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ENGINE LUBRICATION SYSTEM


B ENGINE

                                                                                                                                                                 A


                                                                                                                                                                 LU
                                                                                                    SECTION
                                                            ENGINE LUBRICATION SYSTEM                                                                            C


                                                                                                                                                                 D


                                                                                                                                                                 E
                                                                 CONTENTS
PRECAUTIONS ......................................................... 2.         OIL FILTER ................................................................ 8
                                                                                                                                                       .         F
 Precautions for Liquid Gasket ................................. 2     .          Removal and Installation ......................................... 8 .
   REMOVAL OF LIQUID GASKET SEALING ......... 2                        .            REMOVAL ............................................................ 8
                                                                                                                                                       .
   LIQUID GASKET APPLICATION PROCEDURE 2                               .....        INSTALLATION .................................................... 8.         G
PREPARATION .......................................................... 3
                                                                       .            INSPECTION AFTER INSTALLATION ................. 8                  .
 Special Service Tools .............................................. 3.         OIL PUMP .................................................................. 9
                                                                                                                                                       .
 Commercial Service Tools ....................................... 3    .          Removal and Installation ......................................... 9 .
                                                                                                                                                                 H
LUBRICATION SYSTEM ........................................... 4       .            REMOVAL ............................................................ 9
                                                                                                                                                       .
 Lubrication Circuit ................................................... 4
                                                                       .            INSTALLATION .................................................... 9.
 System Drawing ...................................................... 5
                                                                       .          Disassembly and Assembly ................................... 10      .
ENGINE OIL .............................................................. 6
                                                                       .            DISASSEMBLY .................................................. 10  .          I
 Inspection ................................................................ 6
                                                                       .            INSPECTION AFTER DISASSEMBLY ............... 10                    .
   ENGINE OIL LEVEL ............................................ 6     .            ASSEMBLY ........................................................ 11
                                                                                                                                                       .
   ENGINE OIL APPEARANCE ............................... 6             .         SERVICE DATA AND SPECIFICATIONS (SDS) ..... 12                        .          J
   ENGINE OIL LEAKAGE ....................................... 6        .          Standard and Limit ................................................. 12
                                                                                                                                                       .
   OIL PRESSURE CHECK ..................................... 6          .            OIL PRESSURE ................................................. 12  .
 Changing Engine Oil ............................................... 7 .            OIL PUMP .......................................................... 12
                                                                                                                                                       .
                                                                                                                                                                 K
                                                                                    REGULATOR VALVE ......................................... 12       .
                                                                                    ENGINE OIL CAPACITY .................................... 12        .
                                                                                  Tightening Torque .................................................. 12
                                                                                                                                                       .
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Revision; 2004 April                                                        LU-1                                                                2003 Q45
                                                 PRECAUTIONS

PRECAUTIONS                                                                   PFP:00001

Precautions for Liquid Gasket                                                     EBS0024R

REMOVAL OF LIQUID GASKET SEALING
q    After removing the mounting bolts and nuts, separate the mating
     surface using a seal cutter and remove the old liquid gasket
     sealing.
     CAUTION:
     Be careful not to damage the mating surfaces.
q    In areas where the cutter is difficult to use, use a plastic hammer
     to lightly tap the areas where the liquid gasket is applied.
     CAUTION:
     If for some unavoidable reason a tool such as a flat-bladed
     screwdriver is used, be careful not to damage the mating
     surfaces.                                                                 PBIC0002E



LIQUID GASKET APPLICATION PROCEDURE
1.   Using a scraper, remove the old liquid gasket adhering to the liq-
     uid gasket application surface and the mating surface.
     q Remove the liquid gasket completely from the groove of the
        liquid gasket application surface, mounting bolts, and bolt
        holes.
2.   Wipe the liquid gasket application surface and the mating sur-
     face with white gasoline (lighting and heating use) to remove
     adhering moisture, grease and foreign materials.
3.   Attach genuine liquid gasket tube to the tube presser.
     Use Genuine Thread sealant or equivalent. Refer to GI-46,
     "RECOMMENDED CHEMICAL PRODUCTS AND SEAL-                                  PBIC0003E


     ANTS" .

4.   Apply the liquid gasket without breaks to the specified location
     with the specified dimensions.
     q If there is a groove for the liquid gasket application, apply the
        liquid gasket to the groove.




                                                                               EMA0622D



     q   As for the bolt holes, normally apply the liquid gasket inside
         the holes. Occasionally, it should be applied outside the
         holes. Make sure to read the text of this manual.
     q   Within five minutes of liquid gasket application, install the mat-
         ing component.
     q   If the liquid gasket protrudes, wipe it off immediately.
     q   Do not retighten after the installation.
     q   After 30 minutes or more have passed from the installation, fill
         the engine oil and engine coolant.
         CAUTION:                                                              SEM159F
         If there are specific instructions in this manual, observe
         them.




Revision; 2004 April                                     LU-2                 2003 Q45
                                                       PREPARATION

PREPARATION                                                                                                                   PFP:00002
                                                                                                                                            A
Special Service Tools                                                                                                            EBS0024S

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number                                                                                                                               LU
  (Kent-Moore No.)                                                                       Description
  Tool name

  ST25051001                                                                             Measuring oil pressure
                                                                                                                                            C
  (J25695-1)                                                                             Maximum measuring range:
  Oil pressure gauge                                                                     2,452 kPa (25 kg/cm2, 356 psi)

                                                                                                                                            D

                                                                         S-NT050


  ST25052000                                                                             Adapting oil pressure gauge to cylinder block
                                                                                                                                            E
  (J25695-2)
  Hose
                                                                                                                                            F


                                                                         S-NT559
                                                                                                                                            G
  KV10115801                                                                             Removing and installing oil filter
  (J38956)                                                                               a: 64.3 mm (2.531 in)
  Oil filter wrench
                                                                                                                                            H



                                                                                                                                             I
                                                                         S-NT375


  WS39930000                                                                             Pressing the tube of liquid gasket
  (     --     )
  Tube presser                                                                                                                               J



                                                                                                                                            K
                                                                         S-NT052



Commercial Service Tools                                                                                                         EBS003GF
                                                                                                                                             L
  Tool name                                                                              Description

  Deep socket                                                                            Removing and installing oil pressure switch        M
                                                                                         Deep socket 26 mm (1.02 in)




                                                                         NT818


  Power tool                                                                             Loosening bolts and nuts




                                                                         PBIC0190E




Revision; 2004 April                                            LU-3                                                          2003 Q45
                       LUBRICATION SYSTEM

LUBRICATION SYSTEM                           PFP:15010

Lubrication Circuit                                EBS001KC




                                            PBIC1663E




Revision; 2004 April          LU-4          2003 Q45
                       LUBRICATION SYSTEM

System Drawing                                     EBS0024T

                                                              A


                                                              LU



                                                              C


                                                              D


                                                              E



                                                              F


                                                              G


                                                              H



                                                               I


                                                               J



                                                              K


                                                               L
                                            PBIC1664E




                                                              M




Revision; 2004 April          LU-5          2003 Q45
                                                 ENGINE OIL

ENGINE OIL                                                                                                 PFP:KLA92

Inspection                                                                                                     EBS0024U

ENGINE OIL LEVEL
NOTE:
Before starting the engine, check the oil level. If the engine is already started, stop it and allow 15 minutes
before checking.
1. Put vehicle horizontally.
2. Pull out oil level gauge and wipe it clean.
3. Insert oil level gauge and check that the engine oil level is within
    the range shown in the figure.
4. If it is out of range, adjust it.




                                                                                                            PBIC0801E


ENGINE OIL APPEARANCE
q   Check the oil for a white milky appearance or excessive contamination.
q   If the oil is milky, it is highly probable that it is contaminated with engine coolant. Repair the broken parts.
ENGINE OIL LEAKAGE
Check for engine oil leakage around the following area.
q  Oil pan
q  Oil pan drain plug
q  Oil pressure switch
q  Oil filter
q  Intake valve timing control cover
q  Front cover
q  Mating surface between cylinder block and cylinder head
q  Mating surface between cylinder head and rocker cover
q  Crank oil seal (front and rear)
OIL PRESSURE CHECK
WARNING:
q  Be careful not to burn yourself, as the engine oil is hot.
q  Engine oil pressure check should be done in "Parking position".
1. Check the engine oil level. Refer to LU-6, "ENGINE OIL LEVEL"
   .
2. Remove the engine undercover with power tool.
3. Remove the oil pressure switch to connect the oil pressure
   gauge.
4. After warming up the engine, check that engine oil pressure cor-
   responding to the engine speed is produced.
   NOTE:
   When engine oil temperature is low, the engine oil pressure
   becomes high.                                                                                            PBIC0136E




Revision; 2004 April                                  LU-6                                                2003 Q45
                                                     ENGINE OIL

Engine oil pressure [Engine oil temperature at 80 



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