Engine Oil Cooler

Replace the engine oil cooler assembly on a 2005 Dodge Viper 8.3L V10, including coolant drainage, hose disconnection, and component reinstallation with new seals.

Warnings

Tools required

Parts

• Engine oil cooler assembly × 1 — Use OEM specification
• Oil cooler O-ring seals × 1 — Use OEM specification
• Coolant hose clamps × 4 — Use OEM specification

Fluids

• Zerex G-05 HOAT 50/50 — 3 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely for at least 2 hours
3. Disconnect negative battery cable
4. Raise front of vehicle and support securely on jack stands
5. Remove engine belly pan or lower splash shield to access oil cooler area
6. Position drain pan beneath radiator drain plug and oil cooler area

Procedure

1. 1

   Drain cooling system
   Open the radiator drain plug at the bottom of the radiator and drain sufficient coolant into the drain pan to lower the level below the oil cooler; depending on the cooler's location this may require a substantial or complete drain. Close the drain plug after sufficient coolant is drained. This will lower the coolant level below the oil cooler to minimize spillage. Close the drain plug after sufficient coolant is drained.
   Torque spec

   Coolant Drain Plug15 Nm (11 lb-ft)
2. 2

   Access oil cooler assembly
   Locate the engine oil cooler assembly, which on the 8.3L V10 is a coolant-to-oil heat exchanger integrated with the oil filter housing/adapter. Verify the exact mounting location and orientation against the factory service manual before proceeding, and identify the inlet and outlet coolant hoses as well as the mounting fasteners. The oil cooler is a cylindrical or rectangular housing with coolant hoses connected to it. Identify the inlet and outlet coolant hoses, as well as the mounting bolts securing the cooler to the engine block.
3. 3

   Disconnect coolant hoses
   Using hose clamp pliers or a flathead screwdriver, loosen the hose clamps on both the inlet and outlet coolant hoses connected to the oil cooler. Slide the clamps back along the hoses. Carefully twist and pull the hoses off the oil cooler fittings. Be prepared for residual coolant spillage. Direct coolant into the drain pan.
   ⚠Coolant hoses may be adhered to fittings. Gently twist while pulling to avoid tearing the hose. Do not use excessive force on aging rubber hoses.
4. 4

   Remove oil cooler mounting fasteners
   Remove the bolts securing the oil cooler housing to the engine block. Confirm the exact bolt count and head size against the factory service manual before beginning. Support the oil cooler with one hand while removing the final bolt to prevent it from falling. Support the oil cooler with one hand while removing the final bolt to prevent it from falling.
5. 5

   Remove oil cooler assembly
   Carefully pull the oil cooler assembly away from the engine block. The cooler interfaces with the engine oil passages via O-ring seals. Expect residual engine oil to drain from the cooler and block passages. Tilt the cooler to drain oil into the drain pan. Keep the cooler upright to minimize oil spillage as you remove it from the engine bay.
6. 6

   Clean mounting surfaces
   Using shop towels, thoroughly clean the engine block mounting surface where the oil cooler seals. Remove all old O-ring material, oil residue, and debris. Inspect the mounting surface for cracks or damage. Clean the coolant hose fittings on the new oil cooler if necessary.
7. 7

   Install new O-ring seals
   Install the new O-ring seals onto the new oil cooler assembly. Lightly lubricate the O-rings with clean engine oil to aid installation and ensure proper sealing. Verify the O-rings are seated correctly in their grooves and are not twisted or pinched.
8. 8

   Install new oil cooler assembly
   Carefully align the new oil cooler with the engine block mounting holes and oil passages. Slide the cooler straight onto the mounting surface, ensuring the O-rings remain properly seated. Do not rotate or twist the cooler during installation to avoid damaging the seals.
9. 9

   Install mounting bolts
   Thread the 2 mounting bolts by hand to ensure proper alignment. Once all bolts are started, tighten them gradually in an alternating pattern to the factory-specified torque (verify exact value against the FSM) using a torque wrench. This ensures even pressure on the O-ring seals.
10. 10

    Reconnect coolant hoses
    Slide the inlet and outlet coolant hoses onto their respective fittings on the new oil cooler. Ensure each hose is fully seated on the fitting. Position the hose clamps over the hose-to-fitting connection points. If OEM constant-tension spring clamps are used, reinstall them fully seated over the connection; if worm-gear clamps are used, tighten securely without over-crushing the hose. Verify both clamps are positioned correctly and the hoses are secure.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
11. 11

    Refill cooling system
    Using Zerex G-05 HOAT 50/50 coolant, refill the cooling system through the radiator cap or coolant reservoir to the proper level, adding coolant equal to the amount drained earlier and topping off as needed. Leave the radiator cap off for the next step.
12. 12

    Bleed cooling system
    Start the engine and allow it to idle with the radiator cap off. Monitor the coolant level and add coolant as needed as air bubbles are purged from the system. Run the engine until the thermostat opens and coolant circulates through the system (coolant temperature gauge reaches normal operating range). Squeeze the upper radiator hose several times to help release trapped air. Once no more air bubbles appear and the coolant level stabilizes, turn off the engine and install the radiator cap.
    ⚠Monitor engine temperature closely during the bleeding process. Do not allow the engine to overheat. If temperature rises excessively, shut off the engine immediately and allow to cool.
13. 13

    Inspect for leaks
    With the engine off and cooling, inspect all connections at the oil cooler for coolant or oil leaks. Check the mounting surface, hose connections, and drain plug. Wipe all surfaces dry and monitor for several minutes. If any leaks are detected, address them before proceeding.
14. 14

    Reinstall underbody components
    Reinstall the engine belly pan or lower splash shield. Lower the vehicle from the jack stands. Reconnect the negative battery cable.

Reassembly

1. Reinstall underbody panels removed during access
2. Torque all fasteners to specification
3. Refill cooling system to proper level and bleed air completely
4. Verify all hose clamps are tightened securely

Verification

• Start engine and allow to reach normal operating temperature while monitoring for leaks
• Check coolant level after engine cools and top off if necessary
• Verify no oil or coolant leaks at oil cooler mounting surface or hose connections
• Confirm engine temperature remains in normal range during test drive
• Inspect under vehicle after test drive for any fluid drips or leaks

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