ENGINE LUBRICATION &
COOLING SYSTEMS GI
LC
MA
EM
SECTION
MODIFICATION NOTICE:
I VG30E engine has been added. EC
FE
CONTENTS
CL
PREPARATION................................................................2 ENGINE COOLING SYSTEM..........................................7
Special Service Tools ..................................................2 Cooling Circuit .............................................................7
PRECAUTION..................................................................3 System Check..............................................................7 MT
Liquid Gasket Application Procedure ..........................3 Water Pump .................................................................8
Thermostat.................................................................10
VG30E Radiator .....................................................................11 AT
Cooling Fan ...............................................................12
ENGINE LUBRICATION SYSTEM ..................................4 SERVICE DATA AND SPECIFICATIONS (SDS) ..........13
Lubrication Circuit ........................................................4 Engine Lubrication System........................................13
TF
Oil Pressure Check......................................................4 Engine Cooling System .............................................13
Oil Pump ......................................................................5
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
LC-1
PREPARATION
Special Service Tools
Tool number
Description
Tool name
ST25051001
Oil pressure gauge
Maximum measuring range:
NT558 2,452 kPa (24.5 bar, 25 kg/cm2, 356 psi)
ST25052000 Adapting oil pressure gauge to cylinder block
Hose
NT559
WS39930000 Pressing the tube of liquid gasket
Tube presser
NT052
EG17650301 Adapting radiator cap tester to radiator neck
Radiator cap tester adapter
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
NT564 Unit: mm (in)
LC-2
PRECAUTION
Liquid Gasket Application Procedure
a. Before applying liquid gasket, use a scraper to remove all GI
traces of old liquid gasket from mating surface.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.) MA
I Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide (for oil pan).
I Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) EM
wide (in areas except oil pan).
c. Apply liquid gasket to inner sealing surface around hole
SEM371C perimeter area.
(Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before refilling engine oil and
engine coolant. EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
LC-3
ENGINE LUBRICATION SYSTEM VG30E
Lubrication Circuit
SLC725-A
Oil Pressure Check
WARNING:
I Be careful not to burn yourself, as the engine and oil may
be hot.
I Oil pressure check should be done in “Neutral” gear posi-
tion.
1. Check oil level.
2. Remove oil pressure switch.
SLC369AA
LC-4
ENGINE LUBRICATION SYSTEM VG30E
Oil Pressure Check (Cont’d)
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.
GI
Engine Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi) MA
Idle speed More than 59 (0.59, 0.6, 9)
3,200 363 - 451 (3.63 - 4.51, 3.7 - 4.6, 53 - 65)
EM
If difference is extreme, check oil passage and oil pump for oil
leaks.
SLC926 6. Install oil pressure switch with sealant.
Oil Pump
EC
REMOVAL
1. Drain oil.
2. Remove oil pan. FE
3. Remove oil pump assembly.
CL
MT
SLC936-B
DISASSEMBLY AND ASSEMBLY
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
SLC386B
EL
I Always replace with new oil seal and gasket.
I When installing oil pump, apply engine oil to inner and
outer gears. IDX
LC-5
ENGINE LUBRICATION SYSTEM VG30E
Oil Pump (Cont’d)
INSPECTION
Using a feeler gauge, straightedge and micrometers, check the
following clearance:
Unit: mm (in)
Body to outer rotor radial clearance q
1 0.114 - 0.200 (0.0045 - 0.0079)
Inner rotor to outer rotor tip clearance q
2 Below 0.18 (0.0071)
Body to inner rotor axial clearance q
3 0.05 - 0.09 (0.0020 - 0.0035)
Body to outer rotor axial clearance q
4 0.050 - 0.110 (0.0020 - 0.0043)
SLC072B Inner rotor to brazed portion of housing 0.045 - 0.091 (0.0018 - 0.0036)
clearance q 5
I If the tip clearance (q
2 ) exceeds the limit, replace rotor set.
I If body to rotor clearance (q1 ,q
3 ,q4 ,q 5 ) exceed the limit,
replace oil pump body assembly.
SLC073B
SLC934AC
REGULATOR VALVE INSPECTION
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls smoothly
into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump assembly.
SLC074B
OIL PRESSURE RELIEF VALVE INSPECTION
Inspect oil pressure relief valve for movement, cracks and breaks
by pushing the ball. If replacement is necessary, remove valve by
prying it out with a suitable tool.
Install a new valve by tapping it.
SLC231A
LC-6
ENGINE COOLING SYSTEM VG30E
Cooling Circuit
GI
MA
EM
EC
FE
CL
SLC274B
MT
System Check
WARNING:
I Never remove the radiator cap when the engine is hot; AT
serious burns could be caused by high pressure fluid
escaping from the radiator.
I Wrap a thick cloth around the cap and carefully remove the
TF
cap by turning it a quarter turn to allow built-up pressure
to escape. Then turn it all the way off. PD
FA
CHECKING COOLING SYSTEM HOSES RA
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing or deterioration.
BR
CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with a
tester. ST
Testing pressure: 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
CAUTION:
Higher pressure than specified may cause radiator damage. RS
SLC756AA
CHECKING RADIATOR CAP BT
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard HA
59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 -
14 psi)
EL
IDX
SLC755AA
LC-7
ENGINE COOLING SYSTEM VG30E
Water Pump
REMOVAL
Drain coolant from drain cocks on both sides of cylinder block and
radiator.
SMA207C
SMA208C
SLC387B
CAUTION:
I When removing water pump assembly, be careful not to
get coolant on timing belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
I To avoid deforming timing cover, make sure there is
adequate clearance between it and the hose clamp.
LC-8
ENGINE COOLING SYSTEM VG30E
Water Pump (Cont’d)
INSPECTION
I Check for badly rusted or corroded body assembly and vanes. GI
I Check for rough operation due to excessive end play.
MA
EM
SLC738
INSTALLATION
1. Use a scraper to remove old liquid gasket from water pump. EC
I Also remove old liquid gasket from mating surface of cyl-
inder block.
2. Apply a continuous bead of liquid gasket to mating surface of FE
water pump.
3. Install water pump.
4. Install remaining parts in reverse order of removal. CL
CAUTION:
After installing the water pump, connect the hose and clamp
securely, and then check for leaks using the radiator cap MT
SLC681A
tester.
I When installing drive belts, refer to MA section (“Checking
Drive Belts”, “ENGINE MAINTENANCE”).
AT
I When filling radiator with coolant, refer to MA section
(“Changing Engine Coolant”, “ENGINE MAINTENANCE”). TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
LC-9
ENGINE COOLING SYSTEM VG30E
Thermostat
INSPECTION
1. Check valve seating condition at ordinary temperatures. It
should seat tightly.
SLC383A
2. Check valve opening temperature and maximum valve lift.
Standard
Valve opening temperature °C (°F) 76.5 (170)
Maximum valve lift mm/°C (in/°F) 10/90 (0.39/194)
3. Then check if valve is closed at 5°C (9°F) below valve opening
temperature.
I After installation, run engine for a few minutes, and check
for leaks.
I Be careful not to spill coolant over engine compartment.
SLC343
Use a rag to absorb coolant.
LC-10
ENGINE COOLING SYSTEM VG30E
Radiator
REMOVAL AND INSTALLATION GI
1. Remove under cover.
2. Drain coolant from radiator drain cock. MA
3. Disconnect radiator upper and lower hoses.
4. Remove A/T oil cooler hoses. (A/T model only)
EM
5. Remove radiator lower shroud.
I When removing the shroud, pull it out backward while pushing EC
both the right and left pawls.
I When installing the shroud, align the center notch with the pro-
trusion on the radiator shroud to insert both the right and left FE
pawls.
6. Disconnect reservoir tank hose.
7. Remove radiator. CL
8. After repairing or replacing radiator, install all removed parts in
the reverse order of removal.
MT
JLC389B
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
SLC388B
EL
IDX
LC-11
ENGINE COOLING SYSTEM VG30E
Cooling Fan
SLC558-D
INSPECTION
Check fan coupling for oil leakage or bent bimetal.
SLC072
LC-12
SERVICE DATA AND SPECIFICATIONS (SDS) VG30E
Engine Lubrication System
OIL PRESSURE CHECK OIL PUMP GI
Unit: mm (in)
Approximate discharge
Engine rpm
pressure kPa (bar, kg/cm2, psi)
Body to outer rotor radial 0.114 - 0.200 (0.0045 - 0.0079) MA
clearance
Idle speed More than 59 (0.59, 0.6, 9)
Inner rotor to outer rotor tip Below 0.18 (0.0071)
3,200 363 - 451 (3.63 - 4.51, 3.7 - 4.6, 53 - 65) clearance EM
Body to inner rotor axial clearance 0.05 - 0.09 (0.0020 - 0.0035)
Body to outer rotor axial 0.050 - 0.110 (0.0020 - 0.0043)
clearance
Inner rotor to brazed portion 0.045 - 0.091 (0.0018 - 0.0036)
of housing clearance
EC
Engine Cooling System
FE
THERMOSTAT RADIATOR 2
Unit: kPa (bar, kg/cm , psi)
Standard Cap relief
pressure
Standard 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14) CL
Valve opening temperature °C (°F) 76.5 (170)
Leakage test pressure 98 (0.98, 1.0, 14)
Maximum valve lift mm/°C (in/°F) 10/90 (0.39/194)
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
LC-13
