WARNING  Coolant is toxic.  Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the turbocharger oil supply tube, bypass filter return tube, turbocharger drain tube, and the turbocharger. Refer to Procedure 010-033 in Section 10.
• Remove the lubricating oil filter. Refer to Procedure 007-013 in Section 7.
• Remove the coolant filter. Refer to Procedure 008-006 in Section 8.

For those engine applications utilizing the low mount oil cooler arrangement, follow the same procedure.

Remove the capscrew that holds the oil cooler support bracket to the cylinder block at the rear of the oil cooler.

Remove one of the capscrews that holds the oil cooler support to the cylinder block. Install a guide stud in the hole.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Remove the remaining five capscrews from the oil cooler support, and remove the cooler assembly.

Remove the oil cooler core hold-down capscrews.

NOTE: The oil cooler core can be removed from the transfer housing while still installed on the engine.

Remove the oil cooler core from the oil cooler transfer connection (housing) by pulling the oil cooler water transfer tubes out of the o-ring adapters.

Clean the gasket material from the cooler support and the cylinder block.

After removing the gasket material, clean with solvent and dry with compressed air.

NOTE: Do not allow dirt or gasket material to fall into the oil passages.

Clean the gasket surfaces on the oil cooler housing and the oil cooler core.

Install and clamp a short section of hose over either the inlet or outlet transfer tube of the oil cooler. Install a plug into the opposite end of the section of hose and install the clamp.

Attach a regulated air pressure hose to the other water transfer tube and apply air pressure.

Submerge the oil cooler into a tank of water heated to 82°C [180°F] for 3 to 5 minutes and inspect for leaks.

NOTE: If leaks are found, replace the oil cooler core.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Remove the oil cooler core from the water tank.

Remove the hoses and the clamps from the oil cooler.

Use lubricating oil to flush the oil side of the cooler to remove all the water.

Dry the oil cooler with compressed air.

Lubricate new o-rings with vegetable oil and install onto the oil cooler core transfer tubes.

Install the connection retainer and o-rings adapters with new o-rings. Do not tighten the four retainer capscrews at this time. Adapters must be loose so they will align with the transfer tubes.

NOTE: Make sure to keep o-rings in place when installing the adapters and retainer.

Install the oil cooler core onto the oil cooler transfer connection (housing) by inserting the transfer tubes into the o-ring adapters.

NOTE: Make sure the o-ring adapters move freely when the transfer tubes are inserted as this will allow tubes to be centered in the adapters.

Install the oil cooler core mounting gaskets and holddown capscrews.

Tighten the holddown capscrews.

Alternately tighten the connection retainer capscrews.

Install two guide studs into the oil cooler support mounting holes in the cylinder block.

Install a new oil cooler support gasket over the guide studs with the side marked “Cooler Side” facing outward or visible.

For those engine applications utilizing the low mount oil cooler arrangement, follow the same installation procedure.

Install the oil cooler assembly over the guide studs, and push it against the cylinder block.

Install the oil cooler support bracket capscrew. Do not tighten at this time.

Install four of the support mounting capscrew, and remove the two guide studs.

Install the two remaining capscrews, and tighten all support capscrews.

First, loosen the two capscrews which hold the oil cooler support bracket to the rear of the oil cooler housing.

Then, alternately and evenly, tighten the block mounting capscrew and the oil cooler housing capscrews beginning with the block mounting capscrew.

WARNING  Coolant is toxic.  Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the coolant filter. Refer to Procedure 008-006 in Section 8.
• Install the lubricating oil filter. Refer to Procedure 007-013 in Section 7.
• Install the turbocharger oil supply tube, bypass filter return tube, turbocharger drain tube, and the turbocharger. Refer to Procedure 010-033 in Section 10.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Connect the batteries. Refer to the OEM service manual.
• Check to make sure the lubricating oil system is full. Prelubricate the system.
• Operate the engine at low idle until the oil pressure comes up to 69 kPa [10 psi] minimum.
• Operate the engine at high idle until the water temperature reaches 82°C [180°F], and check for oil and coolant leaks.