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 used, 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.
Do not reuse a lubricating oil cooler element after a debris related engine malfunction since there is no practical method for cleaning the cooler element. Metal particles which can circulate through the lubricating system can remain in the cooler core and cause engine damage. Do not allow dirt to enter the oil passages when cleaning the oil cooler.
Replace the lubricating oil cooler element if debris is found in the oil cooler.
When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of 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 or main bearing failures can be caused if debris is introduced into the cylinder block or lubricating oil cooler housing oil passages. The use of power tools combined with abrasive pads to clean gasket surfaces is not recommended.
Clean gasket surfaces by hand with a gasket scraper or cleaning pad, Part Number 3823258 or equivalent. If the gasket material residue can not be felt with a fingernail, the surface is ready to accept the new gasket.
Use solvent to clean and flush the oil cooler passages and cores.
Do not allow dirt or foreign material to enter oil passages in the cylinder block when cleaning the gasket sealing surfaces. Connecting rod bearing or main bearing failures can be caused if debris is introduced into the cylinder block or lubricating oil cooler housing oil passages. The use of power tools combined with abrasive pads to clean gasket surfaces is not recommended.
Clean the oil cooler to cylinder block gasket surface with Scotch-Brite™ 7448 abrasive pad.
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 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 no leaks are found, the element does not need to be removed but the capscrew torque must be checked and tightened to the specified torque.
Remove the oil cooler leak test kit mounting plate.
When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Remove the plugs from the oil cooler housing.
Use a mild solvent to clean around the oil feed hole.