4BD1T oil cooler replacement.....advice.

**rijidij** · 21st November 2016, 01:24 PM

I need to replace the oil cooler assembly on the drivers side of the engine block. I've removed the intake manifold and various other bits and pieces to gain access, but from what I can see now, it looks like the injector pump has to come off to access the lower bolts of the cooler.
I've misplaced my workshop manual while moving house recently (downloading one now)
I just wanted to ask if anyone can confirm the pump does have to be removed and any advice on removing and replacing the pump. By the look of the pic below, I'm guessing it can only be removed from the front by removing the bolts as indicated, but I'm more concerned with re fitting regarding timing etc.
I'm sure everything will be in the manual in regards to lining things up again, but it's always good to hear from others who have tackled the same job.

I'll be pulling the radiator out anyway as it needs attention, so access to the front of the engine will be ok.

Any advice appreciated.

Cheers, Murray

**Jock The Rock** · 7th January 2017, 10:58 AM

Hey mate

Not a massive job to pull the pump

It can be a bit daunting the first time though. I've never pulled a pump off a 4 BD1, but have off many other engines

The general rule is set the engine to TDC on No. 1 cylinder, (easiest way is to pull the rocker cover and watch the valves). There will then be a way of locking the crankshaft so the engine can't move, next will be a way of locking the pump so that also shouldn't move (either in the form of a pin or behind a cover you pull off the side of the pump)

Then pull the round cover off the timing cover, and loosen the bolt holding the gear. (You may be better off doing this before you lock the engine to prevent damaging your locking pins). You may then need a puller to pull the gear off the taper of the fuel pump

After that it's a matter of removing the bolts and the pump, reassembly is the opposite making sure nothing has moved.

I would suggest scratching a mark between the timing cover and the fuel pump, from memory fuel pump timing on a Suzie is done by twisting the pump on it's mounts

Would definitely recommend finding yourself a manual before you start though

**rijidij** · 11th January 2017, 11:09 AM

Thanks Jock,
Job's done, I worked it all out in the end.
I did download a manual.
It wasn't a difficult job, but time consuming because of all the stuff that had to come off to access the cooler.
I'm just glad to have it back on the road.

Cheers, Murray

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