My question is about oil filter removal and what do you do?
Especially with regarding the crankshaft position sensor being in the way.
I have just fitted a Dyna oil cooler kit p/n: 26081-05 to my 2003 FXDX and part of the installation process of the Dyna oil cooler is to remove the oil filter and install the Oil Cooler Adapter Assembly (p/n: 26065-05), which includes a thermostat to control oil flow to the cooler.
Removing the oil filter before installation, I used Oil Filter Removal Wrench (p/n: 94686-00) which uses a ‘side on action’ to remove the filter. It was a bit of a fiddle to remove the filter, due to the crankshaft position sensor being, some what, in the way.
With the installation of the Oil Cooler Adapter Assembly, it pushes the filter approximately one inch (1.25 cm) towards the Crankshaft Position Sensor.
There is no room to use my oil removal wrench or use a strap wrench, especially with the oil cooler blocking the way.
In the service & owners manual it suggests to use Oil filter wrench (p/n: HD-42311) or (p/n: HD-44067), both which use an ‘end removal action’ and have a ‘cut out’ to get past the crankshaft position sensor. Still after the filter is loose, it can’t be moved past the crankshaft position sensor easily.
In the end I had to remove the crankshaft position sensor to install the filter.
It was a ‘right fiddle’ to re-install it. I found ‘wiggling with swearing’ was the best action. Removing the crankshaft position sensor from the loom means un-hooking it from the plug under the seat area and disconnecting the oil pressure switch - a right pain!
Is there an easier way?
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Its on the side of the block firewall side ... REMOVAL Numbers in text in parenthesis correspond to numbered components in image. Disconnect the wiring harness (1) from the Crankshaft Position (CKP) sensor pigtail. Securely attach a scrap piece of wire about 36 inches long to the CKP sensor pigtail. Later, this piece will be used as a pull wire to guide the new sensor pigtail back through the same routing. Raise and support the vehicle. Remove the oil filter and capture any lost engine oil in a container. Loosen the oil cooler lines at the engine block. Back out the fittings far enough in order to gain sufficient clearance for the sensor pigtail connector to pass between the oil cooler lines and the side of the engine block. Remove the fastening bolt for the CKP sensor (1). Remove the CKP sensor and the O-ring seal from the engine block. Remove the CKP sensor pigtail. Observe the routing of the pigtail. Gently pull the CKP sensor pigtail down through the routing path and out. Guide the pigtail connector along the top of the oil cooler lines around to the side of the engine block. Pass the connector between the lines and the block at the point of the widest gap. Stop when the pull wire is exposed at both ends of the routing path. Disconnect the sensor from the pull wire. INSTALLATION Securely attach the CKP sensor pigtail to the lower end of the pull wire. Pass the pigtail connector between the oil cooler lines and the engine block. Using the pull wire as a guide, pull the sensor pigtail along the top of the oil cooler lines and around to the rear of the engine. Use the pull wire to pull the pigtail into position. Disconnect the pull wire from the sensor pigtail. Connect the sensor pigtail to the harness connector. Thoroughly clean the mating surfaces of the CKP sensor and the engine block. Install the CKP sensor with a new O-ring seal into the engine block. Install the fastening bolt (1) for the CKP sensor. Check the harness for proper routing. Make sure that the wiring cannot come in contact with the exhaust manifold. Tighten the oil cooler lines at the engine block. Install the oil filter. Lower the vehicle. Recheck the engine oil level.
The way to tell on Harleys is as follows (with explanations).
If you pull the oil lines one at a time, the following will happen:
On the oil return, and the vent line, oil will not flow out (except maybe a little residual oil).
On the feed line (oil tank TO oil pump), oil will flow out, especially it the oil cap is removed!
NOW, if you\'re asking because you want to install an inline oil filter or oil cooler, the feed line IS NOT the one you want to install this on!!!
The feed line is gravity fed to the oil pump, and there is no pressurization in this line, and the line could cavitate (suck air), especially if the filter/cooler are mounted too high!
The RETURN line is where you want to install these items, as this line is pressurized with the engine running, forcing the oil through them on the way back to the oil tank.
So which is the vent, and which is the return?
Pull the two lines you have already identified as NOT being the feed line (as described above), start the bike and run for ONLY about 5-30 seconds (or however long is needed), and see which line has oil coming out of it under pressure.
THIS is the line to install an oil filter and/or cooler.
REMOVAL - 2.0, 2.4, 2.4L TURBO The Crankshaft Position Sensor is in the front of the engine block just under the starter motor (CRANKSHAFT POSITION SENSOR LOCATION).
Disconnect the negative battery cable. Raise vehicle and support. On 2.4L SRT-4 remove the lower inner cooler hose from the metal tube. Remove the Structural Collar (Structural Collar and Bending Strut-(Automatic Transaxle Equipped) ), refer to the Engine, Structural Collar Removal and Installation section. Unlock and disconnect the electrical connector to the crankshaft position sensor. Remove the crankshaft position sensor bolt. Remove the sensor. Arrow points to sensor in picture.
Not uncoomon. If you look where the oil filter is in the front of the motor by the radiator. Where the oil filter screws onto is the oil cooler and has coolant passing around it in a jacket. The oil pressure is greater than that of the cooling system pressure. Replace that cooler and flush the cooling system. This should cure it.
Unfasten the two bolts retaining the radiator upper sight shield, then position the shield aside.
Remove the hood weather seal.
Remove the wiper pivot arms.
Remove the LH cowl vent screen and wiper module.
On SC engines, remove intercooler/charge air cooler tubes.
Install a Three Bar Engine Lifting Support D88L-6000-A or equivalent.
Raise and safely support the vehicle.
Remove the front engine support insulator through bolt. On SC, also remove the LH front engine support/mount retaining strap bolt.
Partially lower the vehicle. Raise the engine with the lifting support tool.
Raise and safely support the vehicle. Remove the starter motor assembly.
Position a drain pan, drain the engine oil, and remove the oil filter.
Remove the starter motor wire, ground strap and oil cooler inlet tube (automatic transmission only).
Unfasten the oil pan-to-bell housing bolts and Crankshaft Position (CKP) sensor lower shield retaining bolts (if equipped).
Remove the remaining oil pan retaining bolts.
Remove the steering shaft pinch bolts and separate the steering shaft.
Position a transmission jack under the front of the front subframe. Remove the six rearward bolts on the front of subframe, then loosen the two forward subframe bolts.
Remove the lower shock absorber-to-control arm bolts and nuts (both sides).
Lower the front subframe.
Remove the oil pan and empty any residual oil from the pan.
Clean mating surfaces of the oil pan and cylinder block. Take great care to avoid damaging the machined surfaces!
Apply a bead of RTV silicone gasket sealer to the oil pan.
Fit the oil pan to block to ensure enough clearance has been provided to allow the oil pan to be installed without the sealant being scraped off, under the cylinder block assembly.
Install the oil pan retaining bolts at the cylinder block, bell housing and install the lower crankshaft sensor shield (if equipped). Tighten to 80-106 inch lbs. (9-12 Nm).
Raise subframe into position.
Install the lower shock absorber-to-front suspension lower arm bolts. Tighten to 103-144 ft. lbs. (140-195 Nm).
Install the two forward front sub-frame bolts and six bolts at the rear of the subframe.
Connect the steering column input shaft coupling, install the pinch bolt and tighten to 30-42 ft. lbs. (41-57 Nm).
If equipped with an automatic transaxle, install the oil cooler inlet tube and the oil cooler tube, the starter wire harness and the ground strap.
Install oil filter.
Partially lower the vehicle.
Carefully lower the engine with the engine support, seating the LH side locating pin before the RH side. Install the engine mount through bolts, (on SC engines, install LH mount retaining strap bolt), and tighten to 34-44 ft. lbs. (45-61 Nm).
Remove the engine support and lifting eyes, or equivalent. Carefully lower the vehicle.
On SC engines, install the intercooler/charge air cooler tubes.
Install the wiper module, the LH cowl vent screen and the left and right side wipers.
Install the hood weather seal.
Install the radiator upper sight shield and secure with the two retaining bolts.
Install the air cleaner outlet tube assembly.
Refill the engine crankcase with appropriate type and quantity of engine oil.
Connect the negative battery cable. Start the engine and check for leaks.
The lubrication system is a full flow filtration system pressure feed type. Oil from the oil pan is pumped by an internal gear type oil pump directly coupled to the crankshaft. Its pressure is regulated by a relief valve located in the timing chain case cover. The oil is pumped through an oil filter and feeds a main oil gallery. This oil gallery feeds oil under pressure to the main and rod bearings and the camshaft bearings. Passages in the cylinder block feed oil to the hydraulic lifters and rocker shaft brackets which feeds the rocker arm pivots.
It is necessary to remove the oil pan, oil pump pick-up tube and timing Chain Case Cover (CCC) to service the oil pump rotors. The oil pump pressure relief valve can be serviced by removing the oil pan and oil pickup tube.
Disconnect negative battery cable and drain the cooling system.
Remove the radiator assembly.
Raise and safely support the vehicle.
Drain the engine oil. Remove the oil filter.
Disconnect the sway bar and place it to the rear of the vehicle to gain access to the oil pan.
Remove the transmission support brackets and inspection cover.
Remove the oil pan and the oil pump pick-up tube.
Lower the vehicle.
Remove the accessory drive belts and tensioner pulley bracket.
Remove the power steering pump and set aside. Remove the air compressor mounting bolts and set compressor aside. Remove the compressor mounting bracket. It is not necessary to disconnect the refrigerant lines or evacuate the refrigerant from the air conditioning system.
Using an appropriate puller, remove the crankshaft pulley.
Remove the tensioner pulley bracket.
Remove the camshaft sensor from the chain case cover.
Remove the timing chain case cover mounting bolts and the cover from the front of the engine.
Clean the gasket material from the mating surfaces of the cover and the block.
Remove the oil pump cover retaining screws from the timing cover. Lift off the oil pump cover.
Remove the pump rotors. Wash all parts in solvent and inspect carefully for damage or wear.
Clean all parts well. Assemble the oil pump with new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover.
Install the pump cover and tighten the fasteners to 9 ft. lbs. (12 Nm).
Prime the oil pump prior to installation by filling the rotor cavity with clean engine oil.
Remove the crankshaft oil seal from the front cover.
Install a new cover gasket and O-ring onto the cover.
Rotate the crankshaft so the oil pump drive flats are vertical. Position the oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats.
Install the front cover making sure the pump is correctly engaged on the crankshaft, or severe damage may result.
Install the chain case cover screws and snug the two bottom screws and the top center screw. Ensure the cover is seated to the block then tighten all screws to 20 ft. lbs. (27 Nm).
Install the oil seal and the crankshaft damper.
Install the tensioner pulley bracket and the cam sensor.
Install the air conditioning compressor to the mounting bracket.
Install the accessory drive belt.
Raise and safely support the vehicle. Tighten the oil pan drain plug and install a new oil filter.
Install the oil pump pick-up tube and oil pan. Install the transaxle inspection cover, if removed.
Fill the crankcase with clean engine oil to the proper level. Install a new oil filter.
Install radiator assembly. Check condition of radiator hoses. Fill and bleed the cooling system.
Reconnect the negative battery cable. Run engine and check for leaks. Verify correct oil pressure with a gauge.
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Disconnect the negative battery cable. Drain the engine oil.
Remove the oil dipstick.
If necessary remove the exhaust pipe crossover.
If equipped with automatic transmission, remove the converter housing pan and the transmission oil cooler line retainer from the bracket.
On 1996-98 models, remove the oil filter and if equipped, the oil filter adapter.
If necessary, remove the starter brace and bolt and swing the starter aside.
Remove the strut rods, if equipped.
Remove the oil pan and discard the gaskets.
Apply a suitable sealant such as GM part number 12346192 or its equivalent to the front cover-to-block joint and to the rear crankshaft seal-to-block joint. Apply the sealant about 1 inch (25mm) in both directions from each of the four corners.
Clean all gasket surfaces and use new gaskets to assemble.
Install new gasket and seals.
Install the oil pan.
On 1988-95 models, tighten the pan bolts to 100 inch lbs. (11 Nm). Tighten the pan nuts to 17 ft. lbs. (23 Nm).
On 1996-98 models, tighten the oil pan nuts and bolts to 18 ft. lbs. (25 Nm).
Install the strut rods, if equipped.
If removed, install starter, starter brace and bolt.
If equipped, install the oil filter adapter.
If removed, install the oil filter.
If equipped with automatic transmission, install the converter housing pan and the transmission oil cooler line retainer to the bracket.