Removal and Installation

REMOVAL

1. Disconnect cable from negative terminal of battery.

CAUTION: Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.

2. Drain engine coolant.
3. Remove alternator.
4. Remove oil filter.





5. Disconnect water by-pass hose from oil cooler.





6. Remove oil cooler.
a. Remove the relief valve and plate washer
b. Remove the two nuts, oil cooler and two gaskets.
c. Remove the 0-ring from the oil cooler.





d. Remove the bolt, and disconnect the water by-pass pipe from the oil cooler bracket.





7. Remove oil cooler bracket.
a. Remove the four bolts and oil cooler bracket.
b. Remove the two 0-rings from the oil cooler.


INSTALLATION





1. Install oil cooler bracket.
a. Install two new 0-rings to the oil cooler bracket.





b. Apply a light coat of engine oil on the small 0-ring.





c. Install the oil cooler bracket with the four bolts.
Torque: 7.8 Nm (69 in lb)





2. Install oil cooler.
a. Install new 0-ring and gasket to the oil cooler.





b. Temporarily install the water by-pass pipe with the bolt.





c. Apply a light coat of engine oil on the threads and under the head of the relief valve.
d. Temporarily install two new gaskets and the oil cooler with the plate washer, relief valve and two nuts.





e. Tighten the relief valve.
Torque: 78 Nm (58 ft lb)
f. Tighten the two nuts holding the oil cooler to the water by-pass pipe.
Torque: 12 Nm (9 ft lb)
g. Tighten the bolt holding the water by-pass pipe to oil cooler bracket.
Torque: 18 Nm (13 ft lb)





3. Connect water by-pass hose to oil cooler.
4. Install oil filter.
5. Install alternator.
6. Connect cable to negative terminal of battery.
7. Fill with engine coolant.
8. Start engine and check for leaks.
9. Check engine oil level.