Oil Cooler Line Replacement (Front)

Oil Cooler Line Replacement (Front)

^ Tools Required
- J 28467-B Universal Engine Support Fixture
- J 38185 Spring Hose Clamp Pliers
- J 41803 Engine Support Fixture
- J 44827 Transmission Cooler Quick Disconnect

Removal Procedure





1. Position the front wheels straight ahead, remove the ignition key to lock the steering column.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
3. Drain the cooling system.
4. Raise and suitably support the vehicle.
5. Place a drain pan under the vehicle to catch any fluid.





6. Reposition the plastic retainer, in order to gain access to the lower transmission oil cooler (TOC) connection.
7. Using J 44827, disconnect the lower TOC line from the oil cooler.
8. Lower the vehicle; leave the vehicle on the hoist.
9. Reposition the plastic retainer, in order to gain access to the upper TOC connection.
10. Using J 44827 disconnect the upper TOC line from the oil cooler.
11. Remove the air cleaner assembly.
12. Remove the upper and lower radiator support.





13. Recover the refrigerant from the air conditioning (A/C) system.
14. Remove the front evaporator tube to condenser bolt.

Important: Cap or tape the opening in the front evaporator tube and condenser immediately to prevent contamination.

15. Disconnect the front evaporator tube from the condenser.





16. Using a back-up wrench on the condenser fitting (2), loosen the compressor hose fitting (1) from the condenser.





17. Disconnect the compressor hose from the condenser.
18. Discard the O-ring seal and cap or tape the compressor hose and condenser openings.





19. Using J 38185, release and reposition the coolant surge tank upper hose clamp away from the radiator inlet.
20. Separate the surge tank upper hose from the radiator inlet.





21. Using J 38185, release and reposition the radiator inlet hose clamp away from the radiator inlet.
22. Separate the radiator inlet hose from the radiator inlet.





23. Using J 38185, release and reposition the radiator outlet hose clamp away from the radiator outlet.
24. Separate the radiator outlet hose from the radiator outlet.





25. Carefully pivot the A/C condenser with the radiator forward and tie off to support the assembly.





26. Remove the steering column intermediate shaft lower coupling shield.
27. Match-mark the intermediate shaft lower coupling to the power steering (PS) gear to ensure correct orientation upon installation.
28. Remove the intermediate shaft lower coupling bolt.
29. Disconnect the intermediate shaft lower coupling from the PS gear. Slide the intermediate shaft lower coupling off of the PS gear steering shaft.





30. Remove the PS cooler retaining bolts.





31. Remove the brake pressure modulator valve (BPMV) bracket.
32. Remove the PS gear mounting bolts and nuts.
33. Release the PS gear and cooler from the front suspension crossmember, then slave the gear and cooler forward.
34. Remove the A/C compressor bracket.
35. Remove the generator.
36. Install the J 41803 and the J 28467-B in order to support the engine.
37. Remove the right hand engine mount (and bracket).





38. Remove the TOC front pipe front clip.
39. Raise the vehicle.





40. Remove the TOC front pipe front retaining clamp bolt and retaining clamp.





41. Remove the TOC front pipe rear retaining clamp bolt and retaining clamp.
42. Disconnect the TOC front pipe fittings from the junction fittings at the engine flywheel housing, then cap the pipe fittings and plug the junction fittings to prevent contamination.
43. Lower the vehicle; leave the vehicle slightly above the ground.
44. Finesse the TOC front pipes out of the vehicle (through the top).

Installation Procedure





1. Install the TOC front pipes to the vehicle (through the top of the vehicle).Finesse the pipes into position.
2. Raise the vehicle.
3. Remove the caps from the rear of the TOC front pipes and remove the plugs from the junction fittings at the engine flywheel housing.

Notice:

4. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front upper and lower pipe fittings to the junction fittings at the engine flywheel housing.
Tighten the transmission oil cooler front upper and lower pipe fittings to the junction at the engine flywheel housing to 27 Nm (20 ft. lbs.).
5. Install the TOC front pipe rear retaining clamp and bolt.
Tighten the transmission oil cooler front pipe rear retaining clamp bolt to 2.2 Nm (19 inch lbs.).





6. Install the TOC front pipe front retaining clamp and bolt.
Tighten the transmission oil cooler front pipe front retaining clamp bolt to 12 Nm (106 inch lbs.).





7. Install the TOC front pipe front clip.





8. Install the right hand engine mount (and bracket).
9. Lower the vehicle; leave the vehicle on the hoist.
10. Remove the J 41803 and the J 28467-B.
11. Install the generator.
12. Install the A/C compressor bracket.
13. Position the PS gear and cooler to the front suspension crossmember.
14. Install the BPMV bracket.
15. Install the PS gear mounting bolts and nuts.
Tighten the power steering gear mounting nuts to 100 Nm (74 ft. lbs.).





16. Install the PS cooler retaining bolts.
Tighten the power steering cooler retaining bolts to 11 Nm (97 inch lbs.).





17. Connect the intermediate shaft lower coupling to the PS gear; be sure that the intermediate shaft and the PS gear steering shaft are orientated as marked prior to disconnecting them. Slide the intermediate shaft lower coupling onto the PS gear steering shaft.
18. Install the intermediate shaft lower coupling bolt.
Tighten the steering column intermediate shaft lower coupling bolt to 34 Nm (25 ft. lbs.).
19. Install the intermediate shaft lower coupling shield.
20. Lower the vehicle.





21. Remove the tie-off retainer and carefully pivot the AC condenser and the radiator back into position.





22. Install the radiator outlet hose to the radiator outlet.
23. Using J 38185, position the radiator outlet hose clamp onto the radiator outlet.





24. Install the radiator inlet hose to the radiator inlet.
25. Using J 38185, position the radiator inlet hose clamp onto the radiator inlet.





26. Install the surge tank upper hose to the radiator inlet.
27. Using J 38185, position the coolant surge tank upper hose clamp onto the radiator inlet.





28. Install the compressor hose to the condenser.





29. Using a back-up wrench on the condenser fitting (2), tighten the compressor hose fitting (1) to the condenser.
Tighten the fitting to 24 Nm (17 ft. lbs.).





30. Connect the front evaporator tube to the condenser.
31. Install the front evaporator tube to condenser bolt.
Tighten the front evaporator tube bolt to 27 Nm (20 ft. lbs.).
32. Install the upper and lower radiator support.
33. Install the air cleaner assembly.





34. Connect the upper TOC line to the oil cooler using the following steps:
1. Push the TOC pipe into the quick connect fitting, until a click is heard.
2. Tug gently in the TOC line to ensure a proper connection.
35. Position the plastic retainer over the connection.
36. Raise the vehicle.
37. Connect the lower TOC line to the oil cooler using the following steps:
1. Push the TOC pipe into the quick connect fitting, until a click is heard.
2. Tug gently in the TOC line to ensure a proper connection.
38. Position the plastic retainer over the connection.
39. Lower the vehicle.





40. Connect the negative battery cable.
Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).
41. Fill the cooling system.
42. Recharge the AC system.
43. Check the transmission fluid level. Add if necessary.