Contents: Removal ⇩ Installation ⇩
Removal
CAUTION: Do not carry or use a cell phone when working with any fuel-related parts or in the immediate vicinity of such parts. The air contains highly flammable fuel vapors that can ignite. Failure to follow these instructions may result in personal injury.
CAUTION: Do not attempt to repair the fuel injection system while the engine is running. Fuel pressure in the system can reach 1650 bar. (23,931 psi). Failure to follow this instruction may result in injury.
CAUTION: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related parts. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in personal injury.
CAUTION: This procedure involves contact with fuel. Always be prepared for possible fuel splashing and practice safe fuel handling. Failure to follow these instructions could result in personal injury.
CAUTION: Wait at least 30 seconds after stopping the engine before attempting any repairs to the high pressure fuel injection system. Failure to do so could result in personal injury.
CAUTION: Before disconnecting or disassembling parts, make sure that the area around the contact surfaces and connections is clean. To avoid contamination of the system, close all open connections with plugs.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, it is especially important to maintain absolute cleanliness when working with these components. Open holes or lines must be plugged. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Make sure that the area of the workshop where the vehicle is being worked on is thoroughly cleaned and free of dust. Dirt and dust from clutch, brake, machining or welding work can contaminate the fuel system and cause problems later.
1. Disconnect the ground cable from the battery. For more information, refer to Specification.
2. Drain the coolant from the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
3. Remove the crankcase ventilation oil separator. For more information, refer to Crankcase Ventilation Oil Separator (10/17/04)
4. Disconnect the cooling system air bleed hose from the left EGR coolant inlet hose. Release the retaining clip.
5. Remove the elbow pipe of the cooling system from the cylinder head.
- Release the two clamps and disconnect the hoses.
- Remove four bolts.
- Remove and discard the O-rings.
6. Disconnect the knock sensor electrical connector. Disconnect the knock sensor wiring harness from the valve cover.
7. Remove the left knock sensor. Unscrew the bolt.
8.
NOTE: Some liquid will inevitably spill during this operation.
Remove the oil cooler.
- Remove eight bolts.
- Remove the gasket and discard it.
- Remove the sealing ring and discard it.
Installation
1.
CAUTION: Make sure the gasket is installed correctly.
NOTE: Make sure the contact surfaces of all parts are clean.
Install the oil cooler.
- Install a new gasket.
- Install the sealing ring.
- Insert the eight bolts and tighten them. (tightening torque 10 Nm).
- Screw in the bolts and tighten it. (tightening torque 20 Nm).
- Connect the knock sensor plug.
- Attach the knock sensor wiring harness to the valve cover.
- Install new O-rings.
- Insert the four bolts and tighten them. (tightening torque 10 Nm).
- Connect the hoses and secure them with clamps.
5. Install the crankcase ventilation oil separator. For more information, refer to Crankcase Ventilation Oil Separator (10/17/04)
6. Connect the ground cable to the battery. For more information, refer to Specification.
7. Fill and bleed the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
8. Check the engine oil level and top up if necessary.
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