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Lubrication & Cooling


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                                              ENGINE LUBRICATION &
I                                                 COOLING SYSTEMS

                                                   SECTION        LC
CONTENTS
ENGINE LUBRICATION SYSTEM     ...........................................      LC- 2
ENGINE LUBRICATION SYSTEM     - For Turbocharged Models ....................   LC- 6
ENGINE COOLING SYSTEM     ...............................................      LC- 7
ENGINE COOLING SYSTEM     -
                         For Tuhocharged Models..    ......................    LC-13
SERVICE DATA AND SPECIFICATIONS (S.D.S.) ..............................        LC-15
SPECIAL SERVICE TOOLS ...............................................          LC-17
              ENGINE LUBRICATION SYSTEM
                     Lubrication Circuit




                              '1:   Additional lubrication circuit for turbocharged model
Oil passage                    '2 Additional oil cooler for turbo A I T model




                                                                                            SLC729




                         LC-2
                            ENGINE LUBRICATION SYSTEM


WARNING:                                                  If difference is extreme, check oil passage and oil
  Be careful not t o burn yourself, as the engine         pump for oil leaks.
  and oil may be hot.
0 Oil pressure check should be done in "Neutral"
  gear position.
1. Check oil level.
2. Remove oil pressure switch.




                                                          5. Install oil pressure switch.
                                                          Use proper liquid sealant.
                                                          0 : 13 17 N m (1.3 - 1.7 kgm, 9 - 12 ftJb)
                                                                     ~




                                                 SLCS45


3.   '! II pressure gauge.
4. Start engine and warm it up t o normal operat-
   ing temperature and, then check oil pressure
   with engine running under no-load.

    Engine              Approximate discharge
                       prewre kPs IksJm'. psi)

   Idle speed            More than 59 (0.6.9)

                              -
                 Non.turbo 363 451 13.7.4.6,53.65)
                                      -
                  Turbo 373.432 (3.8 4.4.54.63)




                                                     LC-3
                                            ENGINE LUBRICATION SYSTEM
                                            Oil Pump Disassembly and Assembly

1. Drain oil.
2. Remove oil pan.
   In case of on-vehicle service, refer to Oil Pan
   for removal in section EM.
3. Remove oil pump assembly.

When installing oil pump, apply engine oil to inner
and outer gear.
Be sure that O-ring is properly fitted on.



                                                                             -
                                                                        112 1.6,
                                                                        9.121                  (9)   : N m (kgm, ft-lb)

                                                                                                                 SLC936




                                                      -   Cover


                                                r*.                 4 . 5 (0.4 .0.5,2.9.3.6)

                                                                                 .~
                  Oil pump body         ~




       (9) 6.3 .8.3
           10.64 - 0.85.4.6   - 6.1 I



 (9) : N m Ikg-m. ft-lbl                                                                                        SLC759




                                                             LC-4
                               ENGINE LUBRICATION SYSTEM
            Oil Pump Inspection

1. Visually inspect components for wear and             If excessive wear is found, replace gear set or entire
   damage.                                              oil pump assembly.
2. Check oil pressure regulator valve sliding sur-
   face and valve spring.                               Standard clearance:                            Unit: mm (in)

If damaged, replace as a valve set.                     Body t o outer gear
                                                        clearance 0
                                                                                    I                      -
                                                                                        0.1 1 - 0.20(0.0043 0.0079)

                  Spring   7
            Regulator
            WlW

            /-lI/
                 7         I          \\
                                                                to inner gear
                                                        clearance
                                                                                    I   0.05.0.09 (0.0020 0.0035)
                                                                                                         -

                                                        Housing to   Outer   gear
                                                                                        0.05- 0.11 (0.0020 0.0043)
                                                                                                         -
                                             SLC295
                                                        clearance 0
3. Using a feeler gauge, check the following clear-
    ance.




                                                                  Oil Pressure Relief Valve
                                                                         Inspection

                                                        Inspect for smooth operation by pushing ball.

                                                                                                         -
                        u                   SLC549
                                                                                               A




                                                                                                              SLCS51


                                                        Replace as a valve assembly, when replacing.




                                                     LC-5
                                      ENGINE LUBRICATION SYSTEM
                                       - For Turbocharged Models
                                          Removal and Installation

 OIL DELIVERY SYSTEM
 After installation, run engine for a few minutes and check for leaks.
                                                                                 16-24




         n    15-20
                 Washer      oyTI:
              1 . - 2.0,ll - 14)
               15
                                                 0




                                                         13-16
                                                         (1.3.1.6.9-12)
                                                                                              n   : N m (kgm. ft-lb)
                                                                                                          SLC058A

ENGINE OIL COOLER (A/T models)
Be careful not to burn yourself as engine oil is hot.
After installation, run engine for a few minutes and check for oil leaks.


                                          ~ ( 9 59 - 74 (6.0 - 74.43 -64)
                                                 1




             Oil filter
             bracket
                                                        7 8-1110.8-1.1.6.8-8.0)
                                                  , 4        .r -   .
                                                                    A
                                                                    , "   .
                                                                          I.D.     -
                                                                                 u o*,
                                                        0
                                                        "S

                                             - Washer
                                                                                         L   Oil mder
                                             - Oil filter rud


                           -T
                   [91 14-18'-
                          11.4-1.8,
                          10.13)
                                                   59 - 74 18.0.7.5,43 - 64)




                                                                                                            SLC984




                                                         LC-6
                                ENGINE COOLING SYSTEM
                                             Cooling Circuit

To avoid danger of being scalded, never attempt t o drain coolant when engine is hot.
If it is necessary t o remove radiator cap when radiator i s hot, turn cap slowly counterclockwise t o the first
stop. After all pressure in the cooling system is released, turn cap past the stop and remove it.
Always replaca with new gasket and O-ring.
Refer to MA section for changing engine coolant.




          Radiator cap                    Reservoir tank

                                                                                             Thermostat: Open

            Radiator


              4
          Thermostat
                                            Water outlet
                                            housing
                                                             -                               Thermostat: Closed




              4
          Thermostat
           housing                        Throttle chamber             Turbocharger           Air regulator


              4
                                              Heater
                                                                 *Turbocharged models Only            +
                                                                                                      Intake manifold
          Water pump                                                                                  (Water parlagel
               I                                                                                                A




                                                                                                                  SLC728




                                                       LC-7
                               ENGINE COOLING SYSTEM
                                     Checking Cooling System

WARNING:                                              CHECKING RADIATOR CAP
Never remove the radiator cap when the engine is      Apply pressure to radiator cap by means of a cap
hot; serious burns could be caused by high pressure   tester to see if it is satisfactory.
fluid escaping from the radiator.
Wrap a thick cloth around cap and carefully re-          Radiator cap relief pressure:
move the cap by turning it a quarter turn t o allow
                                                                            -               -
                                                            78 - 98 kPa (0.8 1.0 kg/cm2, 11 14 psi)
built-up pressure t o escape and then turn the cap
all the way off.

CHECKING COOLING SYSTEM HOSES
Check hoses for proper attachment, leaks, cracks,
damage, loose connections, chafing and deteriora-
tion.




CHECKING COOLING SYSTEM FOR LEAKS                                                     \         SLC613

Apply pressure to the cooling system by means of
a tester t o check for leakage.
   Testing pressure:
      157 kPa (1.6 kg/cm2, 23 psi)




                                           SLC612




                                                 LC-8
                                  ENGINE COOLING SYSTEM
               Water Pump Removal and Installation (On-vehicle service)




Water pump can not be disassembled and should be
replaced as a unit
To avoid deforming timing cover, make sure there is
adequate clearance between cover and h o a clamp.
After installingwater pump, connect hosa and clamp
sacurely, then check for leaks using cap tester.
                                                                                                         SLC838

                                                                     Water Pump Inspection
Drain coolant from drain plugs on both sides of
cylinder block, and radiator.                                Check for excessive end play and rough operation.




                                                  SLC815
                                                                                                         SLC738

CAUTION:
When removing water pump assembly, be careful
not to get coolant on timing belt.




                                                           LC-9
                              ENGINE COOLING SYSTEM
                 Thermostat Description (Bottom by-pass coolant flow)

                                         water omlet
                                                                                     Coolant flow om
                                                                     Thermostat
                                                                                   through water outlet

                                                                       Own                A little

                                                              +        ClOS                Much




                                            SLC566



                            Thermostat Removal and Installation

CAUTION:
Drain coolant from drain cocks on cylinder block side and radiator.
Remove radiator shroud, cooling fan and water suction pipe securing bolt, then remove thermostat.
After installation, run engine for a few minutes, and check for leaks.




                                                                                    .-.




                                   L m    1 6 - 2 1 Nmll.6.2.1 kpm.12-15ft-lbI

                                                                                                          SLC939




                                                 LC-10
                                      ENGINE COOLING SYSTEM
                                                Thermosta

1. Check for valve seating condition a t ordinary
   temperatures. It should seat tightly.
2. Check valve opening temperature and maxi-
   mum valve lift.

                               I            Standard

Valve opening temperature
                  'C ( O F )
                               I        76.5 (170)

Maximum valve lift
                      '
          mmf'C (in/'F)
                               I      10/90 (0.39/194)



                                                                                                                              SLC343


                                                                        3. Then check if valve closes a t 5



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