Page 1164 of 1701
ENGINELUBRICATION SYSTEM
Lubrication Circuit
Note: .. :Oil gallery incylinder block
~ :Oil passage
.... -:By-pass passage
II
Hydraulic valve
lifter
Oil
cooler
Relief valve
0
Oil
filter
Oil
pump
SLC609AA
LC-26
Page 1168 of 1701
ENGINELUBRICATION SYSTEM
Oil Pump (Cont'd)
OIL PRESSURE RELIEFVALVEINSPECTION
Inspect oilpressure reliefvalve (indicated byarrow) for
movement, cracksandbreaks bypushing theball. Ifreplace-
ment isnecessary, removevalvebyprying itout with asuitable
tool. Install anew valve inplace bytapping it.
SLC446 OilCooler
SEC. 150-213
RHO
tOJ
16-21
(1.6. 2.1,12•15)
/
tOJ
34-44
11 ~
f:1
(3.5 -4.5, 25-33)
Front ~ LHO
:N.m (kg-m, ft-Ib)
Front
~
SLC047B
CD
Oilcooler
@
Connector
@
a-ring
@
Oilfilter bracket
@
Gasket
@
Cover
INSPECTION
1. Check oilcooler element andhousing forcracks.
2. Check coolant inletofoil cooler forclogging byblowing
through it.
Replace itifnecessary.
Oil cooler
SLC465A LC-30
Page 1188 of 1701
OUTERCOMPONENT PARTS
GA16DE WITHOUT VTC,14DE AND15DE
~ 15.7 •
20.6 (1.60 •2.10,11.58 -
15.19)
SEC.
140.150.210.211.220.221.253
•
l
-Q;Jj
Si ""~
/4J
0/)'
~ff?~~
1ii] •.
28 •'.34 '0.'" •0.851, 55.'•73.9) /
ijJ
'.28 -'.34 (0.'" •0.851, 55.'•73.9)
CIDco:J
19.6•29.4
(2.00 .3.00,
14.46•21.69)~
[jJ :
N.m (kg-m, in-Ib)
~ :N.m (kg-m, fHb)
~ :Apply
liquidgasket.
SEM060FA
G)
Oilpressure switch
@
Distributor
@
Spark plug
@
Thermal transmitter
@
Intake manifold
@
Intake manifold supports
(J)
OiIfilter
@
Thermostat
@
Water pump
EM-9
Page 1238 of 1701

OUTERCOMPONENT PARTS
•
SEM231F
SEC.
130-140-150-210-211-221
~ __to:J
13•16 (1.3 -1.6, 9.12)
to:J
16•21 (1.6. 2.1,12. 15)
to:J
20•29
(2.0 •3.0,
14 .22)
to:J
41-52 (4.2 -5.3, 30-38)
~---- D_?
. 'J ~
~~~ 0
-t::;-.....~ /,
0
to:J
21-26 ./"
(2.1. 2.7, ,./"~/'
12 -1~)
fs\
19-~~7
~ to:J
16•21
Q
to:J
18. 21 ,
to:J
45_60 (1.6-2.1, 0
Ii]
6.3 _8.3
(1.8 •2.1, (4.6•6.1, 12•15)
1
(0.64•0.85,
to:J
16•19 13-15)
to:J
16•21 33•44)
(1.6 -1.9, (1.6-2.1,
to:J
16•21
12 -14)
12•15)
t"J
16•,.
f"-~
t"J
15•21
r::!
*
H
...----4lJ
~~'. '1~
J
r \~ ~~'..,:;
1,
~Q.
/¥i-;:
--'Il
1il3.7 -5.0
J~
--A)
to:J
16-21
~11V>/
(0.38 _0.51, A~ - (1.6.2.1,12•15)\...,//
~to:J
20.29(2.0-3.0, 14-22)
33.0 •44.3)
Y
&'/-
:f~l
to:J
20•26 (2.0 •2.7, 14-20)
to:J :
N'm (kg-m, fl-Ib)
to:J
16-21 (1.6 -2.1, 12-15)~/
Ii] :
N'm (kg-m, in-Ib) •
~ :Apply
liquidgasket.
*:
Refer toLC section
("Thermostat", "ENGINECOOLING SYSTEM").
G)
Oilfiller cap
@
Oilcatcher
@
Thermostat
@
Rocker cover
@
Oilfilter
@
Water inlet
@
PCVvalve
@
Water pipeassembly
@
Starter motor
@
Camshaft
positionsensor,igni-
@
Thermal transmitter
@
Power steering oilpump
tion coiland power transistor
@
Engine coolant temperature adjusting
bar
built intodistributor
sensor
@
Power
steering oilpump
@
Intake manifold supports
@
Thermostat housing bracket
@
Knock sensor
@
Airrelief plug
rJ)
Oilfilter bracket
EM-59
Page 1249 of 1701
TIMINGCHAIN [][]
Removal (Conl'd)
13. Remove oilfilter bracket andpower steering oilpump
bracket.
14. Set NO.1 piston at
TOG
onthe compression strokebyrotat-
ing crankshaft.
• Rotate crankshaft untilmating markoncamshaft sprocketis
set atposition indicated infigure atleft.
15. Remove chaintensioner.
16. Remove distributor.
Do not turn rotor withdistributor removed.
EM-70
Page 1259 of 1701
SEM990C
SEM991C TIMING
CHAIN
[]K]
Installation (Cont'd)
23. Install distributor.
• Make surethatposition ofcamshaft isas shown infigure.
• Make surethatNo.1 piston isset at
TOe
andthat distribu-
tor isset atNo.1 cylinder sparkposition.
24. Install chaintensioner.
Make surethecamshaft sprockets aretightened completely.
Press camstopper downand"press-in" sleeveuntilhook can
be engaged onpin. When tensioner isbolted inposition the
hook willrelease automatically. Makesurearrow "A"points
toward enginefront.
25. Install oilfilter bracket andpower steering oilpump bracket.
EM-80
Page 1360 of 1701

PRECAUTIONS
Engine Oils(ConI' d)
• Wash withsoap andwater toensure alloil isremoved (skin
cleansers andnailbrushes willhelp). Preparations contain-
ing lanolin replace thenatural skinoilswhich havebeen
removed.
• Donot use gasoline, kerosine, dieselfuel,gasoil,thinners
or solvents forcleaning skin.
• If
skin disorders develop,obtainmedical advicewithout
delay.
• Where practicable, degreasecomponents priortohandling.
• Where thereisarisk ofeye contact, eyeprotection should
be worn, forexample, chemicalgogglesorface shields; in
addition aneye wash facility should beprovided.
ENVIRONMENTAL PROTECTIONPRECAUTIONS
Burning usedengine oilinsmall space heaters orboilers can
be recommended onlyforunits ofapproved design.Theheat-
ing system mustmeettherequirements ofHM Inspectorate of
Pollution forsmall burners ofless than 0.4MW. Ifin doubt check
with theappropriate localauthority and/ormanufacturer ofthe
approved appliance.
Dispose ofused oiland used oilfilters through authorized
waste disposal contractors tolicensed wastedisposal sites,or
to the waste oilreclamation trade.Ifin doubt, contact thelocal
authority foradvice ondisposal facilities.
It is illegal topour used oilontothe ground, downsewers or
drains, orinto water courses.
The regulations concerningthepollution ofthe environment
will vary between regions.
Precautions forFuel
GASOLINE ENGINE:
For Europe
Unleaded gasolineofat least 95octane (RON)
CAUTION: Do not use leaded gasoline. Usingleaded gasoline willdamage
the catalytic converter.
Except Europe
Unleaded gasolineofat least 91octane (RON)
DIESEL ENGINE*:
Diesel fuelofat least 50cetane
If two types ofdiesel fuelareavailable, usesummer or
winter fuelproperly according tothe following temperature
conditions.
• Above -rc(20°F) Summer typediesel fuel.
• Below
-rc
(20°F) Wintertypediesel fuel.
CAUTION:
• Donot use home heating oil,gasoline, orother alternate
fuels inyour diesel engine. Theuseofthose cancause
engine damage.
• Donot use summer fuelattemperature below_7°C(20°F).
The cold temperatures willcause waxtoform inthe fuel. As
a result, itmay prevent theengine fromrunning smoothly.
• Donot add gasoline orother alternate fuelstodiesel fuel.
GI-6
Page 1487 of 1701

SECTION
CONTENTS
MAINTENANCE
MA
•
PRECAUTIONS ANDPREPARATION
3
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System) 3
Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System) 3
Special Service Tools 4
Commercial ServiceTool 4
PRE-DELIVERY INSPECTIONITEMS
5
GENERAL MAINTENANCE 6
PERIODIC MAINTENANCE (Exceptfor
Europe) 7
Engine andEmission ControlService 7
Chassis andBody Service 8
Maintenance UnderSevere DrivingConditions 9
PERIODIC MAINTENANCE (ForEurope) 10
Engine Oil
&
Minor Service 10
Engine andEmission ControlService 11
Chassis andBody Services 12
Maintenance UnderSevere Driving Conditions 13
RECOMMENDED LUBRICANTSANDFLUIDS 14
Lubricants andFluids 14
SAE Viscosity Number 15
Anti-freeze CoolantMixtureRatio 16
~ --ll
GA
I I
ENGINE MAINTENANCE 17
Checking DriveBelts 17
Changing EngineCoolant... 19
Checking CoolingSystem 21
Checking FuelLines 22
Changing FuelFilter 22
Cleaning andChanging AirCleaner Filter 23
Changing EngineOil 24
Changing OilFilter 24
Checking andChanging SparkPlugs 25
Checking IgnitionWires 26Changing
PositiveCrankcase Ventilation
(PCV) Filter 26
Checking EVAPVapor Lines 26
Checking OxygenSensor(02S)orHeated
Oxygen Sensor(H02S) 27
~ --ll
SR
I I
ENGINE MAINTENANCE 28
Checking DriveBelts 28
Changing EngineCoolant... 29
Checking CoolingSystem 31
Checking FuelLines 32
Changing FuelFilter 32
Changing AirCleaner Filter 33
Changing EngineOil 33
Changing OilFilter 34
Changing SparkPlugs(Platinum-tipped type)34
Checking IgnitionWires 35
Checking EVAPVapor
&
Purge Lines 36
Checking HeatedOxygen Sensor(H02S) 37
~_~ ..-JI
CD
I I
ENGINE MAINTENANCE
38
Manifold NutCheck 38
Checking DriveBelt 38
Changing EngineCoolant. 38
Checking CoolingSystem .40
Checking FuelLine .40
Changing AirCleaner Filter 41
Water Draining, FuelFilter Check and
Replacement 41
Changing EngineOil .41
Changing EngineOilFilter 42
Checking InjectionNozzle 43
Checking IdleSpeed .44
Replacing TimingBelt 44