Oil Cooler

Oil Cooler









Disassembly

1. Remove the oil cooler. For additional information, refer to Oil Cooler Service and Repair. If the oil cooler is being removed as part of an engine disassembly, refer to Engine Engine - Disassembly.

2. NOTE: Do not discard the oil cooler cover bolts. They are self-tapping bolts and will be used for assembly.

Remove the 8 bolts and the oil filter base.

- Remove and discard the gaskets.





3. Remove the 2 bolts and the EGR cooler supply cover.
- Remove and discard the press-in-place gasket.

- Drain any remaining oil from the oil cooler assembly.





4. Remove the EGR coolant supply port.





5. NOTE: Do not discard the nuts from the oil cooler cover, they will be reused.

Remove the 2 oil cooler-to-oil cooler cover nuts.





6. NOTE: Do not discard the bolts from the oil cooler cover, they will be reused.

Remove the 2 oil cooler-to-oil cooler cover bolts.





7. Using 2 pieces of wood, position the oil cooler assembly so that the oil cooler is suspended between the wood.





8. NOTICE: The oil cooler cover may be difficult to remove. Use care so that the oil cooler cover is not damaged and can be reused.

Using the Front Axle Shaft Bearing Installer and Handle over the inlet and outlet port and tap with a hammer.

- Alternate between the inlet and outlet port until the oil cooler is removed from the cover.

- Discard the oil cooler and O-ring seals.





9. Remove and discard the blue oil cooler cover gasket from the oil cooler cover.





10. Remove and discard the 3 O-rings from the oil cooler cover.





11. NOTE: Not all oil cooler covers will have a threaded insert, some will have a cast boss. If the oil cooler cover has a threaded insert, the O-ring needs to be removed.

NOTE: Do not discard the threaded insert.

If equipped with a threaded insert, remove the threaded insert from the oil cooler cover by pushing down on the insert from the top of the oil cooler cover.





12. If equipped with a threaded insert, remove and discard the O-ring seal from the threaded insert.





13. Inspect the oil cooler cover for damage at the oil filter base and EGR cooler coolant supply cover.





14. Inspect the oil cooler cover for the following:
- sealing surfaces and threads for damage.

- O-ring seal bores of the oil cooler cover were not damaged during the oil cooler removal.

- Clean the oil cooler cover and remove any scale deposits with a wire brush.

15. Using compressed air make sure the drain hole on top of the oil cooler cover is clear of any debris.





16. NOTE: The vent hole is located on the left side, next to the passage, underneath the oil cooler cover.

Using compressed air make sure the vent hole underneath the oil cooler cover is clear of any debris.





Assembly

1. Using clean engine oil, lubricate the 4 O-rings for the oil cooler and install the O-rings on the oil cooler.
- Install the brown O-rings on the bottom slots on the oil cooler.

- Install the black O-rings on the top slots of the oil cooler.





2. If equipped with a threaded insert, lubricate the new O-ring seal with clean engine oil and install on the threaded insert.





3. NOTE: Be sure the threaded insert is well seated as it is held in place when the oil cooler cover is installed and secured to the oil cooler with mounting hardware.

If equipped with a threaded insert, install the threaded insert into the oil cooler cover.





4. Using clean engine oil, lubricate the 2 large O-rings and 1 small O-ring and install the O-rings in the oil cooler cover.





5. Install a new blue oil cooler cover gasket onto the oil cooler cover.





6. Place the new oil cooler on a flat, clean surface with the oil cooler ports facing up.





7. Assemble the oil cooler assembly.
- Position the oil cooler cover onto the oil cooler. Press down firmly on the 2 corners of the oil cooler cover, which are inline with the oil cooler ports, until the O-rings are fully seated into the oil cooler cover.





8. NOTE: Do not tighten the 2 bolts at this time.

Install the 2 oil cooler-to-oil cooler cover bolts.





9. NOTE: Do not tighten the 2 nuts at this time.

Install the 2 oil cooler-to-oil cooler cover nuts.





10. Tighten the 2 oil cooler-to-oil cooler cover bolts.
- Tighten to 22 Nm (16 lb-ft).





11. Tighten the 2 oil cooler-to-oil cooler cover nuts.
- Tighten to 22 Nm (16 lb-ft).





12. Install the EGR coolant supply port.





13. Using clean engine oil, lubricate the press-in-place gasket and install in the EGR coolant supply cover.





14. Install the EGR coolant supply cover and 2 bolts.
- Tighten to 10 Nm (89 lb-in).





15. Install new press-in-place gaskets in the oil filter base.





16. NOTE: The old oil cooler cover bolts or new self-tapping bolts will be used.

Install the oil filter base and 8 bolts.

1. Tighten the 5 bolts to 22 Nm (16 lb-ft).

2. Tighten the 3 bolts to 10 Nm (89 lb-in).





17. Install the oil cooler. For additional information, refer to Oil Cooler Service and Repair. If the oil cooler is being installed as part of an engine reassembly, refer to Engine Engine - Assembly.