ENGINE LUBRICATION &

COOLING SYSTEMS
GI

MODIFICATION NOTICE:
SECTION LC MA

EM

Service information for TB45E engine model has been added.

EC
CONTENTS FE
TB45E Water Pump ...............................................................10
Thermostat.................................................................11 CL
PRECAUTIONS AND PREPARATION............................2
Water Inlet .................................................................12
Liquid Gasket Application Procedure ..........................2
Thermo Switch...........................................................12
Special Service Tools ..................................................3
Radiator .....................................................................13 MT
ENGINE LUBRICATION SYSTEM ..................................4
Cooling Fan (Crankshaft driven) ...............................14
Lubricating Circuit ........................................................4
Sub-radiator ...............................................................15 PD
Oil Pressure Check......................................................4
Cooling Fan Control System .....................................16
Oil Pump ......................................................................5
Radiator (Aluminum type)..........................................18
Oil Jet...........................................................................7
Oil Cooler.....................................................................8
Overheating Cause Analysis .....................................22 FA
SERVICE DATA AND SPECIFICATIONS (SDS) ..........23
ENGINE COOLING SYSTEM..........................................9
Engine Lubrication System........................................23
Cooling Circuit .............................................................9 RA
Engine Cooling System .............................................23
Cooling System Check ................................................9
Refilling Engine Coolant ............................................10
BR

ST

RS

BT

HA

EL

IDX

LC-1
PRECAUTIONS AND PREPARATION TB45E

Liquid Gasket Application Procedure

a. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
b. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
I For areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 mm (0.079 to 0.118 in).
SEM164F c. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
d. Assembly should be done within 5 minutes after coating.
e. Wait at least 30 minutes before refilling engine oil and engine
coolant.

AEM080

LC-2
 PRECAUTIONS AND PREPARATION TB45E

Special Service Tools

*: Special tool or commercial equivalent
Tool number
Tool name
Description GI
ST25051001* Measuring oil pressure
Oil pressure gauge MA
Maximum measuring range:
2,452 kPa (24.5 bar, 25
kg/cm2, 356 psi) EM
NT558

ST25052000* Adapting oil pressure gauge

Hose to cylinder block

EC

NT559 FE
KV10115801 Removing oil filter
Oil filter wrench
CL

NT362 MT
EG17650301 Adapting radiator cap tester
Radiator cap tester to radiator filler neck
adapter
PD

a: 28 (1.10) dia. FA
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
NT564 Unit: mm (in) RA
KV99103510 Installing radiator upper and
Radiator plate pliers A lower tanks
BR

NT224 ST
KV99103520 Removing radiator upper and
Radiator plate pliers B lower tanks RS

BT
NT225

WS39930000 Pressing the tube of liquid gas-

Tube presser ket
HA

EL
NT052

IDX

LC-3
ENGINE LUBRICATION SYSTEM TB45E

Lubricating Circuit

SLC203BA

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.

SLC694A

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.
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)
Idle speed More than 49 (0.49, 0.5, 7)
2,800 294 - 490 (2.94 - 4.90, 3.0 - 5.0, 43 - 71)

SLC178B

LC-4
 ENGINE LUBRICATION SYSTEM TB45E
Oil Pressure Check (Cont’d)
If difference is extreme, check oil passage and oil pump.
6. Install oil pressure switch with sealant.
Oil pressure switch:
: 10 - 16 N⋅m (1.0 - 1.6 kg-m, 87 - 139 in-lb) GI

Oil Pump MA
REMOVAL AND INSTALLATION
1. Drain engine oil. EM
2. Drain engine coolant from radiator and cylinder block. Refer to
“Changing Engine Coolant” in MA section.
3. Remove power steering oil pump drive belt, alternator drive belt
and A/C compressor drive belt. Refer to “Checking Drive Belts”
in MA section.
4. Remove radiator and radiator shroud. Refer to LC-13, “Radia- EC
tor”.
5. Remove fan coupling with fan. Refer to LC-14.
6. Remove crankshaft pulley. FE
7. Remove distributor.
8. Remove power steering oil pump and power steering oil pump
bracket. Refer to PS section. CL
9. Remove alternator and alternator bracket. Refer to EL section.
10. Remove oil pans. Refer to “OIL PAN” in EM section.
11. Remove front cover assembly. Refer to “TIMING CHAIN” in EM MT
section.
12. Remove oil pump assembly.
13. Reinstall any part removed in reverse order of removal. PD

DISASSEMBLY AND ASSEMBLY FA

RA

BR

ST

RS

BT

HA

SLC534B EL

q
1 Oil pump cover q
4 Front cover q
7 Spring
q
2 Inner gear q
5 O-ring q
8 Regulator plug
IDX
q
3 Outer gear q
6 Regulator valve
I When installing oil pump, apply engine oil to gears.

LC-5
ENGINE LUBRICATION SYSTEM TB45E
Oil Pump (Cont’d)
OIL PUMP INSPECTION
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
Body to outer gear clearance q
1 0.114 - 0.260 (0.0045 - 0.0102)
Inner gear to outer gear tip clearance q
2 Below 0.18 (0.0071)
Body to inner gear clearance q
3 0.030 - 0.070 (0.0012 - 0.0028)
Body to outer gear clearance q
4 0.030 - 0.190 (0.0012 - 0.0075)

SLC180B Inner gear to brazed portion of housing clear-

0.045 - 0.091 (0.0018 - 0.0036)
ance q5

I If the tip clearance (q

2 ) exceeds the limit, replace gear set.
I If body to gear clearances (q1 ,q
3 ,q4 ,q 5 ) exceed the limit,
replace oil pump body assembly.

SLC181B

SLC182B

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 cover.

SLC183B

4. Check regulator valve to oil pump cover clearance.

Clearance:
q
6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump cover.

SLC184B

LC-6
ENGINE LUBRICATION SYSTEM TB45E
Oil Pump (Cont’d)
OIL PRESSURE RELIEF VALVE INSPECTION (For oil
cooler)
Inspect oil pressure relief valve for movement, cracks and breaks
by pushing the ball. If replacement is necessary, remove valve by GI
prying it out with suitable tool.
Install a new valve in place by tapping it.
MA

EM
SLC185B

Oil Jet
INSPECTION (For timing chain)
Make sure that the holes are not clogged. Clean them with a wire EC
if necessary.
Drive oil jet into place after positioning alignment mark on cylinder
block. FE

CL
SLC186B
MT
INSPECTION (For piston)
1. Push cut-off valve of oil jet bolt with a clean resin or brass rod
and make sure that cut-off valve moves smoothly with proper PD
repulsion.
2. Make sure that the oil jet passage is not clogged. Clean with a
wire if necessary. FA
I Do not bend the nozzle of the oil jet.

RA

SLC015
BR
When installing oil jet, align oil jet’s boss with hole on cylin-
der block.
ST

RS

BT

SEM773F HA
OIL FILTER
The oil filter is a small, full-flow cartridge type and is provided with EL
a relief valve.

IDX

SLC035B

LC-7
 ENGINE LUBRICATION SYSTEM TB45E

Oil Cooler

SLC525B

q
1 Water hose q
3 Oil filter q
5 Water pipe
q
2 Oil cooler q
4 Gasket q
6 Oil filter bracket

REMOVAL AND INSTALLATION

1. Disconnect water hoses near oil cooler pinching hose end to
prevent engine coolant from spilling out.
2. Remove oil cooler.
3. Installation is in reverse order of removal.
I Do not spill engine coolant and engine oil on the drive belt.

INSPECTION
1. Check oil cooler for cracks.
2. Check oil cooler for clogging by blowing through engine cool-
ant inlet.
If necessary, replace oil cooler assembly.

LC-8
ENGINE COOLING SYSTEM TB45E

Cooling Circuit

GI

MA

EM

EC

FE

CL

MT

PD

SLC532B FA

Cooling System Check

RA
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure engine coolant escap- BR
ing from the radiator.
Wrap a thick cloth around the cap. Slowly turn it a quarter turn
to allow built-up pressure to escape. Carefully remove the cap ST
by turning it all the way.

CHECKING COOLING SYSTEM HOSES RS

Check hoses for the following:
I Improper attachment
I Leaks BT
I Cracks
I Damage
I Chafing HA
I Deterioration
EL

IDX

LC-9
 ENGINE COOLING SYSTEM TB45E
Cooling System Check (Cont’d)
CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher pressure than specified may cause radiator damage.

SLC134B

CHECKING RADIATOR CAP

To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
108 - 127 kPa
(1.08 - 1.27 bar, 1.1 - 1.3 kg/cm2, 16 - 18 psi)
Limit
90 kPa (0.9 bar, 0.9 kg/cm2, 13 psi)

SLC135B

Pull the negative pressure valve to open it.

Check that it closes completely when released.

SMA967B

Refilling Engine Coolant

For details on refilling engine coolant, refer to “Changing Engine
Coolant” in MA section.

Water Pump
CAUTION:
I When removing water pump assembly, be careful not to
get engine coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
I Always replace with new gasket.
I After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
Refer to MA section.
SLC189B

LC-10
 ENGINE COOLING SYSTEM TB45E
Water Pump (Cont’d)
REMOVAL
1. Drain engine coolant from radiator and cylinder block.
Refer to “Changing Engine Coolant” in MA section.
2. Remove power steering oil pump drive belt, alternator drive belt GI
and A/C compressor drive belt. Refer to “Checking Drive Belts”
in MA section.
3. Remove radiator shroud. Refer to LC-13, “Radiator”. MA
4. Remove fan coupling with fan. Refer to LC-14, “Cooling Fan-
(Crankshaft driven)”.
5. Remove water pump. EM
SMA974C

INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
2. Check for rough operation due to excessive end play. EC

FE

CL
SLC082A
MT
Thermostat
I After installation, run engine for a few minutes and check
for leaks. PD
I Be careful not to spill engine coolant in engine compart-
ment. Use a rag to absorb engine coolant.
FA
REMOVAL
Drain engine coolant from radiator and cylinder block. Refer to RA
“Changing Engine Coolant” in MA section.
SLC190B
BR
INSPECTION
1. Check valve seating condition at ordinary temperatures. It
should seat tightly. ST
2. Check valve opening temperature and maximum valve lift.
Tropical type and Standard type RS
Gulf standard and Australia Frigid type
model model
Valve opening tem-
BT
76.5 (170) 82 (180) 88 (190)
perature °C (°F)
SLC695A Maximum valve lift
10/90 (0.39/194) 10/95 (0.39/203) 10/100 (0.39/212)
HA
mm/°C (in/°F)

3. Then check if valve closes at 5°C (9°F) below valve opening EL

temperature.

IDX

LC-11
 ENGINE COOLING SYSTEM TB45E
Thermostat (Cont’d)
INSTALLATION
Install in the reverse order of removal.
I Install thermostat with whole circumference of each flange part
fit securely inside O-ring.
I Install thermostat with jiggle valve facing upwards.

SEM862FA

Water Inlet
INSPECTION
Visually inspect water leaks. If there is leakage, replace gasket.

SLC191B

Thermo Switch
INSPECTION
Check thermo switch for proper operation.
Operating temperature °C (°F) Operation
Increasing to 97 - 103 (207 - 217) OFF , ON
Decreasing to 90 - 96 (194 - 205) ON , OFF

OFF: Continuity does not exist.

ON: Continuity exists.
SLC139A

SLC533B

LC-12
 ENGINE COOLING SYSTEM TB45E

Radiator

GI

MA

EM

EC

FE

CL

MT

PD

FA

RA
SLC526B

q
1 Radiator cap q
7 Rubber mount q
13 Thermo switch
BR
q
2 Radiator shroud (upper) q
8 Bracket q
14 Drain plug
q
3 Radiator shroud (lower) q
9 Air guide q
15 Radiator hose (lower)
q
4 Radiator hose (upper) q
10 Radiator q
16 Sub-radiator hose (upper)
ST
q
5 Reservoir tank q
11 Hose q
17 Sub-radiator hose (lower)
q
6 Reservoir tank cap q
12 Water pipe q
18 Radiator hose (lower)
RS

REMOVAL AND INSTALLATION

BT
1. Drain engine coolant from radiator and cylinder block. Refer to
“Changing Engine Coolant” in MA section.
2. Remove radiator hose (upper and lower). HA
3. Remove radiator shroud (upper and lower).
4. Remove alternator drive belt. Refer to “Checking Drive Belts” in
MA section. EL
5. Remove fan coupling with fan. Refer to LC-14, “Cooling Fan-
(Crankshaft driven)”.
IDX

LC-13
 ENGINE COOLING SYSTEM TB45E
Radiator (Cont’d)
6. Remove lower air guide.
7. Remove radiator.
8. Reinstall any part removed in reverse order of removal.

SLC531B

Cooling Fan (Crankshaft driven)

DISASSEMBLY AND INSTALLATION
I Do not release the drive belt tension by removing the fan/water
pump pulley.
I Fan coupling cannot be disassembled and should be replaced
as a unit. If front mark q F is present, install fan so that side
marked q F faces the front.
I Install the drive belt only after the fan and fan coupling to water
pump flange bolts/nuts have been properly torqued.
I Proper alignment of these components is essential. Improper
SLC527B
alignment will cause them to wobble and may eventually cause
the fan to separate from the water pump causing extensive
damage.

INSPECTION
Check fan coupling for rough operation, oil leakage or bent bimetal.

SLC072

After assembly, verify the fan does not wobble or flap while the
engine is running.
WARNING:
When the engine is running, keep hands and clothing away
from moving parts such as drive belts and fan.

SLC528B

LC-14
 ENGINE COOLING SYSTEM TB45E

Sub-radiator

GI

MA

EM

EC

FE

CL

MT

PD

SLC530B FA
q
1 Cooling fan assembly q
5 Drain plug q
8 Sub-radiator hose (upper)
q
2 Spacer q
6 Sub-radiator hose (upper) q
9 Sub-radiator hose (lower) RA
q
3 Sub-radiator q
7 Water pipe q
10 Water pipe
q
4 Bracket
BR
REMOVAL AND INSTALLATION
1. Drain engine coolant from radiator and cylinder block. Refer to ST
“Changing Engine Coolant” in MA section.
2. Remove sub-radiator (hose upper and lower).
3. Disconnect radiator fan harness. RS
4. Remove sub-radiator with cooling fan assembly.
5. Reinstall any part removed in reverse order of removal.
BT

HA

EL

IDX

LC-15
 ENGINE COOLING SYSTEM TB45E

Cooling Fan Control System

OPERATION
Engine coolant temperature °C (°F) Cooling fan
Increasing to 97 - 103 (207 - 217) OFF , ON
Decreasing to 90 - 96 (194 - 205) ON , OFF
OFF: Stopped ON: Operated

SLC529B

INSPECTION
For electrical inspection of cooling fan control system, refer to
LC-17, “WIRING DIAGRAM”.

ELECTRICAL COMPONENTS LOCATION

Cooling fan relay
Cooling fan relay is located on front left side in engine compart-
ment.

SLC541B

Thermo switch
Thermo switch is located on sub-radiator hose (upper). Refer to
LC-12, “Thermo Switch”.

LC-16
 ENGINE COOLING SYSTEM TB45E
Cooling Fan Control System (Cont’d)
WIRING DIAGRAM

GI

MA

EM

EC

FE

CL

MT

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

GLC009A

LC-17
 ENGINE COOLING SYSTEM TB45E

Radiator (Aluminum type)

SLC882AF

Aluminum radiator can be disassembled by using special proce-

dures and special service tools.

DISASSEMBLY
1. Remove upper and lower tanks with Tool.

SLC903

I Grip the crimped edge and bend it upwards so that Tool slips
off.
Do not bend excessively.

SLC893

LC-18
 ENGINE COOLING SYSTEM TB45E
Radiator (Aluminum type) (Cont’d)
I In areas where Tool cannot be used, use a screwdriver to bend
the edge up.
Be careful not to damage tank.
2. Remove sealing rubbers. GI

MA

EM
SLC908A

3. Make sure the edge stands straight up.

4. Remove oil cooler from tank. (A/T model only)
EC

FE

CL
SLC931
MT
ASSEMBLY
1. Install oil cooler. (A/T model only)
Pay attention to direction of conical washer. PD

FA

RA

SLC894
BR
2. Clean contact portion of tank.

ST

RS

BT

SLC932 HA
3. Install sealing rubber.
Push it in with fingers.
Be careful not to twist sealing rubber.
EL

IDX

SLC917A

LC-19
 ENGINE COOLING SYSTEM TB45E
Radiator (Aluminum type) (Cont’d)
4. Caulk tank in specified sequence with Tool.

SLC904

SLC896

I Use pliers in the locations where Tool cannot be used.

SLC897

5. Make sure that the rim is completely crimped down.

Standard height “H”:
10.0 - 11.0 mm (0.394 - 0.433 in)
6. Confirm that there is no leakage.
Refer to Inspection.

SLC554A

INSPECTION
1. Apply pressure with Tool.
Specified pressure value:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler to seal its inlet and outlet. (A/T
model only)

SLC933

LC-20
 ENGINE COOLING SYSTEM TB45E
Radiator (Aluminum type) (Cont’d)
2. Check for leakage by soaking radiator in water container.

GI

MA

EM
SLC934

EC

FE

CL

MT

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

LC-21
 ENGINE COOLING SYSTEM TB45E

Overheating Cause Analysis

Symptom Check items

Water pump malfunction Worn or loose drive belt

Thermostat stuck closed —

Dust contamination or paper

Poor heat transfer Damaged fins clogging —

Physical damage

Excess foreign material (rust,

Clogged radiator cooling tube
dirt, sand, etc.)

Cooling fan does not operate

Fan coupling does not operate

Reduced air flow Fan assembly —
High resistance to fan rotation

Damaged fan blades

Damaged radiator shroud — — —

Improper engine coolant mix-

— — —
Cooling ture ratio
system parts
Poor engine coolant quality — Engine coolant viscosity —
malfunction
Loose clamp
Cooling hose
Cracked hose

Water pump Poor sealing

Loose
Radiator cap
Poor sealing
Engine coolant leaks
O-ring for damage, deteriora-
Insufficient engine coolant tion or improper fitting
Radiator
Cracked radiator tank

Cracked radiator core

Reservoir tank Cracked reservoir tank

Cylinder head deterioration

Exhaust gas leaks into cooling
Overflowing reservoir tank Cylinder head gasket deteriora-
system
tion

High engine rpm under no load

Driving in low gear for extended

Abusive driving
time
Driving at extremely high speed
— Overload on engine Powertrain system malfunction

Installed improper size wheels

and tires —
Except
Dragging brakes
cooling
system parts Improper ignition timing
malfunction
Blocked bumper —

Installed car brassiere

Blocked radiator grille Mud contamination or paper
Blocked or restricted air flow clogging —
Blocked radiator —

Blocked condenser
Blocked air flow
Installed large fog lamp

LC-22
 SERVICE DATA AND SPECIFICATIONS (SDS) TB45E

Engine Lubrication System

OIL PRESSURE CHECK OIL PUMP INSPECTION
Unit: mm (in) GI
Approximate discharge pressure
Engine rpm Body to outer gear clearance 0.114 - 0.260 (0.0045 - 0.0102)
kPa (bar, kg/cm2, psi)
Inner gear to outer gear tip clear-
Idle speed More than 49 (0.49, 0.5, 7)
ance
Below 0.18 (0.0071) MA
2,800 294 - 490 (2.94 - 4.90, 3.0 - 5.0, 43 - 71)
Body to inner gear clearance 0.030 - 0.070 (0.0012 - 0.0028)
Body to outer gear clearance 0.030 - 0.190 (0.0012 - 0.0075) EM
Inner gear to brazed portion of
0.045 - 0.091 (0.0018 - 0.0036)
housing clearance

REGULATOR VALVE
Unit: mm (in)
EC
Regulator valve to oil pump cover
0.040 - 0.097 (0.0016 - 0.0038)
clearance
FE
Engine Cooling System
CL
THERMOSTAT RADIATOR
Unit: kPa (bar, kg/cm2, psi)
Tropical type Standard
and Gulf type and 108 - 127
MT
Frigid type Standard
standard Australia Radiator cap (1.08 - 1.27, 1.1 - 1.3, 16 - 18)
model model relief pressure
Limit 90 (0.9, 0.9, 13)
Valve opening tem- PD
76.5 (170) 82 (180) 88 (190) Leakage test pressure 157 (1.57, 1.6, 23)
perature °C (°F)

Maximum valve lift 10/90 10/95 10/100

mm/°C (in/°F) (0.39/194) (0.39/203) (0.39/212)
FA
THERMO SWITCH
Unit: °C (°F)
RA
Operation Operating temperature

OFF , ON 97 - 103 (207 - 217)

BR
ON , OFF 90 - 96 (194 - 205)

ST

RS

BT

HA

EL

IDX

LC-23