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Installing an Oil Cooler PDF Print E-mail
Written by Kent Christensen #1681   
Tuesday, 01 June 1999

Steps are quoted literally from original instructions. Clarifying notes are added where necessary in green font. Send questions or comments to Kent Christensen #1681 at This e-mail address is being protected from spam bots, you need JavaScript enabled to view it

1

Drain off oil.
Unscrew the 3 hex. bolts at the oil-filter cover, take off the cover and remove filter element.
2

Use a screwdriver to unscrew the short tube from the engine block.
Degrease threaded bore (use suitable degreaser).
3

Screw in long tube from conversion kit until it projects only 3 mm from the engine block (insert with Loctite). Take O-ring off short tube and put it on long tube and push it inward with a new filter element.
Note: Centering lugs of filter element must face outward.

Note: Second instruction (take o-ring off ...) here is now irrelevant as o-ring is now attached to filter. In "old days" it was a separate item. Just put in the new filter.
4

Remove O-ring (1) from the old cover.
Take O-ring (2) from conversion kit.
5

Mount oil filter head to engine block with the existing hex. head screws (tighten in several stages). Take out blanking plugs.
6

Preassemble oil cooler with bracket. The pipe clamp (arrow) must face horzontally to the rear.
7

Screw oil cooler to lower crossmember. Unscrew the screw caps and secure oil hoses to cooler with the cap nuts.
Note: Fit short hose on the right - viewed in the normal direction of travel.
8

Secure oil lines to oil filter head with hollow screws and seals 1 and 2 (see illustration).
9

Fill up with oil (2.5 liters including oil cooler and hoses). Change M 6 hex. bolt (arrow) for assembly screw (1) and tighten down to obtain good seal. Crank engine over on starter (with spark plug terminals removed or spark plugs unscrewed) until oil telltale lamp in combination instrument stops glowing. Change assembly screw for standard screw (renew sealing ring if necessary).
Note: The same procedure must be used for repair work involving disconnection of the oil hoses or oil cooler and after every oil filter change.

Note: Oil capacity figure applies to old-style oil pan (as shown in step 5). Since '81 a deeper pan is standard and capacity is then 2.75 liters. Cooler adds 250cc to total capacity.

Important: For '81-on models with factory electronic ignition do NOT crank engine "with spark plug terminals removed or spark plugs unscrewed." Just start engine and leave at idle speed until oil pressure comes up.

 

Illustrated Parts Breakdown
(as of 1984--see dealer for latest part numbers, etc.)

 

Cover of original instructions

 
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