Page 311 of 1865
INSTALLATION 1C
Accelerator Cable
Install the accelerator cable.
76G01C-235
76G01C-236
Engine Oil
Add the specified amount and type of engine oil. (Re-
fer to Section 2B)
Coolant
Close the drain plug, fill the radiator and reservoir tank
with the specified amount and type of coolant. (Re-
fer to Section 3B)
Check Engine Condition
1. Check for leaks.
2. Perform engine adjustments if necessary.
3. Perform a road test.
4. Recheck the oil and coolant levels.
1C—99
Page 316 of 1865

INSPECTION, ENGINE OIL 2A
86U02X-004
INSPECTION
ENGINE OIL
1. Be sure the vehicle is on level ground.
2. Warm up the engine to normal operating temper-
ature and stop it.
3. Wait for five minutes.
4. Remove the oil level gauge and check the oil lev-
el and condition.
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.
69G02A-006
76G02A-005
86U02X-006
2. Screw the SST into the pressure switch installa-
tion hole.
3. Warm up the engine to normal operating tem-
perature.
4. Run the engine at 3,000 rpm, and note the gauge
reading.
Oil pressure:
343—441 kPa
(3.5—4.5 kg/cm2, 50—64 psi)...DOHC 2g4 392 kPa
(3.0—4.0 kg/cm2, 43—57 psi)...SOHC
5. If the pressure is not as specified, check for the
cause, and repair if necessary.
(Refer to Troubleshooting Guide.)
ENGINE OIL
REPLACEMENT
1. Warm up the engine to the normal operating tem-
perature and stop it.
2. Remove the oil filler cap and the oil pan drain plug.
3. Drain the oil into a suitable container.
Warning
Be careful when draining, the oil is very hot.
2A-5
Page 317 of 1865

2A OIL FILTER, OIL COOLER
j
F
k
4
4. Install the drain plug and a new gasket.
5. Refill the engine with the specified type and amount
of oil.
6. Refit the oil filler cap.
Oil pan capacity:
3.6 liters (3.8 US qt, 3.2 Imp qt)
7. Recheck the oil level after the engine has been run.
76G02A-006
TbJ
r
86U02X-008
76G02A-007
0
A
if \ lO
/O
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©
76G02A-008
OIL FILTER
REPLACEMENT
1. Remove the oil filter 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 oil to the rubber
seal of the new filter.
Warning
Be careful that the engine and filter are very
hot.
4. (DOHC)
Install the oil filter until the rubber seal contacts the
base and then tighten the filter
1
and
1
/6 turn with
a wrench.
(SOHC)
Install the oil filter and tighten it by hand only. Do
not use a wrench.
5. Start the engine and inspect around the filter seal
for leaks.
6. Check the oil level and add oil if necessary.
Oil filter capacity:
0.20 liters (0.21 US qt, 0.18 Imp qt)...DOHC
0.30 liters (0.32 US qt, 0.26 Imp qt)...SOHC
OIL
COOLER
(DOHC, 12-valve,
ECE
8-valve)
REMOVAL AND 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:
29—39
N
m (3.0—4.0 m-kg, 22—29 ft-lb)
2A-6
Page 319 of 1865

2A OIL PAN
4BG02X-037
76G02A-013
76G02A-014
(SOHC)
1. Remove the oil pan mounting bolts.
2. Insert a scraper or a suitable tool between the oil
pan and the stiffener or the cylinder block to sep-
arate them.
3. Remove the oil pan.
Caution
Do not bend the oil pan when prying loose.
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 the
installation note.
Installation Note
Stiffener (FE 8-valve...only ECE, 12-valve)
1. Remove any dirt or other material from the con-
tact surface.
2. Apply silicon sealant to the stiffener around inside
of the bolt holes and overlap the ends.
3. Install the stiffener.
Tightening torque:
7—12 Nm (70—120 cm-kg, 61—104 in-lb)
Oil pan
1. Apply silicon sealant to the oil pan around inside
of the bolt holes and overlap the ends.
2. Install the oil pan.
Tightening torque:
7—12 Nm (70—120 cm-kg, 61—104 in-lb)
Caution (DOHC)
Oil pan projection and recession from the end
of the cylinder block must not be more than
1.5 mm (0.06 in).
2A—8
Page 322 of 1865
OIL PUMP 2A
DISASSEMBLY
Disassemble in the sequence shown in the figure. 69G02B-012
1. Pump cover
2. Outer gear
3. Inner gear
4. Pressure relief
valve
5. Oil seal
6. Oil pump body
76G02A-018
INSPECTION
(DOHC)
1. Check the following and replace any faulty parts.
(1) Distorted or damaged oil pump body or cover
(2) Worn or damaged plunger
(3) Weak or broken plunger spring
2. Measure the side clearance.
Clearance: 0.10 mm (0.004 in) max.
76G02A-019
3. Measure the tooth tip clearance.
Clearance: 0.18 mm (0.007 in) max.
69G02B-015
2A-11
Page 323 of 1865
2A OIL PUMP
86U02X-021
76G02A-020
76G02A-021
4. Measure the outer gear to pump body clearance.
Clearance: 0.20 mm (0.008 in) max.
(SOHC)
1. Check the following and replace any faulty parts.
(1) Distorted or damaged oil pump body or cover
(2) Worn or damaged plunger
(3) Weak or broken plunger spring
2. Measure the side clearance.
Clearance: 0.10 mm (0.004 in) max.
3. Measure the outer gear tooth tip and crescent
clearance.
Clearance: 0.35 mm (0.014 in) max.
4. Measure the inner gear tooth tip and crescent
clearance.
Clearance: 0.40 mm (0.016 in) max.
76G02A-022
2 A—12
Page 329 of 1865
INSPECTION 2B
A
76G02B-006
INSPECTION
ENGINE OIL
1. Be sure the vehicle is on level ground.
2. Warm up the engine to normal operating temper-
ature and stop it.
3. Wait for five minutes.
4. Remove the oil level gauge and check the oil lev-
el and condition.
5. Add or replace oil if necessary.
Note
The distance between the L and F marks on
the level gauge represents 1.2 liters (1.26 US
qt, 1.05 Imp qt).
OIL PRESSURE
1. Disconnect the oil hose (vacuum pump—cylinder
block).
76G02B-007
2. Set the SST as shown.
3. Remove the vacuum pump drive belt to prevent
heat damage to bearing.
4. Warm up the engine to normal operating tem-
perature.
76G02B-008
5. Run the engine first at 1,000 rpm, then at 3,000
rpm and note the gauge reading.
Standard oil pressure kPa (kg/cm2, psi)
1,000 rpm 147-245 (1.5-2.5, 21-36)
3,000
rpm
343—441 (3.5-4.5, 50—64)
6. If the pressure is not as specified, check for the
cause, and repair if necessary.
(Refer to Troubleshooting Guide.)
76G02B-009
2B—5
Page 330 of 1865

2B
ENGINE OIL, OIL
FILTER
86U02X-006
76G02B-010
86U02X-008
ENGINE OIL
REPLACEMENT
1. Warm up the engine to the normal operating tem-
perature and stop it.
2. Remove the oil filler cap and the oil pan drain plug.
3. Drain the oil into a suitable container.
Warning
Be careful when draining, the oil is very hot.
4. Install the drain plug and a new gasket.
Tightening torque:
29—41 N-m (3.0—4.2 m-kg, 22—30 ft-lb)
5. Refill the engine with the specified type and amount
of oil.
6. Refit the oil filler cap.
Oil pan capacity:
5.0 liters (5.3 US qt, 4.4 Imp qt)
7. Recheck the oil level after the engine has been run.
OIL
FILTER
REPLACEMENT
1. Remove the oil filter with a suitable wrench.
2. Use a clean rag to wipe off the mounting surface
on the engine.
3. Apply a coat of engine oil to the filter rubber seal.
4. Install the oil filter until the rubber seal contacts the
oil cooler by hand. Then tighten it a 7/6 turn fur-
ther with a band type wrench.
5. Start the engine and inspect around the filter seal
for leaks.
6. Check the oil level and add oil if necessary.
Oil filter capacity:
0.50 liters (0.52 US qt, 0.44 Imp qt)
76G02B-011
2B—6