

1. Loosen the 2 nuts.

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

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

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.