Replacing the seals of an oil cooler on a 642-diesel engine was an infamous repair. Down in between the engine valley lies the oil cooler hiding beneath a unique intake plenum containing coolant passages. When the seals fail, a noticeable oil leak results with the potential for coolant and oil to mix.

Luckily updated seals have been designed and have since remedied this problem. To perform this repair, the top of the engine is essentially stripped down to its cylinder head. The most significant components that have been re-installed are as follows: Windshield wiper system, turbocharger, intake system, engine wiring harness, and fuel rail system.

Great attention to detail is required to perform this repair successfully. The average time expectancy for this job is approximately 8 hours. The amount of time to properly clean all traces of oil in this repair takes about one hour. Common mistakes typically result in broken components and an exhaust, intake, fuel, or coolant leak. In some cases, mistakes aren’t caught until after the final assembly.