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lc


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                                                                                           ENGINE LUBRICATION &
                                                                                              COOLING SYSTEMS


                                                                                                   SECTION                      LC
                                                               CONTENTS
                                      QG                                                    COMPONENTS .......................................................18
                                                                                            CONTROL SYSTEM ................................................18
ENGINE LUBRICATION SYSTEM..................................3                            Changing Engine Coolant..........................................18
  Precautions ..................................................................3         - DRAINING ENGINE COOLANT - ............................18
     LIQUID GASKET APPLICATION PROCEDURE ............3                                    - REFILLING ENGINE COOLANT - ...........................19
  Preparation ..................................................................3         - FLUSHING COOLING SYSTEM -............................20
     SPECIAL SERVICE TOOLS ........................................3                    Radiator (Aluminum type)..........................................21
  Lubrication Circuit ........................................................4           PREPARATION .......................................................21
  Oil Pressure Check......................................................5               DISASSEMBLY ........................................................21
  Oil Pump ......................................................................5        ASSEMBLY .............................................................22
     REMOVAL AND INSTALLATION .................................5                          INSPECTION ...........................................................23
     DISASSEMBLY AND ASSEMBLY................................6                          Overheating Cause Analysis .....................................24
     INSPECTION .............................................................7          Service Data and Specifications (SDS).....................25
     REGULATOR VALVE INSPECTION ............................8                             THERMOSTAT ........................................................25
  Changing Engine Oil....................................................8                RADIATOR ..............................................................25
  Changing Oil Filter.......................................................9             COOLANT CAPACITY ..............................................25
  Service Data and Specifications (SDS).....................10
     OIL PRESSURE CHECK ..........................................10                                                       YD
     OIL PUMP INSPECTION ..........................................10
     REGULATOR VALVE INSPECTION ..........................10                         ENGINE LUBRICATION SYSTEM................................26
     OIL CAPACITY ........................................................10           Precautions ................................................................26
ENGINE COOLING SYSTEM........................................11                           LIQUID GASKET APPLICATION PROCEDURE ..........26
  Precautions ................................................................11       Preparation ................................................................26
     LIQUID GASKET APPLICATION PROCEDURE ..........11                                     SPECIAL SERVICE TOOLS ......................................26
  Preparation ................................................................11       Lubrication Circuit ......................................................27
     SPECIAL SERVICE TOOLS ......................................11                    Oil Pressure Check....................................................28
  Cooling Circuit ...........................................................12        Oil Pump ....................................................................28
  System Check............................................................12              REMOVAL AND INSTALLATION ...............................28
     CHECKING COOLING SYSTEM HOSES ...................12                                  DISASSEMBLY AND ASSEMBLY..............................29
     CHECKING RADIATOR ............................................13                     OIL PUMP INSPECTION ..........................................29
     CHECKING RADIATOR CAP ....................................13                         REGULATOR VALVE INSPECTION ..........................30
     CHECKING COOLING SYSTEM FOR LEAKS ............13                                  Changing Engine Oil..................................................31
  Water Pump ...............................................................14         Oil Filter Bracket ........................................................32
     REMOVAL AND INSTALLATION ...............................14                           REMOVAL AND INSTALLATION ...............................32
     INSPECTION ...........................................................14          Changing Oil Filter.....................................................32
  Thermostat.................................................................15           REMOVAL ...............................................................33
     REMOVAL AND INSTALLATION ...............................15                           INSTALLATION........................................................33
     INSPECTION ...........................................................16          Oil Cooler...................................................................34
  Radiator .....................................................................17        REMOVAL AND INSTALLATION ...............................34
     COMPONENTS .......................................................17              Service Data and Specifications (SDS).....................35
  Cooling Fan ...............................................................18           OIL PRESSURE CHECK ..........................................35
                                                   CONTENTS                                (Cont'd)
       REGULATOR VALVE INSPECTION ..........................35                           REMOVAL AND INSTALLATION ...............................41
       OIL PUMP INSPECTION ..........................................35                  INSPECTION ...........................................................42
       ENGINE OIL CAPACITY ...........................................35             Radiator .....................................................................42
ENGINE COOLING SYSTEM........................................36                        COMPONENTS .......................................................42
  Precautions ................................................................36       REMOVAL AND INSTALLATION ...............................43
    LIQUID GASKET APPLICATION PROCEDURE ..........36                                 Cooling Fan ...............................................................43
  Preparation ................................................................36       COMPONENTS .......................................................43
    SPECIAL SERVICE TOOLS ......................................36                     CONTROL SYSTEM ................................................43
  Cooling Circuit ...........................................................37      Changing Engine Coolant..........................................44
  System Check............................................................38           - DRAINING ENGINE COOLANT - ............................44
    CHECKING COOLING SYSTEM HOSES ...................38                                - REFILLING ENGINE COOLANT - ...........................45
    CHECKING RADIATOR ............................................38                   - FLUSHING COOLING SYSTEM -............................46
    CHECKING RADIATOR CAP ....................................38                     Radiator (Aluminum type)..........................................47
    CHECKING COOLING SYSTEM FOR LEAKS ............39                                 Overheating Cause Analysis .....................................47
  Water Pump ...............................................................39       Service Data and Specifications (SDS).....................48
    REMOVAL AND INSTALLATION ...............................39                         THERMOSTAT ........................................................48
    REMOVAL ...............................................................40          RADIATOR ..............................................................48
    INSPECTION ...........................................................40           ENGINE COOLANT CAPACITY ................................48
    INSTALLATION........................................................40
  Thermostat.................................................................41




                                                                              LC-2
                                   ENGINE LUBRICATION SYSTEM                                                         QG
                                                                                                             Precautions
                                             Precautions
                                             LIQUID GASKET APPLICATION PROCEDURE                                     NJLC0001
                                             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 3.5 to 4.5 mm
                                                  (0.138 to 0.177 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                                                   NJLC0002


Tool number
                     Description
Tool name

ST25051001                                                           Measuring oil pressure
Oil pressure gauge




                     NT050

ST25052000                                                           Adapting oil pressure gauge to cylinder block
Hose




                     NT559

KV10115801                                                           Removing oil filter
Oil filter wrench




                     NT772

WS39930000                                                           Pressing the tube of liquid gasket
Tube presser




                     NT052




                                                      LC-3
                      ENGINE LUBRICATION SYSTEM      QG
Lubrication Circuit

                           Lubrication Circuit       NJLC0003




                                                  SEM852FB




                                                   SLC339B



                                 LC-4
ENGINE LUBRICATION SYSTEM                                                  QG
                                                             Oil Pressure Check

           Oil Pressure Check                                              NJLC0004
           WARNING:
           + Be careful not to burn yourself, as the engine and oil may
              be hot.
           + For M/T models, put gearshift lever in Neutral "N" posi-
              tion. For A/T models, put selector lever in Park "P" posi-
              tion.
           1. Check oil level.
           2. Remove oil pressure switch.

SEM853F

           3. Install pressure gauge.
           4. Start engine and warm it up to normal operating temperature.
           5. Check oil pressure with engine running under no-load.
           For Sedan
                   Engine speed           Approximate discharge pressure
                       rpm                     kPa (bar, kg/cm2, psi)

                       600                  More than 69 (0.69, 0.7, 10)

                      2,000                More than 284 (2.84, 2.9, 41)

SLC926-A              6,000                More than 422 (4.22, 4.3, 61)


           For Hatchback
                   Engine speed           Approximate discharge pressure
                       rpm                     kPa (bar, kg/cm2, psi)

                       600                  More than 98 (0.98, 1.0, 14)

                      2,000                More than 294 (2.94, 3.0, 43)

                      6,000                More than 392 (3.92, 4.0, 57)

           +    If difference is extreme, check oil passage and oil pump
                for oil leaks.
           6.   Install oil pressure switch with sealant.
                        : 13 - 17 N



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