LUBRICATION

OIL AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . LU–1

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU–4
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU–18
OIL NOZZLE AND OIL JET
PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . LU–22
 LU–1
LUBRICATION – OIL AND FILTER

Recommended Viscosity (SAE)

OIL AND FILTER LU0H8–01

20 W – 50
INSPECTION
15 W – 40 1. CHECK ENGINE OIL QUALITY
10 W – 30 Check the oil for deterioration, entry of water, discoloring or thin-
5 W – 30 ning.
If the quality is visibly poor, replace the oil.
°C –29 –18 –7 4 16 27 38
°F –20 0 20 40 60 80 100 Oil grade:
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE B08043
API grade CF–4 or CF
(You may also use API CE or CD)
Recommended viscosity:
Refer to illustration
2. CHECK ENGINE OIL LEVEL
After warming up the engine, and then 5 minutes after the en-
gine stops, oil level should be between the low level and full lev-
el marks of the dipstick.
If low, check for leakage and add oil up to the full level mark.

3. CHECK OIL PRESSURE

(a) Using a 24 mm deep socket wrench, remove the oil pres-
Oil Pressure Switch sure switch.

24 mm Deep
Socket Wrench B07991

Oil Pressure Gauge (b) Install the oil pressure gauge.

(c) Allow the engine to warm up to normal operating tempera-
ture.
(d) Check the oil pressure.
Oil pressure:
At idle 29 kPa (0.3 kgf/cm2, 4.2 psi) or more
At 4,500 rpm 245 – 588 kPa (2.5 – 6.0 kgf/cm2, 36 – 85 psi)
(e) Remove the oil pressure gauge.
B07992

(f) Apply adhesive to 2 or 3 threads of the oil pressure switch.

Adhesive Adhesive:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
(g) Reinstall the oil pressure switch.
(h) Start the engine and check for oil leak.

P13638
LU–2
LUBRICATION – OIL AND FILTER
LU0GJ–02

REPLACEMENT
CAUTION:
S Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
S Care should be taken, therefore, when changing en-
gine oil to minimize the frequency and length of time
your skin is exposed to used engine oil. Protective
clothing and gloves that cannot be penetrated by oil
should be worn. The skin should be thoroughly
washed with soap and water, or use water–less hand
cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
S In order to preserve the environment, used oil and
used oil filters must be disposed of only at desig-
nated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a contain-
er.

2. REPLACE OIL FILTER

(a) Install a vinyl tube on the pipe of the oil drain container.

Vinyl Tube

B07997

(b) Using SST, remove the oil filter.

SST 09228–10002
(c) Clean the oil filter contacting the oil filter mounting.
SST
(d) Lubricate the filter rubber gasket with clean engine oil.

B07993
 LU–3
LUBRICATION – OIL AND FILTER

(e) Tighten the oil filter by hand until the rubber gasket con-
tacts the seat of the filter mounting.

B07994

(f) Using SST, give it an additional 3/4 turn to seat the filter.
SST SST 09228–10002
(g) Remove the vinyl tube.
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
(b) Fill with new engine oil.
Additional
3/4 Turn Capacity:
B07995 Drain and refill w/ Oil filter change 6.4 liters (6.8 US qts, 5.6 lmp. qts)
w/o Oil filter change 5.4 liters (5.7 US qts, 4.8 lmp. qts)
Dry fill 6.5 liters (6.9 US qts, 5.7 lmp. qts)

(c) Reinstall the oil filler cap.

4. START ENGINE AND CHECK FOR OIL LEAK
5. RECHECK ENGINE OIL LEVEL
LU–4
LUBRICATION – OIL PUMP

OIL PUMP
LU03J–05

COMPONENTS
* Gasket Timing Belt

Timing Belt Plate

No.2 Timing Belt Cover

Service Hole Cover

9 (90, 78 in.·lbf)

Seal Washer
x7
Engine Mounting Bracket
Timing Belt
Tensioner
36.8 (375, 27)

63.7 (650, 47) 21 (210, 15)

No.1 Timing Belt Cover

Timing Belt Guide

x5 * Gasket
Oil Pump Insulator
Seal Washer
Crankshaft Pulley Grommet
180 (1,800, 130)
Glow Plug
Connector

Glow Plug
Drive Belt

N·m (kgf·cm, ft·lbf) : Specified torque

* Replace only if damaged B08038
 LU–5
LUBRICATION – OIL PUMP

Drive Belt Adjusting Bar

No.2 Idler Pulley

31.4 (320, 23)

x5

20.5 (210, 15)

z Gasket
8.0 (80, 69 in.·lbf)
Oil Pump
8.8 (90, 78 in.·lbf)
31.4 (320, 23)
46.6 (475, 34)
31.4 (320, 23)
Crankshaft Timing Pulley
Crankshaft Position Sensor
20.5 (210, 15)
No.1 Oil Pan
x 19
8.0 (80, 69 in.·lbf)

z Gasket
Oil Strainer
13.2 (135, 10)
Oil Pan Insulator
20.5 (210, 15)
Oil Dipstick
No.2 Oil Pan and Guide
z Gasket z O–Ring

Drain Plug
34.3 (350, 25)
18 (185, 13)
x 15

11.7 (120, 9)

Oil Level Sensor

N·m (kgf·cm, ft·lbf) : Specified torque
z Non–reusable part B08039
LU–6
LUBRICATION – OIL PUMP

Driven Rotor

z Crankshaft Front Oil Seal

Relief Valve

Spring

z Gasket

Plug
49 (500, 36)

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part B07996
 LU–7
LUBRICATION – OIL PUMP
LU0H9–01

REMOVAL
HINT:
When repairing the oil pump, the oil pan and strainer should be
removed and cleaned.
1. DRAIN ENGINE OIL
2. REMOVE TIMING BELT (See page EM–12)
3. REMOVE NO.2 IDLER AND CRANKSHAFT TIMING
PULLEYS (See page EM–12)

4. REMOVE DRIVE BELT ADJUSTING BAR

Remove the 3 bolts and adjusting bar.

B08003

5. REMOVE OIL DIPSTICK AND GUIDE

(a) Remove the bolt holding the dipstick guide to the supply
pump stay.
(b) Pull out the dipstick guide together with the dipstick from
the No.1 oil pan.
(c) Remove the O–ring from the dipstick guide.

O–Ring
B08016

6. REMOVE OIL LEVEL SENSOR

Remove the 4 bolts and level sensor.
NOTICE:
Be careful not to drop the oil level sensor when removing
it.

B07998

7. REMOVE NO.2 OIL PAN

(a) Remove the 15 bolts and 3 nuts.

B07983
LU–8
LUBRICATION – OIL PUMP

(b) Insert the blade of SST between the No.1 and No.2 oil
pans, and cut off applied sealer and remove the No.2 oil
pan.
SST 09032–00100
NOTICE:
Be careful not to damage the contact surfaces of the No.1
SST SST
and No.2 oil pans.

B08601

8. REMOVE OIL STRAINER

Remove the 2 bolts, 2 nuts, oil strainer and gasket.

B07984

9. REMOVE OIL PAN INSULATOR

Remove the bolt and oil pan insulator.

B08009

10. REMOVE NO.1 OIL PAN

(a) Remove the 21 bolts and 3 nuts.

B07999

(b) Using a screwdriver, remove the oil pan by prying the por-
tions between the cylinder block and No.1 oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and No.1 oil pan.
11. REMOVE CRANKSHAFT POSITION SENSOR

B08000
 LU–9
LUBRICATION – OIL PUMP

12. REMOVE OIL PUMP

(a) Remove the 9 bolts.
(b) Remove the oil pump by prying a screwdriver between the
the oil pump and main bearing cap.
(c) Remove the gasket.

B08002
LU–10
LUBRICATION – OIL PUMP
LU0HA–01

DISASSEMBLY
1. REMOVE DRIVEN ROTOR
Pull out the driven rotor.

2. REMOVE RELIEF VALVE

(a) Carefully mount the oil pump body in a soft jaw vise.
(b) Remove the plug, gasket, spring and relief valve.

B08013
 LU–11
LUBRICATION – OIL PUMP
LU0HH–01

INSPECTION
1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly
into the valve hole by its own weight.
If it doesn’t, replace the relief valve. If necessary, replace the oil
pump assembly.
2. INSPECT DRIVE AND DRIVEN ROTORS
(a) Place the driven rotor into the oil pump body.
B08014
(See page LU–14)

(b) Inspect the rotors for tip clearance.

Using a feeler gauge, measure the clearance between
the drive and driven rotor tips.
Standard tip clearance:
0.08 – 0.16 mm (0.0031 – 0.0063 in.)
Maximum tip clearance: 0.20 mm (0.0079 in.)
If the tip clearance is greater than maximum, replace the oil
pump assembly.
B08011

(c) Inspect the rotors for body clearance.

Using a feeler gauge, measure the clearance between
the driven rotor and body.
Standard body clearance:
0.10 – 0.17 mm (0.0039 – 0.0067 in.)
Maximum body clearance: 0.20 mm (0.0079 in.)
If the tip clearance is greater than maximum, replace the oil
pump assembly.
B08012
LU–12
LUBRICATION – OIL PUMP
LU0HB–01

REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL (See page EM–70)
 LU–13
LUBRICATION – OIL PUMP
LU0GM–02

REASSEMBLY
1. INSTALL RELIEF VALVE
(a) Insert the relief valve and spring into the oil pump body.
(b) Install the plug with a new gasket.
Torque: 49 N·m (500 kgf·cm 36 ft·lbf)

B08013

Mark 2. INSTALL DRIVEN ROTOR

Install the driven rotor into pump with the mark on the driven ro-
tor facing the pump body side.

Driven Rotor

B08010
LU–14
LUBRICATION – OIL PUMP
LU0HC–01

INSTALLATION
1. INSTALL OIL PUMP STUD BOLT
Adhesive
HINT:
When using a new oil pump, stud bolt must be installed.
Apply adhesive to the threads of the stud bolt and install it.
Adhesive: Part No. 08833–00070, THREE BOND 1324
or equivalent
2. INSTALL OIL PUMP
B07975
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.
S Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
S Thoroughly clean all components to remove all the
loose material.
S Using a non–residue solvent, clean both sealing
surfaces.

New Gasket (b) Apply seal packing to the oil pump as shown in the illustra-
Seal Width tion.
2 – 4 mm
Seal packing: Part No. 08826–00080 or equivalent
Seal NOTICE:
Packing
Avoid applying an excessive amount to the surface.
S Install a nozzle that has been cut to a 2 – 4 mm (0.08
– 0.16 in.) opening.
S Parts must be assembled within 15 minutes of ap-
B07987 plication. Otherwise the material must be removed
and reapplied.
S Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install a new gasket to the oil pump.

(d) Pour in 0.5 cm3 (0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(e) Install the oil pump with the 9 bolts.
Torque: 31.4 N·m (320 kgf·cm, 23 ft·lbf)

B08024
 LU–15
LUBRICATION – OIL PUMP

(f) Measure the oil pump rotating torque.

(1) Check that the pump rotates smoothly without ab-
normal noise.
(2) Using a torque wrench, check the pump rotating
torque.
Rotating torque: 3.0 N·m (30 kgf·cm, 26 in.·lbf) or less
3. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
B08238 4. INSTALL NO.1 OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the No.1 oil
pan, cylinder block, oil pump and rear oil seal retainer.
S Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces.
S Thoroughly clean all components to remove all the
loose material.
S Using a non–residue solvent, clean both sealing
surfaces.

(b) Apply seal packing to the No.1 oil pan as shown in the il-
A lustration.
B
Seal packing: Part No. 08826–00080 or equivalent
S Install a nozzle that has been cut to a 4 – 7 mm (0.16
– 0.28 in.) opening.
S Parts must be assembled within 15 minutes of ap-
Seal Width
4 – 7 mm
plication. Otherwise the material must be removed
and reapplied.
S Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil pan with the 21 bolts and 3 nuts.
Torque:
A B 8.0 N·m (80 kgf·cm, 69 in.·lbf) for 10 mm head bolt and
nut
20.5 N·m (210 kgf·cm, 15 ft·lbf) for 12 mm head bolt
5. INSTALL OIL PAN INSULATOR
Install the oil pan insulator with the bolt.
Torque: 7.5 N·m (75 kgf·cm, 65 in.·lbf)
B07990

6. INSTALL OIL STRAINER

Install a new gasket and the oil strainer with the 2 bolts and 2
nuts.
Torque:
20.5 N·m (210 kgf·cm, 15 ft·lbf) for bolt
13.2 N·m (135 kgf·cm, 10 ft·lbf) for nut
7. INSTALL NO.2 OIL PAN
(a) Remove any old seal packing (FIPG) material and be
B07984 careful not to drop any oil on the contact surfaces of the
No.1 and No.2 oil pans.
LU–16
LUBRICATION – OIL PUMP

S Using a razor blade and gasket scraper, remove all

the old packing (FIPG) material from the gasket sur-
faces.
S Thoroughly clean all components to remove all the
loose material.
S Using a non–residue solvent, clean both sealing
surface.
NOTICE:
Do not use a solvent which will affect the painted surfaces.

(b) Apply a seal packing to the oil pan shown in the illustra-
tion.
Seal packing: Part No. 08826–00080 or equivalent
S Install a nozzle that has been cut to a 4 – 7 mm (0.16
A – 0.28 in.) opening.
B S Parts must be assembled within 15 minutes of ap-
Seal Width
4 – 7 mm plication. Otherwise the material must be removed
and reapplied.
S Immediately remove nozzle from the tube and rein-
stall the cap.
(c) Install the oil pan with the 15 bolts and 3 nuts. Uniformly
tighten the bolts and nuts in several passes.
Torque: 11.7 N·m (120 kgf·cm, 9 ft·lbf)
A

B08042

8. INSTALL OIL LEVEL SENSOR

Install the level sensor with the 4 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

B07998

9. INSTALL OIL DIPSTICK AND GUIDE

(a) Install a new O–ring to the dipstick guide.
(b) Apply engine oil to the O–ring.
(c) Push in the dipstick guide end into the guide hole of the
No.1 oil pan.
(d) Install the dipstick guide with the bolt.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(e) Apply engine oil to the O–ring on the dipstick.
New O–Ring
B08016 (f) Install the dipstick.
 LU–17
LUBRICATION – OIL PUMP

10. INSTALL DRIVE BELT ADJUSTING BAR

Install the adjusting bar with the 3 bolts.
Torque:
18.1 N·m (185 kgf·cm, 13 ft·lbf) for bolt (A)
(B) 31.4 N·m (320 kgf·cm, 23 ft·lbf) for bolt (B)
HINT:
(B) Tighten the bolt (A) after having the drive belt installed.
(A)
11. INSTALL CRANKSHAFT TIMING AND NO.2 IDLER
B08003 PULLEYS (See page EM–18)
12. INSTALL TIMING BELT (See page EM–18)
13. FILL WITH ENGINE OIL
14. START ENGINE AND CHECK FOR OIL LEAK
15. RECHECK ENGINE OIL LEVEL
LU–18
LUBRICATION – OIL COOLER

OIL COOLER
LU03Q–05

COMPONENTS

31 (320, 23)

z Gasket
Vacuum Pump Oil Pipe

Turbo Oil Inlet Pipe

z Gasket
31 (320, 23)

Nut
66 (670, 48)

Turbo Oil Outlet Hose

No.2 Oil Cooler Hose

No.1 Oil Cooler Hose

Oil Filter
N·m (kgf·cm, ft·lbf) : Specified torque z O–Ring
z Non–reusable part Oil Cooler B07986
 LU–19
LUBRICATION – OIL COOLER
LU0HI–01

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE OIL FILTER (See page LU–2)

3. REMOVE TURBO OIL INLET PIPE

Remove the 2 union bolts, 2 gaskets, bolt, nut and inlet pipe.

Union Bolt

B07982

4. REMOVE VACUUM PUMP OIL PIPE

(a) Disconnect the 2 oil hoses.
(b) Remove the bolt, nut and oil pipe.

B07981

SST 5. REMOVE OIL COOLER

(a) Using SST, remove the nut and oil cooler.
SST 09229–55010
(b) Remove the O–ring from the oil cooler.

B07978
LU–20
LUBRICATION – OIL COOLER
LU03S–05

INSPECTION
INSPECT OIL COOLER
Check the oil cooler for damage or clogging.
IN
If necessary, replace the oil cooler.
OUT

B07977
 LU–21
LUBRICATION – OIL COOLER
LU0HJ–02

New O–Ring
INSTALLATION
1. INSTALL OIL COOLER
(a) Clean the oil cooler contact surface on the oil cooler
mounting.
(b) Install a new O–ring to the oil cooler.

B07980

Protrusion SST (c) Apply a light coat of engine oil on the threads and under
the nut.
(d) Align the cutout of the oil cooler with the protrusion of the
cylinder block.
(e) Using SST, install the oil cooler with the nut.
SST 0929–55010
Cutout
Torque: 66 N·m (670 kgf·cm, 48 ft·lbf)

B07979

2. INSTALL VACUUM PUMP OIL PIPE

(a) Install the oil pipe with the bolt and nut.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(b) Connect the 2 oil hoses.

B07981

3. INSTALL TURBO OIL INLET PIPE

(a) Apply a light coat of engine oil to 2 new gaskets and on
the threads and under the heads of the union bolts.
(b) Install the 2 gaskets and the inlet pipe with the 2 union
bolts, bolt and nut.
Union Bolt NOTICE:
Use the new gasket by separating it into two.
HINT:
B07982 The turbocharger side union bolt is yellow and the cylinder
block side union bolt is black.
Torque:
31 N·m (320 kgf·cm, 23 ft·lbf) for union bolt
8.8 N·m (90 kgf·cm, 78 in.·lbf) for bolt and nut
4. INSTALL OIL FILTER (See page LU–2)
5. FILL WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR LEAK
7. CHECK ENGINE OIL LEVEL
LU–22
LUBRICATION – OIL NOZZLE AND OIL JET PRESSURE VALVE

OIL NOZZLE AND OIL JET PRESSURE VALVE

LU0HD–01

COMPONENTS

Oil Jet Pressure Valve

30 (310, 22)

z Gasket

8.0 (80, 69 in.·lbf)

Oil Nozzle

7.4 (75, 65 in.·lbf)

20.5 (210, 15)

18 (185, 13)

Oil Dipstick
and Guide
No.1 Oil Pan

x 19 z O–Ring
8.0 (80, 69 in.·lbf)

z Gasket
20.5 (210, 15)
Oil Pan Insulator
13.2 (135, 10)
Oil Strainer

z Gasket 20.5 (210, 15)

No.2 Oil Pan

Drain Plug
34.3 (350, 25)

x 15
N·m (kgf·cm, ft·lbf) : Specified torque
z Non–reusable part 11.7 (120, 9)
B08046
 LU–23
LUBRICATION – OIL NOZZLE AND OIL JET PRESSURE VALVE
LU0HE–01

REMOVAL
1. REMOVE NO.2 AND NO.1 OIL PANS
(See page LU–7)

2. REMOVE OIL NOZZLES

Remove the bolt and oil nozzle. Remove the 4 oil nozzles.

B08015

3. REMOVE OIL JET PRESSURE VALVE

Using an 8 mm hexagon wrench, remove the pressure valve
and gasket.

8 mm
Hexagon
Wrench

A09519
LU–24
LUBRICATION – OIL NOZZLE AND OIL JET PRESSURE VALVE
LU0HF–01

INSPECTION
1. INSPECT OIL NOZZLES
Check the oil nozzle for damage or clogging.
If necessary, replace the oil nozzle.

A09504

2. INSPECT OIL JET PRESSURE VALVE

Push the valve with a wooden stick to check if it is stuck.
If stuck, replace the pressure valve.
Push

B07989
 LU–25
LUBRICATION – OIL NOZZLE AND OIL JET PRESSURE VALVE
LU0HG–01

INSTALLATION
1. INSTALL OIL JET PRESSURE VALVE
Using an 8 mm hexagon wrench, install a new gasket and the
pressure valve.
8 mm Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
Hexagon
Wrench

A09519

2. INSTALL OIL NOZZLES

Install the oil nozzle with the bolt. Install the 4 oil nozzles.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
3. INSTALL NO.1 AND NO.2 OIL PANS
(See page LU–14)

B08015