Centinel System – Repair Manual – 007-003   Lubricating Oil Cooler

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

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  Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.

• Drain the cooling system.
  Refer to Procedure 008-018 (Cooling System) in Section 8.
• Remove the lubricating oil filter.
  Refer to Procedure 007-013 (Lubricating Oil Filter (Spin-On) in Section 7.
• Remove the variable geometry turbocharger.
  Refer to Procedure 010-033 (Turbocharger) in Section 10.
• Remove the EGR valve.
  Refer to Procedure 011-022 (EGR Valve) in Section 11.
• Remove the EGR cooler connection.
  Refer to Procedure 011-024 (EGR Cooler Connection) in Section 11.
• Remove the EGR cooler.
  Refer to Procedure 011-019 (EGR Cooler) in Section 11.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

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  Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.

• Drain the cooling system.
  Refer to Procedure 008-018 (Cooling System) in Section 8.
• Remove the lubricating oil filter.
  Refer to Procedure 007-013 (Lubricating Oil Filter (Spin-On)) in Section 7.
• Remove the turbocharger. This step is
  not required with a die cast oil cooler.
  Refer to Procedure 010-033 (Turbocharger) in Section 10.
• Remove the alternator.
  Refer to Procedure 013-001 (Alternator) in Section 13.

Remove two oil cooler mounting capscrews and install the guide pins.

Clean the area above the oil cooler to prevent debris entry into the oil passages.

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 18 capscrews, oil cooler, and gasket. Discard the gasket.

CAUTION  Immediately upon removal of the lubricating oil cooler assembly, a plug must be inserted into the housing and cylinder block oil passage drillings. Failure to insert the oil passage plug can result in a bearing failure, crankshaft failure, or both.

The reusable plugs, Part Numbers 4918322, 4918324, and 4918340, are included in protective plug kit, Part Number 4918319. These plugs are necessary to prevent debris from entering the lubrication system during the repair.

Plug the oil cooler housing filtered oil passage with plug, Part Number 4918323, the block filtered oil passage with plug, Part Number 4918340, and the block oil pump passage with plug, Part Number 4918322.

Firmly push the plugs into the oil passages to prevent all debris from entering the lubrication system when cleaning the gasket surface.

Inspect the oil thermostat seat depth.

Remove the oil thermostat.
Refer to Procedure 007-039 (Lubricating Oil Thermostat) in Section 7.

Measure from the spot face to the oil thermostat seat. Reference graphic for measurement points. If the measured diminsion for lubricating oil cooler housing with integrated filter head is less than the minimum dimension, the oil cooler housing will need to be replaced.

Install the oil thermostat.
Refer to Procedure 007-039 (Lubricating Oil Thermostat) in Section 7.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.

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

CAUTION  Do not allow dirt or foreign material to enter oil passages in the cooler housing when cleaning the gasket sealing surfaces. Connecting rod bearing failures can be caused if debris is introduced into the cylinder block or lubricating oil cooler housing oil passages.

Plug the oil cooler passages with rubber plugs, Part Numbers 4918322, 4918323, and 4918340, included in kit, Part Number 4918319, to prevent debris from entering the cooler when cleaning the gasket surface.

Clean gasket surfaces by hand with a gasket scraper or cleaning pad, Part Number 3823258. If the gasket material residue can
not be felt with a finger, the surface is ready to accept the new gasket.

Use solvent to clean and flush the oil cooler passages and cores.

Blow dry with compressed air.

Remove the rubber plugs when cleaning is complete.

CAUTION  Do not allow dirt or foreign material to enter oil passages in the cylinder block when cleaning the gasket sealing surfaces. Connecting rod bearing failures can be caused if debris is introduced into the cylinder block or lubricating oil cooler housing oil passages. Therefore, use of power tools combined with abrasive pads to clean gasket surfaces is not recommended.

Plug the oil passages in the cylinder block with rubber plugs.

Clean the oil cooler to cylinder block gasket surface with Scotch-Brite™ 7448 abrasive pad.

Remove the rubber plugs when cleaning is complete.

It is important to leak test the oil cooler assembly as a unit, so leaks at the mounting joints can be identified. These leaks can
not be found when testing individual elements that have been removed from the assembly. An element is replaced
only if it is found to be leaking.

This procedure is
most effective when the oil cooler assembly is tested in water below 7°C [44°F].

Use the mounting capscrews from the lubricating oil cooler to attach the two plates and corresponding o-rings from oil cooler leak test kit, Part Number 4918200, to the lubricating oil cooler housing.

Remove the threaded male union that connects to the turbocharger oil supply.

Install the threaded plug, Part Number 3089567.

Insert the o-ring from the oil filter into the filter head cap, Part Number 4918204.

Use engine oil to lubricate the gasket surface and install the filter head cap.

Attach air pressure regulator, Part Number 3164231, to the outlet plate air fitting and pressurize the assembly to 689 kPa [100 psi].

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.

Place the oil cooler assembly under water.

If bubbles are observed, carefully determine the source of the bubbles and replace the components as necessary.

If the element is suspected of leaking, refer to Procedure 007-007 (Lubricating Oil Cooler Element) in Section 7. for leak testing individual elements. Mounting joint leaks are much more common than element leaks. Do not replace components that do not leak.

If no leaks are found and the engine serial number is in the range of 14023600 to 1405000 and 7900000 to 79012457, replace the capscrews and gaskets if the elements are to be reused.

If no leaks are found and the engine serial number is not in the above ranges, the element does not get removed, but the capscrew torque is to be checked and then tightened to the specified torque.

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.

When installing a new two-element oil cooler on an older engine, be sure the cooler element mounting capscrews do
not interfere with the cylinder block.

Install the guide pins.

Remove the protective plugs from the oil passages. Make sure no debris enters the lubrication system. Using a clean shop towel, carefully wipe out the oil passages and inspect to make sure no debris is left in these passages.

Install a new mounting gasket and the oil cooler housing assembly.

Install the 18 capscrews.

Remove the guide pins and install the two capscrews.

Tighten the capscrews in a circular motion from the center out.

• Install the EGR cooler.
  Refer to Procedure 011-019 (EGR Cooler) in Section 19.
• Install the EGR cooler connections.
  Refer to Procedure 011-024 (EGR Cooler Connection ) in Section 11.
• Install the EGR valve.
  Refer to Procedure 011-022 (EGR Valve ) in Section 11.
• Install the lubricating oil filter.
  Refer to Procedure 007-013 (Lubricating Oil Filter (Spin-On)) in Section 7.
• Install the variable geometry turbocharger.
  Refer to Procedure 010-033 (Turbocharger) in Section 10.
• Fill the cooling system.
  Refer to Procedure 008-018 (Cooling System) in Section 8.
• Prime the lubricating oil system.
  Refer to Procedure 007-037 (Lubricating oil System) in Section 7.
• Fill the engine with clean oil.
• Operate engine to normal operating range and check for oil and coolant leaks.

• Install the oil filter. Install the alternator.
  Refer to Procedure 013-001 (Alternator) in Section 13.
• Install the turbocharger.
  Refer to Procedure 010-033 (Turbocharger) in Section 10.
• Fill the cooling system.
  Refer to Procedure 008-018 (Cooling System) in Section 8.
• Prime the lubricating oil system.
  Refer to Procedure 007-037 (Lubricating oil System) in Section 7.
• Fill the engine with clean oil.
• Operate the engine to normal operating range and check for oil and coolant leaks.