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                                                                                             ENGINE LUBRICATION &
                                                                                                 COOLING SYSTEMS


                                                                                                     SECTION                      LC                                        LC




                                                                        CONTENTS
PRECAUTION..................................................................3          ENGINE COOLING SYSTEM........................................33
PREPARATION ...............................................................4             Cooling Circuit ...........................................................33
  Special Service Tools ..................................................4              System Check............................................................33
                                                                                         Cooling System Inspection ........................................33
                                   GA16DE                                                Water Pump...............................................................34
                                                                                         Thermostat.................................................................35
ENGINE LUBRICATION SYSTEM..................................6                             Radiator .....................................................................37
  Lubrication Circuit ........................................................6
  Oil Pressure Check......................................................7
                                                                                                                          CD20T
  Oil Pump ......................................................................8
ENGINE COOLING SYSTEM........................................11                        ENGINE LUBRICATION SYSTEM................................38
  Cooling Circuit ...........................................................11          Lubrication Circuit ......................................................38
  System Check............................................................11             Oil Pressure Check....................................................39
  Water Pump...............................................................12            Oil Pump ....................................................................39
  Thermostat.................................................................14          Oil Cooler...................................................................42
  Radiator .....................................................................15     ENGINE COOLING SYSTEM........................................43
                                                                                         Cooling Circuit ...........................................................43
                                   QG18DE                                                System Check............................................................44
                                                                                         Water Pump...............................................................45
ENGINE LUBRICATION SYSTEM................................16                              Thermostat.................................................................46
  Lubrication Circuit ......................................................16           Radiator .....................................................................48
  Oil Pressure Check....................................................17
  Oil Pump ....................................................................17
  Oil Filter .....................................................................19
ENGINE COOLING SYSTEM........................................20                            Overheating Cause Analysis .....................................49
  Cooling Circuit ...........................................................20
  System Check............................................................20                                             GA16DE
  Water Pump...............................................................22
  Thermostat.................................................................23        SERVICE DATA AND SPECIFICATIONS (SDS) .........51
  Radiator .....................................................................25       Oil Pressure Check....................................................51
                                                                                         Oil Pump Inspection ..................................................51
                                                                                         Regulator Valve Inspection........................................51
                                   SR20DE
                                                                                         Thermostat.................................................................51
ENGINE LUBRICATION SYSTEM................................27                              Radiator .....................................................................51
  Lubrication Circuit ......................................................27
  Oil Pressure Check....................................................28                                               QG18DE
  Oil Pump ....................................................................29
  Oil Filter .....................................................................31       Oil Pressure Check....................................................52
  Oil Cooler...................................................................32          Oil Pump Inspection ..................................................52
                                                         CONTENTS (Cont'd)
Regulator Valve Inspection........................................52                 Thermostat.................................................................53
Thermostat.................................................................52        Radiator .....................................................................53
Radiator .....................................................................52
                                                                                                                     CD20T
                               SR20DE
                                                                                     Oil Pressure Check....................................................54
Oil Pressure Check....................................................53             Oil Pump Inspection ..................................................54
Oil Pump Inspection ..................................................53             Thermostat.................................................................54
Regulator Valve Inspection........................................53                 Radiator .....................................................................54




                                                                              LC-2
                                               PRECAUTION

                                          LIQUID GASKET APPLICATION PROCEDURE
                                          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.
                                 Inner    2.    Apply a continuous bead of liquid gasket to mating surfaces.
                                 side
                                                (Use Genuine Liquid Gasket or equivalent.)
                                          +     Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide
                                                for SR engine and 3.5 to 4.5 mm (0.138 to 0.177 in) wide for
Groove       Bolt hole                          GA, QG and CD engine (for oil pan).
                                          +     Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide
                                 SEM164
                                                (in areas except oil pan).
                                          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.




                         Inner side
  Groove
         .
                                 AEM080




                                                    LC-3
                                                   PREPARATION
Special Service Tools

                                                  Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
                                                                                                            Engine
 Tool number                                                                                               application
                         Description
 Tool name
                                                                                                      GA   SR     CD     QG

 ST25051001*                                                                  Measuring oil
 Oil pressure gauge                                                           pressure
                                   PS1/4x19/in
                                                                              Maximum measuring       X    X       X     X
                                                                              range: 2,452 kPa
                                                                              (24.5 bar, 25 kg/cm2,
                         NT558                                                356 psi)

 ST25052000*                                                                  Adapting oil
 Hose                                                       PS1/8x28/in       pressure gauge to
                             PS1/4x19/in                                      cylinder block

                                                                                                      X    X       X     X



                         NT559

 KV10105900                                                                   Removing oil filter
 Oil filter wrench

                                             15 faces
                                             Inner span 80 mm (3.15 in)
                                             (Face to opposite corner)



                                                                                                      X    --      --    --




                                                                              a: 78 mm(3.07 in)
                                                                              (Face to opposite
                         NT638
                                                                              corner)

 KV10115801 or                                                                Removing oil filter
 KV10115800
 Oil filter wrench                           15 faces,
                                             Inner span: 64.3 mm (2.531 in)                           --   X       --    X
                                             (Face to opposite face)


                         NT362

 99545R2500                                                                   Removing oil filter
 (KV10106S0)
 Oil filter wrench                          15 faces,
                                            Inner span: 92.5 mm (3.642 in)                            --   --      X     --
                                            (Face to opposite corner)

                         NT631
*:Special tool or commercial equivalent




                                                            LC-4
                                    PREPARATION
                                                                           Special Service Tools (Cont'd)

                                                                                      Engine
Tool number                                                                          application
                      Description
Tool name
                                                                              GA     SR     CD     QG

WS39930000                                        Pressing the tube of
Tube presser                                      liquid gasket

                                                                               X      X      X      X


                      NT052

EG17650301                                        Adapting radiator
Radiator cap tester                               cap tester to radiator
adapter                                           filler neck
                                                                               X      X      X      X
                                                  a: 28 (1.10) dia.
                                                  b: 31.4 (1.236) dia.
                                                  c: 41.3 (1.626) dia.
                      NT564                       Unit: mm (in)




                                       LC-5
                                                   ENGINE LUBRICATION SYSTEM                                                                 GA16DE
Lubrication Circuit


                                                                  Lubrication Circuit
                                                   Oil drop




                             Intake camshaft                                                Exhaust camshaft




                       Main gallery




                                                                                                                       Idler sprocket
                        Chain tensioner


                      Oil filter by-pass valve




                                                Oil filter


                                                                                                                   Oil pump
                                                                Oil strainer



                                                                                                                                                    NLC051



                 Regulator                       Oil pressure                               Oil passage
                   valve                         relief valve                               Oil gallery in cylinder block
                                                                                            By-pass passage
                                                                                            Drain
                  Oil pump                         Oil filter


                                                                  Main oil
                                                                  gallery               Orifice


                                   Main                                                              Cylinder head
                                  bearing                                                              oil gallery



                                                     Chain        Timing                Chain             Idler                   Camshaft
                                Crankshaft
                                                   tensioner      chain               tensioner         sprocket                   journal



                                Connecting                                             Timing                        Timing         Cam      Distributor
                                rod bearing                                            chain                         Chain         surface    coupling



                                Connecting                                                                                         Valve
                                   rod                                                                                             lifter




                                  Oil jet



                                 Piston pin
                                 piston and
                                cylinder wall




                     Oil                                        Oil pan
                  strainer                                                                                                                          NLC052



                                                                               LC-6
                      ENGINE LUBRICATION SYSTEM                                             GA16DE
                                                                                     Oil Pressure Check

                                 Oil Pressure Check
Oil pressure switch
                                 WARNING:
                                 + Be careful not to burn yourself, as the engine and oil may
                                    be hot.
                                 + Oil pressure check should be done in ``Neutral'' gear posi-
                                    tion.
                       Front
                                 1. Check oil level.
                                 2. Remove oil pressure switch.

                      SLC416A


                                 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.
        ST2051001
                                         Engine speed            Approximate discharge pressure
                                             rpm                     kPa (bar, kg/cm2, psi)

                                          Idle speed                More than 59 (0.59, 0.6, 9)

                                            2,000                  More than 245 (2.45, 2.5, 36)
     ST25052000
                      SLC926-A              6,000                  More than 422 (4.22, 4.3, 61)


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




                                          LC-7
                       ENGINE LUBRICATION SYSTEM                                                              GA16DE
Oil Pump

                                     Oil Pump
     SEC. 135v150                                                           3.7 - 5.0 (0.38 - 0.51, 33.0 - 44.3)


                                                                                  6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)




                                                                       6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
                                                                                    : Do not re-use.
                                                                                    : N



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