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ENGINE LUBRICATION SYSTEM


B ENGINE

                                                                                                                                                                 A




                                                            ENGINE LUBRICATION SYSTEM
                                                                                                    SECTION                    LU                                LU



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                                                                                                                                                                 D


                                                                                                                                                                 E
                                                                 CONTENTS
PRECAUTIONS ......................................................... 2.         OIL FILTER ................................................................ 9
                                                                                                                                                       .         F
 Precautions for Liquid Gasket ................................. 2     .          Removal and Installation ......................................... 9 .
   REMOVAL OF LIQUID GASKET SEALING ......... 2                        .            REMOVAL ............................................................ 9
                                                                                                                                                       .
   LIQUID GASKET APPLICATION PROCEDURE 2                               .....        INSTALLATION .................................................... 9.         G
PREPARATION .......................................................... 3
                                                                       .         OIL PUMP ................................................................ 10
                                                                                                                                                       .
 Special Service Tools .............................................. 3.          Removal and Installation ....................................... 10  .
 Commercial Service Tools ....................................... 3    .            REMOVAL .......................................................... 10
                                                                                                                                                       .
                                                                                                                                                                 H
LUBRICATION SYSTEM ........................................... 4       .            INSTALLATION .................................................. 10 .
 Lubrication Circuit ................................................... 4
                                                                       .          Disassembly and Assembly ................................... 11      .
 System Drawing ...................................................... 5
                                                                       .            DISASSEMBLY .................................................. 11  .
ENGINE OIL .............................................................. 6
                                                                       .            INSPECTION AFTER DISASSEMBLY ............... 11                    .          I
 Inspection ................................................................ 6
                                                                       .            ASSEMBLY ........................................................ 12
                                                                                                                                                       .
   OIL LEVEL ........................................................... 6
                                                                       .         SERVICE DATA AND SPECIFICATIONS (SDS) ..... 13                        .
   OIL APPEARANCE .............................................. 6     .          Standard and Limit ................................................. 13
                                                                                                                                                       .          J
   OIL LEAKAGE ...................................................... 6.            OIL PRESSURE ................................................. 13  .
   OIL PRESSURE CHECK ..................................... 7          .            OIL PUMP .......................................................... 13
                                                                                                                                                       .
 Changing Engine Oil ............................................... 7 .            REGULATOR VALVE ......................................... 13       .
                                                                                                                                                                 K
                                                                                    OIL CAPACITY ................................................... 13.
                                                                                  Tightening Torque .................................................. 13
                                                                                                                                                       .

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                                                                                                                                                                 M




Revision: 2004 April                                                        LU-1                                                                2002 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 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 sur-
faces.
                                                                            PBIC0002E


LIQUID GASKET APPLICATION PROCEDURE
1.   Using a scraper, remove the old liquid gasket adhering to the
     gasket application surface and the mating surface.
q    Remove the liquid gasket completely from the groove of the gas-
     ket application surface, mounting bolts, and bolt holes.
2.   Wipe the gasket application surface and the mating surface with
     white gasoline (lighting and heating use) to remove adhering
     moisture, grease and foreign materials.
3.   Attach genuine liquid gasket to the tube presser.
     Use Genuine Ultra Grey RTV silicone sealant Part No.
     999MP-AM003 or equivalent.
                                                                            PBIC0003E




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




                                                                            EMA0622D




q    As for the bolt holes, normally apply the 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 gasket application, install the mating com-
     ponent.
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 coolant.
CAUTION:                                                                    SEM164F
If there are specific instructions in this manual, observe them.




Revision: 2004 April                                  LU-2                 2002 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 oil filter
  (J38956)
  Oil filter wrench
                                                                                                                                            H



                                                                                                                                             I
                                                                         S-NT772


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



                                                                                                                                            K
                                                                         S-NT052



Commercial Service Tools                                                                                                         EBS003GF
                                                                                                                                             L
  Tool number
  (Kent-Moore No.)                                                                       Description
  Tool name                                                                                                                                 M
  Power tool                                                                             Loosening bolts and nuts




                                                                         PBIC0190E




Revision: 2004 April                                            LU-3                                                          2002 Q45
                       LUBRICATION SYSTEM

LUBRICATION SYSTEM                           PFP:15010

Lubrication Circuit                                EBS001KC




                                            PBIC0133E




Revision: 2004 April          LU-4          2002 Q45
                       LUBRICATION SYSTEM

System Drawing                                     EBS0024T

                                                              A


                                                              LU



                                                              C


                                                              D


                                                              E



                                                              F


                                                              G


                                                              H



                                                               I


                                                               J



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                                                               L
                                            PBIC0134E




                                                              M




Revision: 2004 April          LU-5          2002 Q45
                                                  ENGINE OIL

ENGINE OIL                                                                                                   PFP:KLA92

Inspection                                                                                                          EBS0024U

OIL LEVEL
NOTE:
q  Before starting the engine, check the oil level. If the engine is already started, stop it and allow 15 minutes
   before checking.
Models Produced Before September 2001
1.   Put vehicle horizontally.
2.   Pull out oil level gauge and wipe it clean.
3.   Insert gauge so circle of oil level gauge handle faces engine
     front side.
4.   Amount of oil on oil level gauge may look different from each
     other as on side A or B (both sides with cross hatch) because of
     its inclination. Side A is upper face and side B is lower face.
     Check oil amount as on side A, which has less oil amount on oil
     level gauge.



                                                                                                                 PBIC0228E



5.   Check that the oil level is within the range shown in the figure.
6.   If it is out of range, adjust it.




                                                                                                                 PBIC0135E


Models Produced After and in September 2001
1.   Put vehicle horizontally.
2.   Pull out oil level gauge and wipe it clean.
3.   Insert it and check that the oil level is within the range shown in
     the figure.
4.   If it is out of range, adjust it.




                                                                                                                 PBIC0801E


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 coolant. Repair the broken parts.
OIL LEAKAGE
Check for oil leakage around the following area.
q  Oil pan
q  Oil pan drain plug
q  Oil pressure switch
Revision: 2004 April                                    LU-6                                                2002 Q45
                                                    ENGINE OIL

q    Oil filter
q    Intake valve timing control cover                                                                                               A
q    Front cover
q    Mating surface between cylinder block and cylinder head
                                                                                                                                     LU
q    Mating surface between cylinder head and rocker cover
q    Crank oil seal (front and rear)
OIL PRESSURE CHECK                                                                                                                   C
WARNING:
q  Be careful not to burn yourself, as the engine oil is hot.
q  Oil pressure check should be done in "Parking position".                                                                          D
1. Check the oil level.
2. Remove the under cover with power tool.
3. Remove the oil pressure switch to connect the oil pressure                                                                        E
   gauge.
4. After warming up the engine, check that oil pressure corre-
   sponding to the engine speed is produced.                                                                                         F
   NOTE:
   When oil temperature is low, the oil pressure becomes high.
                                                                                                                                     G
                                                                                                                       PBIC0136E


    Engine oil pressure [Oil temperature is 80 



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