ENGINE LUBRICATION & COOLING SYSTEMS

SECTION LC
CONTENTS
LUBRICATION SYSTEM .................................... LC-2 ENGINE COOLANT SYSTEM ............................ LC-6
Specifications ................................................. LC-2 Specifications ..................................................LC-6
Adjustment Value ........................................... LC-2 Adjustment Value ............................................LC-6
Oil Pressure .................................................... LC-2 Tightening Torque ...........................................LC-6
Tightening Torque .......................................... LC-2 Trouble Diagnosis ...........................................LC-6
Trouble Diagnosis .......................................... LC-3 Cooling System Configuration .........................LC-7
Lubrication Schematic Diagram ..................... LC-4 Water Pump ....................................................LC-8
Oil Pump ......................................................... LC-5 Thermostat ......................................................LC-9

LC
 LUBRICATION SYSTEM

LUBRICATION SYSTEM Specifications

MAIN SPECIFICATIONS
Lubrication method Pressured supply

Oil pump Spur gear type

Oil filter Total flow, cartridge type

Adjustment Value
OIL PUMP Unit: mm
Clearance between pump gear and main 0.4 or less
body
Backlash of pump gear 0.5 or less
Pump gear clearance in vertical direction 0.3 or less

Oil Pressure
OIL PRESSURE Unit: kPa (kgf/cm2)
Discharge pressure Oil temperature 80°C
At Idle 98 (1.0)
At 2,000 rpm 274 - 313 (2.8 - 3.2)

Tightening Torque
N·m kgf-m

Oil pump bolt 15.7 - 17.7 1.6 - 1.81

Oil pump cover bolt 6.37 - 7.45 0.65 - 0.76
Oil pump 6.37 - 7.45 0.65 - 0.76
Oil pan drain plug 29.4 - 39.2 3.0 - 4.0

LC-2
 LUBRICATION SYSTEM

Trouble Diagnosis
Condition Possible causes Action

Oil leakage • Cracks or damages in pump body cover Replacement

• Oil leakage from gasket and oil seal Replacement
• Oil leakage from near spindle support Replace the O-ring seals or inspect the pump body
and replace it as necessary.
• Oil leakage from near distributor Replace the O-ring seals or inspect the pump body
and replace it as necessary.
• Oil leakage between timing chain housing and Disassemble and reassemble/apply liquid packing
cylinder block again.
• Loose rocker cover retaining nuts and oil leakage. Additionally tighten.
• Loose oil pan mounting bolts and oil leakage Additionally tighten.
• Oil leakage from crankshaft front oil seal Replacement
• Oil leakage from crankshaft rear oil seal Replacement
• Oil leakage from regulator valve Additionally tighten or replace.
• Oil leakage from plugs in lubrication system Replace or additionally tighten.
MWL ON • Loose oil filter Additionally tighten.
• Use of inappropriate quality of oil Replace with specified oil.
• Engine over temperature (Overheat) Already described
• Oil pump regulator valve malfunction Overhaul or replace the oil pump.
• Oil pump malfunction Overhaul or replace the oil pump.
• Inappropriate oil pump installation Additionally tighten.
• Damaged oil pump gasket Replacement
• Oil filter malfunction Replacement
• Enlarged clearance between sliding parts Disassemble and replace the relevant sliding parts.
• Loose mounting of rocker shaft bracket Tighten bolts.
• Clogged oil strainer Wash.
• Malfunction of oil pressure gauge pressure switch Replacement
• Oil pressure switch malfunction Replacement
• Insufficient oil in oil pan Fill oil and identify/repair the factor causing non-
standard condition.
• Loose oil pan drain plug or damaged gasket Additionally tighten or replace.
• Incident in electrical system Inspect the electric circuits.
Noise • Excessive backlash of pump rotor Replacement

LC-3
LUBRICATION SYSTEM

Lubrication Schematic Diagram

LCM0022

LC-4
 LUBRICATION SYSTEM

Oil Pump
COMPONENT PARTS LOCATION

LCM0023

INSPECTION
1. Check the following items for wear or damages.
• Pump body and cover
• Pump gear section
• Driving spindle
The pump gear section and main body have no internal compo-
nents that can be serviced separately. If the pump gear or main
body is worn or damaged, replace the drive shaft assembly or
oil pump assembly.
2. Inspect the clearance at the following points using a feeler
gauge.
If the clearance exceeds the specified limit, replace the drive
shaft assembly or oil pump assembly.
Clearance between pump gear and main body:
0.4 mm or less
Backlash of pump gear: 0.5 mm or less
Pump gear clearance in vertical direction: 0.3 mm or less

SLC136

3. Inspect the regulator valve spring of the oil pump.

If damaged, replace the spring or pump assembly.
Free length 41.5±1 mm
Repair limit 40.0 mm

LCM0024

LC-5
 ENGINE COOLANT SYSTEM

ENGINE COOLANT SYSTEM Specifications

Cooling method Water cooled, controlled circulation

Water pump Centrifugal

Thermostat Wax pellet

Adjustment Value
WATER PUMP
Fan belt deflection
11 - 13
When pushed with a force of 98N (10 kg) [mm]

THERMOSTAT
Standard specification

Valve opening temperature (°C) 76.5

Maximum lift (mm/°C) 8/90

Tightening Torque
N·m kgf-m

Water pump retaining bolt M8 15.7 - 17.7 1.6 - 1.81

Water pump retaining bolt M6 6.37 - 7.45 0.65 - 0.76
Thermostat housing bolt 15.7 - 17.7 1.6 - 1.81

Trouble Diagnosis
Condition Possible causes Action

Water leakage • Water leakage from water pump shaft seal Replace the water pump assembly.
• Water leakage from water pump mounting face Additionally tighten. If the leakage still remains,
packing replace the packing.
• Water leakage from radiator cap Replace the packing or assembly.
• Coolant leakage from engine coolant Additionally tighten or replace.
temperature sensor
• Loose connection Additionally tighten.
• Damaged head gasket Replace and check engine oil for contamination.
• Cracks in cylinder block Replace and check engine oil for contamination.
• Cracks in cylinder head Replacement
• Loose head bolt Additionally tighten.
Insufficient circulation of • Insufficient flow rate in coolant circuit Remove any contamination and rust from the coolant
coolant circuit, and inspect the hose clamps.
• Insufficient amount of coolant Fill.
• Water pump malfunction Replacement
• Loose fan belt. Belt tension adjustment
• Thermostat malfunction Replacement
Corrosion • Excessive amount of impurities in coolant Use clean softened water.
• Insufficient cleaning of coolant circuit Perform cleaning/flushing more frequently.

LC-6
 ENGINE COOLANT SYSTEM

Trouble Diagnosis (Cont’d)

Condition Possible causes Action

Engine over temperature • Thermostat malfunction Replacement

(Overheat)
• Radiator fins plugged with dirt and dust Clean with compressed air.
• Inappropriate ignition timing and valve timings Adjust the ignition timing and valve clearances.
• Contamination and sludge deposits in engine oil Clean inside the engine and refill it with oil.
• Water pump malfunction Replacement
• Loose fan belt. Belt tension adjustment
• Plugged radiator Clean inside the radiator.
• Poor accuracy of coolant temperature gauge Replacement
• Insufficient amount of coolant Fill.
• Air in coolant circuit Bleeding
• Contaminated engine coolant Use clean softened water.
Overcool • Thermostat malfunction Replacement
• Malfunctioning coolant temperature sensor Replacement
Noise • Noise from water pump mechanical seal Replacement
• Wear or damage of water pump bearing Replacement

Cooling System Configuration

LCM0025

LC-7
ENGINE COOLANT SYSTEM

Water Pump
1. Open the drain of the radiator and extract coolant into an
appropriate container.

CAUTION:
Do not drain coolant when engine is still hot. Contact by hot
coolant may result in burns and injury.
2. Remove the radiator shroud.
3. Loosen the fan belt.
• Loosen the alternator adjusting bolt.
• Fully put aside the alternator toward the engine.
• Remove fan and fan pulley.
• Remove the water pump together with the gasket.

SLC190

INSPECTION
Do not disassemble water pump. If any non-standard condition is
found, replace the water pump.
1. Check the water pump vanes for rust and pitching.

SLC070

2. Check the water pump bearing for proper end play and smooth
operation.

SLC071

ASSEMBLY
1. Install the water pump in the reverse order of removal. Always
use a new gasket.
2. Adjust the fan belt tension. For the adjustment value, refer to
page MA-section.

CAUTION:
• Before filling with coolant, always loosen the air purge plug.
• After refilling, make sure to tighten the plug.

LC-8
ENGINE COOLANT SYSTEM

Thermostat
REMOVAL
1. Remove the radiator upper hose from the water outlet and
extract coolant.

WARNING:
Do not drain coolant when engine is still hot. Contact by hot
coolant could result in burns and injury.
2. Remove water inlet and remove thermostat.

INSPECTION
Inspect the thermostat as instructed below and replace it as
necessary.
1. Inspect valve seating status under ordinary temperature. The
valve must be seated firmly.
2. Inspect the opening temperature and maximum valve lift by
heating the valve in a container.

CAUTION:
Do not touch the thermostat, container or hot water inside until
the temperature lowers sufficiently. Contact by a hot
thermostat, container or hot water may result in burns and
injury.
3. make sure that the valve closing temperature is approx. 5°C
lower than the opening temperature. Also perform the same
CO097 inspection before installing a new thermostat.

INSTALLATION
Install in the reverse order of removal.
Always use a new water inlet gasket.

LC-9