ENGINE LUBRICATION & COOLING SYSTEMS SECTION CONTENTS. 1c-10 1c-11 1c-13. 1c-15 1c-16 LC- 2 LC- 4 LC- 6 LC- 7 LC- 8

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1 i ENGINE LUBRICATION & COOLING SYSTEMS LC SECTION CONTENTS ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM -Oil Pump ENGINE LUBRICATION SYSTEM -Oil Pressure Relief Valve ENGINE LUBRICATION SYSTEM - Lubricating Oil Passage for Turbocharger COOLING SYSTEM COOLING SYSTEM -Water Pump COOLING SYSTEM -Thermostat COOLING SYSTEM - Radiator COOLING SYSTEM -Cooling Fan COOLING SYSTEM - Electric Cooling Fan for Turbocharger SERVICE DATA AND SPECIFICATIONS (S D S 1 SPECIAL SERVICE TOOLS LC- 2 LC- 4 LC- 6 LC- 7 LC- 8 1c-10 1c-11 1c-13 LC- 14 1c-15 1c-16 LC-I 8

2 ENGINE LUBRICATION SYSTEM Lubrication Circuit Note 011 m parrage 011 gallery in cylinder block f--- By-parr parrage Maan 011 gallery I-- i r-il Crankshaft '1 Additional lubrication circuit for turbocharged model + Turbocharger Cylinder head --/I- CO""eCll"g rod bearing Valve lifier guide 011 gallery + e -0 Piiton and cylinder well + Rockerrhaft Rocker arm Camshaft Valve hfter pan 1 1 SLC544 LC-2

3 ENGINE LUBRICATION SYSTEM Oil Pressure Check In-vehicle service) Be careful not to burn yourself, as the englne and oil may be hot 1 Warm up engine 2 Stop engine and remove oil pressure switch The above table shows data tested when SAE 1OW-30 oil is used and oil temperature is between 77 and 83 C (171 and 181 F). Slight difference will be found because of oil viscosity or oil temperature If difference is extreme, check oil passage and oil pump for oil leaks SLC545 3 Install pressure gauge 4 Start engine and check oil pressure with engine running under no-load Engine rpm I Approximate discharge pressure kpa (kglcm2, psi1 1, ( , (3.431 i (4.571 Oil pressure at 600 rpm (Idling) should be more than 78 kpa (0.8 kg/cm2, 11 PSI) ST LC-3

4 ENGINE LUBRICATION SYSTEM -Oil Pump- 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 Always replace with new oil seal and gasket. When installing oil pump, apply engine oil to inner and outer gear. Be sure that O-ring is properly fitted on. Disassembly and Assembly 1 IO L(nl N rn lkg-m ft-lbl SLC547 Front I R ( R 4.5 I R N rn Ikg-m ft-lbl SLC548 LC-4

5 ENGINE LUBRICATION SYSTEM -Oil Pump- tion Visually inspect components for wear and damage Check oil pressure regulator valve sliding surface and valve spring Spr'ng 7 Regulalor,,/ valve \ Washer If it exceeds the limit, replace gear set or entire oil pump assembly. Body to outer gear clearance (i7 Unit rnrn (in) I ( Outer gear to crescent ( ) SLC295 Using a feeler gauge, check the following clearance SLC550 LC-5

6 ENGINE LUBRICATION SYSTEM - Oil Pressure Relief Valve Inspection Inspect for its smooth operation by pushing ball -- _A 1 SLC551 LC-6

7 ENGINE LUBRICATION SYSTEM -Lubricating Oil Passage for Turbocharger- Disassembly and Assembly Always replace with new gasket. After installation, run engine for a few minutes and check for leaks Lm N m (kg-m. ft-lbl SLC552 LC-7

8 COOLING SYSTEM Coolicg Circuit To avoid danger of being scalded, never attempt to drain coolant when engine is hot. Always replace with new gasket and O-ring. V Radlaror f + - Thermostat Thermostat housing water OuIlet Heater Cylinder block Cylinder head t 1 Thermostat I intake manifold (Water parragel Thermostat Open Closed SLC553 LC-8

9 COOLING SYSTEM -Changing Engine Coolant 1 2 Refer to Changing Engine Coolant in section MA If the hoses connecting engine and heater have been disconnected to dismount heater core unit and engine. always perform the following work before filling with engine coolant Set the heater temperature lever or button to "Full Hot" position Disconnect the upper hose from water cock, and fill the heater core unit with 500 mp (16.9 US fl 02, 17 6 Imp fl 02) or more of coolant CHECKING COOLING SYSTEM FOR LEAKS Apply pressure to the cooling system by means of a tester to check for leakage Test i ng pressure. 157 kpa (1 6 kg/cm2, 23 psi) DO not remove englne ter 3 Connect the hoses. v SLC609 CHECKING RADIATOR CAP Apply pressure to radiator cap by means of a cap tester to see if it is satisfactory Radiator cap relief pressure: kpa ( kglcm', 9-14 psi) -Checking Cooling Systern- WARNING: Never remove the radiator cap when the engine IS hot, serious burns could be caused by high pressure fluid escaping from the radiator Wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow built-up pressure to 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 deterioration "\ SLC613 LC-9

10 COOLING SYSTEM -Water Pump- Drain coolant from right side drain cocks on cylinder block and radiator CAUTION. When removing water pump assembly, be careful Always replace with new gasket. To avoid deforming timing cover, make sure there is adequate clearance between cover and hose clamp. After installing water pump, connect hose and clamp securely, then check for leaks using cap tester N m I kgm. 12- Eft-lbl SLC554 Inspection end play and rough operation LC-10

11 COOLING SYSTEM -Thermostat- Description (Bottom by-pass coolant flow) - water OUtkt Thermostat Coalant flow out through water Outlet Open A few r) close Much SLC565 Disassembly and Assembly 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. Always replace with new gasket. After installation. run engine for a few and check for leaks. minutes, \ N m ( kg-m, ft-lbl SLC555 LC-11

12 COOLING SYSTEM -Thermostat- inspection 1 Check for valve seating condition at ordinary temperatures It should seat tightly 2 Check valve opening temperature and rnaxlmum valve lift I Standard Valve opening temperature OC (OF) Maximum valve lift mmioc ( df) 76 5 (170) I 10/90 (0 39/194) SLC556 3 Then check if valve closes at 5 C (9 F) below valve opening temperature LC-12

13 COOLING SYSTEM -Radiator- Disassembly and Assembly Before removing radtator, remove front bumper assembly Always replace with new gasket and O-ring When filling radiator with coolant, refer to MA section Reservoir tank.f' \ \ &em ) - Water outlet Mounting rubber +Drain plug 3-5 IO ) N rn lkg-m. ft Ibl SLC557 LC-13

14 COOLING SYSTEM -Cooling Fan- -Disassembly and Assembly Inspection ( ( Check fan coupling for oil leakage or bent bimetal. i( ) (91 N rn lkg-m, ft-lbl SLC558 SLC072 LC-14

15 COOLING SYSTEM -Electric Cooling Fan for Turbocharger- Disassembly and Assembly AW condmoner condenser 7 I I I SLC559 Refer to HA section for electric circwt Inspection Check water temperature switch for proper operation Operating temperature OFF + ON 100 C (212 F) LC-15

16 SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Lubri tion System Oil pressure check 011 pump Engine rpm Approximate discharge Dresure kpa Ikdcm, DII) (0 8,ll I 1, (2,281 2, (3, SLC573 Unit mm Inn1 Height H, H* Except turbo model 125 IO IO 7281 Turbo model 15 5 IO (0 846) Tightening torque Unlt Nm kg-m it-lb 011 Pumpsecuring bolt M6 M8 011 pump cover screw Regulator valve cap bolt 081 strainer bolt M6 M8 011 pressure switch Turbocharger Oil inlet tube to cylinder block 011 inlet tube to turbocharger 011 outlet pipe to turbochar~er Unit mm lml Body to Outer gear inner gear to CreKent Outer gear to crescent Housing to mnergear Clearance 0 Housing to outer gear IO ) ( ( ) Oil pressure regulator valve Valve spring free length mm On1 xxxxx Valve spring assembly length mm/n lmm/kg, dlbl xxxxx Opening pressure kpa Ikglcrn. Pril/rpm /2,000 rpm LC-16

17 ~~ ~ ~ ~~~ ~ ~ ~ SERVICE DATA AND SPECIFICATIONS (S. D.S.) Engine Cooling System Radiator Cap relief pressure Leakase terr mesure Unit kpa lkg/cm'. psi I Thermostat Standard Valve opentng temperature "C I'FI Maximum valve lift mmpc I d FI 76 5 I IO 39/194) Fan coupling Cut Off point rpm LOW 750 Hlgh Except turbo model Turbo model Low+ Hightemperature'C I'FI Temperature switch (Turbocharged model) Operatmg temperatwe OFF - ON "C I'FI 100 (2121 Tightening torque Unit Nm kgm ft-lb Water pump securing bolt Thermostat housing securing bolt Water inlet securing bolt Water outlet securing bolt Coolant filler housing bolt Radiator securing bolt Radiator hose clamp Cooling fan securing bolt Fan Coupling securing bolt _- LC-1 f

18 SPECIAL SERVICE TOOLS Tool number (Kent-Moore No ) EG ( - ) Tool name Radiator cap tester adapter LC-18