N14 Base Engine Troubleshooting and Repair Manual – 007-003   Lubricating Oil Cooler

Table of Contents

Remove
Clean
Pressure Test
Install

Remove

TOC

Drain the cooling system. Refer to Procedure

008-018-005.

Disconnect the battery.

NOTE: If the coolant is

not
going to be used again, dispose of used coolant and antifreeze in accordance with federal, state, and local laws and regulations.

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Remove the turbocharger oil supply tube, the bypass filter return tube, the turbocharger drain tube, and the turbocharger.

Remove the oil filter and the coolant filter.

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

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

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

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

 WARNING 

Because this part weighs more than 23 kg [50 lb], two people or a hoist will be required to lift the oil cooler assembly to avoid personal injury.

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Remove the oil cooler core holddown capscrews.

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

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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.

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Clean

TOC

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.

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 CAUTION 

Do not attempt to repair a damaged oil cooler core; it must be replaced.
 
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Clean the gasket surfaces on the oil cooler housing and the oil cooler core.

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Pressure Test

TOC

 CAUTION 

Do not reuse an oil cooler core after an engine failure since there is not a practical method to clean the cooler core. Metal particles which can circulate through the lubricating system can remain in the cooler core and can cause engine damage. Do not allow dirt or gasket material to enter the oil passages when cleaning the oil cooler and the cylinder block surface.
 
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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.

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Attach a regulated air pressure hose to the other water transfer tube and apply 81 kPa [60 psi] air pressure.

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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.

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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.

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Install

TOC

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

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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: Be careful to keep o-rings in place when installing the adapters and retainer.

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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.

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Install the oil cooler core mounting gaskets and holddown capscrews.

Tighten the holddown capscrews.

Torque Value:  27  n.m  [20 ft-lb]

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Alternately tighten the connection retainer capscrews.

Torque Value:  47  n.m  [35 ft-lb]

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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.

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

 
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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.

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

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

Torque Value:  47  n.m  [35 ft-lb]

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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.

Torque Value:  47  n.m  [35 ft-lb]

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Install the turbocharger, turbocharger oil supply tube, the bypass filter return tube, and the turbocharger drain tube. Refer to Procedure

010-033-026.

Fill and install a new oil filter and coolant filter. Refer to Procedures

007-013-026 and

008-006-026, respectively.

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Fill the cooling system. Refer to Procedure

008-018-028.

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.

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Last Modified:  12-May-2003