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ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION LC
CONTENTS
ENGINE LUBRICATION SYSTEM..................................2 CHECKING RADIATOR ............................................11
Precautions ..................................................................2 CHECKING RADIATOR CAP ....................................11
LIQUID GASKET APPLICATION PROCEDURE ............2 CHECKING COOLING SYSTEM FOR LEAKS ............12
Preparation ..................................................................2 Water Pump ...............................................................12
SPECIAL SERVICE TOOLS ........................................2 COMPONENTS .......................................................12
Lubrication Circuit ........................................................3 REMOVAL ...............................................................12
Oil Pressure Check......................................................4 INSPECTION ...........................................................14
INSTALLATION........................................................14
Oil Pump ......................................................................4
REMOVAL AND INSTALLATION .................................4
Thermostat.................................................................16
DISASSEMBLY AND ASSEMBLY................................5 REMOVAL AND INSTALLATION ...............................16
OIL PUMP INSPECTION ............................................5 INSPECTION ...........................................................16
REGULATOR VALVE INSPECTION ............................6 Water Control Valve...................................................17
OIL PRESSURE RELIEF VALVE INSPECTION REMOVAL AND INSTALLATION ...............................17
(FOR OIL COOLER)...................................................6 INSPECTION ...........................................................18
OIL FILTER ...............................................................6 Radiator .....................................................................18
Oil Cooler.....................................................................7 REMOVAL AND INSTALLATION ...............................18
REMOVAL AND INSTALLATION .................................7 Cooling Fan Control System .....................................19
Service Data and Specifications (SDS).......................8 Refilling Engine Coolant ............................................19
OIL PRESSURE ........................................................8 Radiator (Aluminum type)..........................................20
REGULATOR VALVE .................................................8 PREPARATION .......................................................20
OIL PUMP .................................................................8 DISASSEMBLY ........................................................20
ENGINE COOLING SYSTEM..........................................9 ASSEMBLY .............................................................21
Precautions ..................................................................9 INSPECTION ...........................................................22
LIQUID GASKET APPLICATION PROCEDURE ............9 Overheating Cause Analysis .....................................23
Preparation ..................................................................9 Service Data and Specifications (SDS).....................24
SPECIAL SERVICE TOOLS ........................................9 THERMOSTAT ........................................................24
Cooling Circuit ...........................................................10 WATER CONTROL VALVE .......................................24
System Check............................................................11 RADIATOR ..............................................................24
CHECKING COOLING SYSTEM HOSES ...................11
ENGINE LUBRICATION SYSTEM
Precautions
Precautions
LIQUID GASKET APPLICATION PROCEDURE NFLC0001
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
+ For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
+ For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.
AEM080
Preparation
SPECIAL SERVICE TOOLS NFLC0002
Tool number
Description
Tool name
ST25051001 Measuring oil pressure
Oil pressure gauge Maximum measuring range: 2,452 kPa (24.5
bar, 25 kg/cm2, 356 psi)
NT558
ST25052000 Adapting oil pressure gauge to upper oil pan
Hose
NT559
WS39930000 Pressing the tube of liquid gasket
Tube pressure
NT052
LC-2
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Lubrication Circuit NFLC0003
SLC026BA
SLC335B
LC-3
ENGINE LUBRICATION SYSTEM
Oil Pressure Check
Oil Pressure Check NFLC0004
WARNING:
+ Be careful not to burn yourself, as the engine and oil may
be hot.
+ Oil pressure check should be done in "Neutral position"
(M/T) or "Parking position" (A/T).
1. Check oil level.
2. Remove oil pressure switch.
3. Install pressure gauge.
4. Start engine and warm it up to normal operating temperature.
SLC240B
5. Check oil pressure with engine running under no-load.
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)
Idle speed More than 69 (0.69, 0.7, 10)
2,000 390 (3.90, 3.98, 56.6)
If difference is extreme, check oil passage and oil pump
for oil leaks.
6. Install oil pressure switch with sealant.
SLC926-A
Oil Pump
REMOVAL AND INSTALLATION NFLC0005
CAUTION:
When removing the oil pans, oil pump assembly and timing
chain from engine, first remove the camshaft position sensor
(PHASE) and the crankshaft position sensor (REF)/(POS) from
the assembly.
Be careful not to damage sensor edge.
1. Drain engine oil.
2. Remove drive belts.
3. Remove camshaft position sensor (PHASE), and crankshaft
position sensor (REF)/(POS).
4. Remove engine lower covers.
5. Remove crankshaft pulley.
6. Remove front exhaust tube and its support.
7. Support engine at right and left side engine slingers with a
suitable hoist.
8. Remove engine right side mounting insulator and bracket bolts
and nuts.
9. Remove center member assembly.
10. Remove air compressor assembly and bracket.
11. Remove oil pans. Refer to EM-12, "Removal".
12. Remove water pump cover.
13. Remove front cover assembly.
14. Remove timing chain. Refer to EM-21, "Removal".
15. Remove oil pump assembly.
16. Reinstall any parts removed in reverse order of removal.
LC-4
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont'd)
DISASSEMBLY AND ASSEMBLY NFLC0006
SLC253BB
+ When installing oil pump, apply engine oil to rotors.
OIL PUMP INSPECTION NFLC0007
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
Body to outer rotor radial clearance 1 0.114 - 0.200 (0.0045 - 0.0079)
Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)
2
Body to inner rotor axial clearance 3 0.030 - 0.070 (0.0012 - 0.0028)
Body to outer rotor axial clearance 4 0.050 - 0.110 (0.0020 - 0.0043)
SLC932A
Inner rotor to brazed portion of hous- 0.045 - 0.091 (0.0018 - 0.0036)
ing clearance 5
+ If the tip clearance (2) exceeds the limit, replace rotor set.
+ If body to rotor clearances (1, 3, 4, 5) exceed the limit,
replace oil pump body assembly.
SLC933A
SLC934AB
LC-5
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont'd)
REGULATOR VALVE INSPECTION NFLC0008
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump body.
SLC251B
4. Check regulator valve to oil pump body clearance.
Clearance:
6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump body.
SLC935AA
OIL PRESSURE RELIEF VALVE INSPECTION (FOR OIL
COOLER) NFLC0036
Inspect oil pressure relief valve for movement, cracks and breaks
by pushing the ball. If replacement is necessary, remove valve by
prying it out with suitable tool.
Install a new valve in place by tapping it.
SLC033B
OIL FILTER NFLC0009
The oil filter is a small, full-flow cartridge type and is provided with
a relief valve.
+ Use Tool specified in MA-21 for changing oil filter.
SLC035B
LC-6
ENGINE LUBRICATION SYSTEM
Oil Cooler
Oil Cooler
REMOVAL AND INSTALLATION NFLC0037
SLC032B
1. Drain engine oil and coolant.
2. Remove oil cooler.
3. Installation is in reverse order of removal.
+ Do not spill coolant on the drive belt.
Inspection NFLC0037S01
Oil Cooler NFLC0037S0101
1. Check oil cooler for cracks.
2. Check oil cooler for clogging by blowing through coolant inlet.
If necessary, replace oil cooler assembly.
Oil Pressure Relief Valve NFLC0037S0102
Inspect oil pressure relief valve for movement, cracks and breaks
by pushing the ball. If replacement is necessary, remove valve by
prying it out with a suitable tool. Install a new valve in place by
tapping it.
LC-7
ENGINE LUBRICATION SYSTEM
Service Data and Specifications (SDS)
Service Data and Specifications (SDS)
OIL PRESSURE =NFLC0010
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)
Idle speed More than 69 (0.69, 0.7, 10)
2,000 390 (3.90, 3.98, 56.6)
REGULATOR VALVE NFLC0011
Unit: mm (in)
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)
OIL PUMP NFLC0012
Unit: mm (in)
Body to outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079)
Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)
Body to inner rotor axial clearance 0.030 - 0.070 (0.0012 - 0.0028)
Body to outer rotor axial clearance 0.050 - 0.110 (0.0020 - 0.0043)
Inner rotor to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036)
LC-8
ENGINE COOLING SYSTEM
Precautions
Precautions
LIQUID GASKET APPLICATION PROCEDURE NFLC0013
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
+ For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
+ For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.
AEM080
Preparation
SPECIAL SERVICE TOOLS NFLC0014
Tool number
Description
Tool name
WS39930000 Pressing the tube of liquid gasket
Tube pressure
NT052
EG17650301 Adapting radiator cap tester to radiator filler neck
Radiator cap tester a: 28 (1.10) dia.
adapter b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
NT564
KV99103510 Installing radiator upper and lower tanks
Radiator plate pliers A
NT224
KV99103520 Removing radiator upper and lower tanks
Radiator plate pliers B
NT225
LC-9
ENGINE COOLING SYSTEM
Cooling Circuit
Cooling Circuit NFLC0015
SLC336B
SLC272B
LC-10
ENGINE COOLING SYSTEM
System Check
System Check NFLC0016
WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSES NFLC0016S01
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR NFLC0016S02
Check radiator for mud or clogging. If necessary, clean radiator as
follows.
+ Be careful not to bend or damage the radiator fins.
+ When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically downward.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically downward.
+ Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71
psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
CHECKING RADIATOR CAP NFLC0016S03
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
SLC755AA
Pull the negative pressure valve to open it.
Check that it closes completely when released.
SMA967B
LC-11
ENGINE COOLING SYSTEM
System Check (Cont'd)
CHECKING COOLING SYSTEM FOR LEAKS NFLC0016S04
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
The pressure should not drop.
CAUTION:
Higher than the specified pressure may cause radiator
damage.
SLC756AA
Water Pump
COMPONENTS NFLC0017
SLC154BE
CAUTION:
+ When removing water pump assembly, be careful not to
get coolant on drive belt.
+ Water pump cannot be disassembled and should be
replaced as a unit.
+ After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
REMOVAL NFLC0018
1. Drain coolant from drain plugs on radiator and both sides of
cylinder block. Refer to MA-16, "Changing Engine Coolant".
2. Remove right side engine mounting, mounting bracket and
nuts.
3. Remove drive belts and idler pulley bracket.
4. Remove water pump drain plug.
5. Remove chain tensioner cover and water pump cover.
SLC939A
LC-12
ENGINE COOLING SYSTEM
Water Pump (Cont'd)
6. Pushing timing chain tensioner sleeve, apply a stopper pin so
it does not return. Then remove the chain tensioner assembly.
SLC940A
7. Remove the 3 water pump fixing bolts. Secure a gap between
water pump gear and timing chain, by turning crankshaft pul-
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