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Lubrication System (Chapter D)

The document outlines the lubrication system specifications, troubleshooting guide, and maintenance procedures for engine oil, oil filters, oil coolers, oil pans, and oil pumps. It includes detailed steps for inspection, removal, installation, and replacement of various components, along with recommended oil specifications and troubleshooting tips. Key parameters such as oil pressure, capacity, and viscosity are also specified to ensure proper engine lubrication and performance.

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Antony Carpio
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61 views10 pages

Lubrication System (Chapter D)

The document outlines the lubrication system specifications, troubleshooting guide, and maintenance procedures for engine oil, oil filters, oil coolers, oil pans, and oil pumps. It includes detailed steps for inspection, removal, installation, and replacement of various components, along with recommended oil specifications and troubleshooting tips. Key parameters such as oil pressure, capacity, and viscosity are also specified to ensure proper engine lubrication and performance.

Uploaded by

Antony Carpio
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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LUBRICATION SYSTEM SPECIFICATIONS... TROUBLESHOOTING GUIDE. INSPECTION... PREPARATION ENGINE OIL. OIL PRESSURE .. ENGINE OIL ... REPLACEME! OIL FILTER REPLACEMENT. OIL COOLER . REMOVAL J INSTALLATION OIL PAN .. REMOVAL ... INSPECTION ... INSTALLATION OIL PUMP PREPAR) REMOVAL DISASSEMBLY INSPECTION ASSEMBLY .. INSTALLATION © CO WOOIVODMANTARARAROOON 9 ¥ INDEX INDEX ENGINE OIL SPECIFICATION API SERVICE SF OF SG TOTAL CAPACITY 46 Mere (4.9 US at, 40 Imp a) HYDRAULIC LASH ADJUSTER ‘SERVICE, SECTION B 1.0L pump. Removal Installation Removal / Installation. 3. Oil fiter Replacement... b-2 page D- 8 page 0-10 page D- 9 page D-10 page D- 9 page D- 6 page D- 5 aD DIE 4. il pan Removal ssnnnnnnnnneses PAGe D= 6 Instaliation svnnnnnne PAGE D= 7 5. Oil cooler (Turbo) Removal / Installation. page D- 5 6. Oil pressure Inspection. sees Page D= 4 7. Engine oil Inspection... page D- 4 Replacement... page D- 4 OUTLINE, TROUBLESHOOTING GUIDE D OUTLINE SPECIFICATIONS Traine z am Tacs ena Sanaa Tasted Type Trochoid gear. # pump Regulated pressure kPa (kgicm’, psi) 294392 (3.0—4.0, 43—57) a -_ THB SES Sa TO (OF pressure. KPa (elem? psi)— 294—392 (3.0—4.0, 43—-57}—3,000 eae eels TuFlon bape Sonor Relief pressure differential kPa (kgicm?, pai) 78—118 (0.8—1.2, 11-17) roar — i aie tape = Ol warning pressure kPa (kg/om?, psi) 29 (0.3, 4.3) Total (dry engine) liters (US gt, Imp at) 46 (4.9, 4.0) otcpeay [Grp firs U5 gt no a) Geates Oil fiter | liters (US gt, Imp at) 0.22 (0.23, 0.19) Engine 6 Psa) ees Recommended SAE Viscosity = | cele ete cA) 20 o 20 40 60 80 100 120 a > > a aa z Engi ot ——=a_— rr ZOW=i0 2OW-50 ‘Temperature range anticipated before next oll change, °O(°F) emma! TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Engine hard starting | Improper engine all Replace Da Inguticient engine of Add ail D4 Excessive oll (il working up oF working down eter fo Section B consumption Oil leakage Repair = Oil pressure drop | Insuffcient ol ‘Add oil D-4 Oil leakage Repair ~ Worn or damaged ol pump gear (outer and inner roto) | Replace o-3 Worn plunger (inside oll pump) or weak spring Replace O98 Clogged al strainer Clean = Excessive main bearing or connecting rod bearing eter to Section B clearance ‘Warning lamp tlumi- | Oil pressure drop ’As described above = hated while engine | Malluncton of of pressure switch Rete to Section T running Malfunction of electical system Reler to Section T ‘SUG et b-3 D INSPECTION, ENGINE OIL INSPECTION PREPARATION ssT ( 49 0187 260 For inspection of o Oitpressure pressure gauge BEUOOX 0 ENGINE OIL 1. Be sure the vehiole is on level ground. 2. Warm up the engine to normal operating temperature and stop it 3. Wait for five minutes, 4, Remove the oll level gauge and cheok the oil level and con- dition. 5. Add or replace oil if necessary. Note © The distance between the L and F marks on the level gauge represents 1.0 liter (1.06 US qt, 0.88 Imp qt). OIL PRESSURE 1, Remove the oil pressure switch. 2. Screw the SST into the pressure switch installation hole. ‘3. Warm up the engine to normal operating temperature. 4, Run the engine at 3,000 rpm, and note the gauge reading, Oil pressure: 147—245 kPa (1.5—2.5 kg/em?, 21—36 ps!)—1,000 rpm 294—302 kPa (3.0—4.0 kg/em?, 43-57 psi)—3,000 rpm 5. If the pressure is not as specified, check for the cause, and samam © ——repairif necessary. (Refer to Troubleshooting Guide.) ENGINE OIL REPLACEMENT 1. Warm up the engine to the normal operating temperature and stop it 2. Remove the oil filer cap and the oil pan drain plug. 3. Drain the oil into a suitable container. ( Warning © Be careful when draining, the oll Is very hot. ENGINE OIL, OIL FILTER, OIL COOLER D 4. Install the drain plug and a new gasket. 5, Refill the engine with the specified type and amount of en- ine oil 6. Refit the oil filer cap. Oil pan capacity: 3.9 liters (4.1 US gt, 3.4 Imp qt) 7. Recheck the oil level after the engine has been run. Ea OIL FILTER REPLACEMENT 1. Remove the oil fier with a suitable wrench. 2. Use a clean rag to wipe off the mounting surface on the engine. 3. Apply a small amount of engine oilto the rubber seal of the new filter. 4. Install the oil fiter until the rubber seal contacts the base, and then tighten the fier 1-1/6 turn with a wrench, ly 5. Start the engine and inspect around the fiter seal for leaks. 6. Check the oil level and add oil if necessary. Olt filter capacity: 0.22 liters (0.23 US qt, 0.19 Imp qt) TeuooKome OIL COOLER (Turbo) REMOVAL / INSTALLATION Remove in the sequence shown in the figure, Install in the reverse order of removal. 1. Water hose 2. Oil filter 3. Nut 4. Oil cooler Nut tightening torque: famorae 29-39 Nm (3.0—4.0 m-kg, 22—29 ft-lb) D OIL PAN OIL PAN REMOVAL 1. Disconnect the negative battery cable. 2. Drain the engine oil 3. Remove in the order shown in the figure, referring to Removal Note. se 00x04 (eo“H10 om, 6205 wm) seme 88 HO) Bea Nm oi 0) TOUIOXO05 4, Exhaust pipe 5. 0il pan 2. Gusset plate 6. Oil strainer 3, Clutch housing under cover 7. Stitener 4, Sub frame (RH) Removal Note Oil pan 1, Remove the oil pan mounting bolts. 2. Insert a scraper or a suitable tool between the oil pan and the stifener to separate them. 3, Remove the oil pan. Caution © Do not bend the oll pan when prying loose. OIL PAN D aoa TeuoK aT INSPECTION Check the following points. Repair or replace if necessary, 1. Cracks, deformation, damage 2, Damaged drain plug threads INSTALLATION Install in the reverse order of removal, referring to Installa- tion Note. Installation Note Stiffener, oil strainer, oil pan 1. Remove any dirt or other material from the contact surface, 2. Apply silicon sealant to the stiffener around the inside of the bolt holes and overlap the ends. 3. Install the stiffener. Tightening torque: 7—12 Nam (70—120 cm-kg, 61—104 in-Ib) 4. Install the oil strainer and a new gasket. Tightening torqu 8—12 Nm (80—120 cm-kg, 69—104 in-Ib) 5. Apply a continuous bead of silicon sealant to the oil pan around the inside of the bolt holes and overlap the ends, Caution * Secure the stiffener and oll pan wi after applying the sealant. 6. Install the oil pan. Tightening torqu 7-12 Nm (70—120 cm-kg, 61—104 in-Ib) ‘Steps After Installation 1. Supply the specified amount and type of oil 2. Start the engine and check for leakage. D OlL PUMP OL PUMP PREPARATION Sst sosi20 710 For so 1011 1014 rer fcevel and (cova and oder, couping

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