Removal Procedure
Remove the bracket for the Electronic Control Module.
Drain the coolant from the cooling system into a suitable container.
Place a suitable container below the engine oil cooler in order to catch any fluids that might be spilled.
Engine oil cooler with a blanking plate
Engine oil cooler with a high mounted filter base
If the engine has a left hand side oil filter, remove the oil filter base. If the engine has a right hand side oil filter, follow Steps to remove the blanking plate (12). Remove the four setscrews (11). Remove the blanking plate (12).
Remove the joint. Discard the joint.
Make temporary identification marks on the plastic tube assemblies (3) in order to show the correct position of the tube assemblies.
Remove the plastic tube assemblies (3). Plug all plastic tube assemblies with new plugs. Cap all open ports with new caps.
Follow Steps to disconnect the engine wiring harness (4).
Disconnect the engine wiring harness (4) from the position sensor (2) for the fuel injection pump.
Disconnect the engine wiring harness (4) from the solenoid (1) for the fuel injection pump.
Disconnect the engine wiring harness (4) from the oil pressure sensor (13).
Cut the cable ties that secure the engine wiring harness (4) to the assembly of the oil cooler (6). Position the harness away from the assembly of the oil cooler.
Remove the tube assembly (9) for the fuel return from the cylinder head (not shown) and from the transfer pump (8). Plug the tube assembly with new plugs. Cap all open ports with new caps.
Engine oil cooler with a blanking plate or with a low mounted filter base
If necessary, loosen the two setscrews (15). Remove the setscrews (7) and remove the brackets (5) and (10) for the tube assemblies. Remove the assembly of the oil cooler (6) from the cylinder block. The setscrews are different lengths. Note the position of the different setscrews. Note the location and the orientation of the brackets for the tube assemblies.
Disassembly Procedure (Engine Oil Cooler with a Low Mounted Filter Base)
Remove the two setscrews (15). Remove the cooler matrix (19) from the spacer plate (17). Remove the joint (18). Discard the joint.
Disassembly Procedure (Engine Oil Cooler with a High Mounted Filter Base)
Remove the four nuts (23) from the assembly of the oil cooler (6).
Remove the cooler matrix (20) from the housing (22).
Remove the two joints (21). Discard the joints.
Assembly Procedure (Engine Oil Cooler with a Low Mounted Filter Base)
See disassembly illustrations.
Ensure that the cooler matrix (19) is clean and free from damage. Ensure that the spacer plate (17) is clean and free from damage. Replace any damaged components.
Position a new joint (18) onto the spacer plate (17). Install the cooler matrix (19) to the spacer plate.
Install the two setscrews (15) finger tight.
Position the brackets (5) and (10) onto the assembly of the oil cooler (6). Install the setscrews (7). Ensure that brackets for the tube assemblies are installed in the correct location and the correct orientation. The setscrews are different lengths. Ensure that the different setscrews are installed in the correct location.
Install the joint (16) to the assembly of the oil cooler (6). Push the setscrews (7) through the holes in the joint. The holes in the joint have serrations that hold the setscrews captive.
Assembly Procedure (Engine Oil Cooler with a High Mounted Filter Base)
See disassembly illustrations.
Ensure that the cooler matrix (20) and the housing (22) are clean and free from damage. Replace any damaged components.
Install two new joints (21) to the cooler matrix (20).
Install the cooler matrix (20) to the housing (22).
Install the four nuts (23) to the assembly of the oil cooler (6). Tighten the nuts to a torque of 22 N�m (16 lb ft).
Install the setscrews (7) to the assembly of the oil cooler (6).
Install the joint (16) to the assembly of the oil cooler (6). Push the setscrews (7) through the holes in the joint.
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Installation Procedure
See removal illustrations
Clean the joint face of the cylinder block.
Install the assembly of the oil cooler (6) to the cylinder block. Tighten the setscrews (7) finger tight. If the engine has a high mounted oil filter base, install the oil filter base (14) finger tight.
Tightening sequence for an engine oil cooler with a blanking plate or with a low mounted oil filter base
Tightening sequence for an engine oil cooler with a high mounted oil filter base
If the engine has a low mounted oil filter base or a blanking plate, tighten the setscrews to a torque of 22 N�m (16 lb ft) in the sequence that is shown in Illustration. If the engine has a high mounted oil filter base,
tighten the setscrews to a torque of 22 N�m (16 lb ft) in the. Tighten the remaining setscrews that secure the oil filter base to a torque of 22 N�m (16 lb ft).
Remove the plugs from the tube assembly (9). Remove the caps for the fuel return from the cylinder head and from the transfer pump (8). Install the tube assembly (9) to the cylinder head and to the transfer pump (8).
Follow Steps 5.a through 5.e in order to connect the engine wiring harness (4).
Place the harness in position.
Connect the engine wiring harness (4) to the position sensor (2) for the fuel injection pump.
Connect the engine wiring harness (4) to the oil pressure sensor (13).
Connect the engine wiring harness (4) to the solenoid (1) for the fuel injection pump.
Install new cable ties in order to secure the engine wiring harness (4) to the assembly of the oil cooler (6).
Remove the plugs from all plastic tube assemblies (3). Remove the caps from the appropriate ports. Install the plastic tube assemblies (3).
If the engine has a low mounted oil filter on the left hand side, install the oil filter base.
If the engine has a right hand side oil filter, follow Steps to install the blanking plate (12). Install the four setscrews (11) to the blanking plate (12).
Position a new joint (not shown) onto the blanking plate (12).
Install the assembly of the blanking plate to the assembly of the oil cooler (6). Tighten the setscrews (11) to a torque of 22 N�m (16 lb ft).
Fill the cooling system to the correct level.
Check the level of the engine lubricating oil.
Install the bracket for the Electronic Control Module (ECM).
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