Oil Cooler: Service and Repair

REMOVAL







1. Drain engine coolant.
2. Remove air cleaner cap and hose.
3. Remove front exhaust pipe.
(a) Disconnect the heated oxygen sensor connector.





(b) Remove the 2 nuts and 2 bolts holding the front exhaust pipe to the rear Three-Way Catalytic Converter (TWC).
(c) Disconnect the front exhaust pipe, and remove the gasket.
(d) Loosen the clamp bolt and disconnect the clamp from the No. 1 support bracket.
(e) Remove the 2 bolts and No. 1 support bracket.





(f) Remove the 4 nuts, front exhaust pipe and 2 gaskets.
4. Remove No. 1 exhaust manifold.





(a) Remove the 3 bolts and No. 1 heat insulator.





(b) Remove the 6 nuts, exhaust manifold and gasket.





5. Remove oil pressure switch.





6. Remove oil cooler and oil cooler cover assembly.
Remove the 10 bolts, 2 nuts, oil cooler and oil cooler cover assembly and gasket.





7. Separate oil cooler and oil cooler cover.
Remove the 4 nuts, oil cooler and 2 gaskets from the oil cooler cover.





8. Remove relief valve.
Remove the plug, gasket, spring and relief valve.

INSTALLATION





1. Install relief valve.
Install the relief valve, spring and a new gasket with the plug.
Torque: 37 Nm (27 ft. lbs.)
2. Assemble oil cooler and oil cooler cover.
Install 2 new gaskets and the oil cooler to the oil cooler cover with the 4 nuts.
Torque: 17 Nm (12 ft. lbs.)
3. Install oil cooler and oil cooler cover assembly.
Install a new gasket, the oil cooler and oil cooler cover assembly with the 10 bolts and 2 nuts.
Torque: 21 Nm (15 ft. lbs.)
4. Install oil pressure switch.





(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No.08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
(b) Install the oil pressure switch.
5. Install No. 1 exhaust manifold.
(a) Install a new gasket and the exhaust manifold with the 6 nuts.
Torque: 39 Nm (29 ft. lbs.)
(b) Install the heat insulator with the 3 bolts.
Torque: 19 Nm (14 ft. lbs.)
6. Install front exhaust pipe.
(a) Install 2 new gaskets and the front exhaust pipe with the 4 nuts.
Torque: 63 Nm (46 ft. lbs.)
(b) Install the No. 1 support bracket with the 2 bolts.
Torque: 24 Nm (17 ft. lbs.)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19.5 Nm (14 ft. lbs.)
(d) Connect the front exhaust pipe to the rear Three-Way Catalytic Converter (TWC) with a new gasket, 2 bolts and 2 nuts.
Torque: 46 Nm (34 ft. lbs.)
7. Install air cleaner cap and hose.
8. Fill radiator with engine coolant.
9. Start engine and check for leaks.
10. Check engine oil.