Page 226 of 2189
Oil Seals
lnstallation
NOTE:
. Engine removal is not required.
. The crankshaft oil seal housing should be dry.
Apply a light coat of grease to the crankshaft and to
the lips of the seals.
1. Using the special tool, drive in the timing pulley-
end seal until the driver bottoms against the oil
pump.
When the seal is in place, clean any excess grease
off the crankshaft and check that the oil seal lip is
not distorted.
07947 -S800200
lnstall seal with thepart number sadefacing out.
I
2. Measure the flvwheel-end seal thickness and the oil
seal housing depth. Using the special tool. drive the
flywheel-end seal into the rear cover to the point
where the clearance between the bottom of the oil
seal and the right side cover is 0.5 - 0.8 mm (0.02 -
0.03 in) (see page 7-23).
NOTE: Align the hole in the driver attachment with
the Din on the crankshaft.
DRIVER ATTACHMENT0794a-s800101lnslall seal with thepart number sidefacing out.
DRIVER07749-0010000
7 -29
Page 232 of 2189
Engine Oil
Inspection
1.Park the vehicle on level ground, and turn off theengine. Allow the oil a few minutes to drain backinto the oil pan so the dipstick will show the actuallevel.
Make certain that the oil level indicated on the dip_stick is between the upper and lower marks.
lf the level has dropped close to the lower mark.add oil until it reaches the upper mark.
CAUTION: lmert thc dipstick car€fully to avoid b€nd_ing it.
Bl6A2 angin.:
,,7.fp--)*,".
rowrn-u l
D16Y5, D16Y7, Dt6y8 ongines:
8-6
Replacement
CAUTION: Removo the drain boli carefully while lhoengine is hot; the hot oil may causo scalding.
:1. Warm up the engine.
2. Drain the engine oil.
81642, D16Y7 engin€s:
{rl N.m (4.5 kgf.m,33 tbt ft}Do not overtighten.
D16Y5, Dl6Y8 6ngin93:
WASHER
DRAIN BOLT39 N.m 14.0 kgfm, 29 tbf,f0uo not overtighten.
DRAIN BOLT
Page 233 of 2189

RequirementAPI Service Grade: Use an "Energy
Conserving" SJ grade oil or an"Energy Conserving ll" SH grade oil,
SAE 5W - 30 preferred
You can also use an oil that bears the
API CERTIFICATION mark.
Capacity[atolz engine:
3.7 f (3.9 US qt,3.3 lmp qtl
I at oil change.
J 4.0 r 9.2 US qt, 3.5 lmp qtl
I at oil change, including filter'
| 4.8 f (5.1 Us qt,4.2 lmp qt)
I after engine overhaul
I Dl6Y7 engine:
3.6 f (3.8 US qt, 3.2 lmP qt)
I at change. including filter.
I 3.3 f (3.5 US qt,2.9 lmP qtl
I at change, without filter.
I 4.3 f (4.5 us qt,3.8 lmp qtl
I after engine overhaul.
J D16Y5, D16Y8 engines:
L 3.3 { {3.5 US qt,2.9 lmp qt}
I at change, including filter.
3.01 (3.2 US qt,2.6lmp qt)
I at change, withoutfilter.
3.7 { (3.9 US qt,3.3 lmp qt}- '1.€fter engine overhaul.
ChangeEvery 7,500 miles (12,000 km) or
12 months (Normal Conditions).
Every 3,750 miles (6,000 kml or
6 months (Severe Conditions).
3. Reinstall the drain bolt with a new washer. and rbfill
the engine with the recommended oil.
NOTE: Under normal conditions, the oil filter should be
replaced at every other oil change Under severe condi-
tions, the oilfilter should be replaced at each oil change'
The numbers in the middle of the API Service label tell
you the oil's SAE viscosity or weight Select the oil for
vour car according to this chart:
30 20 -10 010 20 30 4OoC
An oil with a viscosity of 5W - 30 is preferred for
improved tuel economy and year-round protection in the
car. You may use a 10W - 30 oil if the climate in your area
is limited to the temperature range shown on the chart'
Ambient Temoerature
API CERTIFICATION MARK
API SERVICE LABEL
Run the engine tor more than three minutes, then
check for oii leakage
8-7
Page 237 of 2189
Oil Pump
Overhaul
NOTE:
. Use new O rings when reassembllng.
. Apply oil to O-rings before installation.
. Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003
. The rotors must be installed to the same direction in order'
o After reassembly, check that the rolors move without binding'
B15A2 engine:
6x1.0mm7 N.m (0.7 kgf m, 5 lbf ft)
OUTER ROTORInspection, page 8-13
INNER ROTORpage 8-13
OOWELPIN
O-RINGReplace.
6x1.0mm11 N.m (1.1
8 tbtfrlkgf.m,
PUMP HOUSINGInspection, page 8-13
Apply liquid gasket
to the mating surface of
the cylinder blockwhen installing.
8 x 1.25 mm24 N,m {2.i1 kgl.m.
17 tbf.ft)RELIEF VALVEValve mlst slide freeiy
in housing bore.Replace if scored.OIL SEALReplace.lnstallation,page 8-14
SEALING BOLT39 N.m l4O kgt'm,29 tbt frl
\(cont'd)
SPRING
8-11
Page 238 of 2189
Oil Pump
Overhaul (cont'dl
NOIE:
. Use new O rings when reassembling.. Apply oil to O rings before instalraUon.. Use liquid gasket, Parr No. 08718 - 0001 or08718_0003.. The rotors must be installed to the same direction.. After reassembly, check that the rotors move without binding.
D16Y5, D16Y7, D16Y8 engines:
(
6x1.0mm7 N.m (0.7 kgI.m, 5 lbf ftl
PUMP HOUSINGInspection, page 8 13Apply liquid gasketto mating surface ofthe cylinder biockwhen installing.
INNER ROTORInspectron, page 8 13
DOWEL PIN
PUMP COVEB
O-RING
_.feor,""
\6x1.0mm11 N.m {1.1 kgf.m,8lbl.ft)RELIEF VALVEValve must slide freelyin housing bore.Replace if scored
OIL SEAL
[".?li;:;"". *,", ,.rg
""rc
@.-*or"."
9''ggttt*
8-12
Page 256 of 2189
Cooling
fllustrated Index ."..."... ""' 10-2
Radiator
Replacement .'....'...."..."
Engine Coolant Refilling and
Bleeding
Cap Testing
Testing
Thermostat
Replacement .............'....
Testing
10-6
10-7
10-9
10-9
10-10
10-10
Engine Goolant TemPerature
(ECT) Switch
Testing """ 10-11
Water PumP
fffustrated Index ......'... " 10-12
Inspection ' 10'14
Replacement ..'..'...."...'.'....'..'.....'.""" 10-14
!
Page 257 of 2189

lllustrated Index
@@ system is under high pressure when theengine is hot. To avoid dangsr of rsleasing scaldingengine coolant, removo the cap only when the engine iscoot.
Total Cooling System Capacity flncluding heater andfoservoir (0.4 f (0.42 US qt, 0.35 tmp qt)ll:
*2: 81642 engine*3: D16Y7 engine*4: D16Y8 engine
CAUTION: lf any engine coolant spills on painted por-tions of the body, rinse it off immediately.
NOTE:
. Check all cooling system hoses for damage, leaks ordeterioration and replace if necessary.. Check all hose clamps and retighten if necessary.. Use new O-rings when reassembling.
RADIATOR CAPPressure test, page '10 86x1.0mm9.8 N.m {1.0 kgtm,7.2 tbt.ltl
UPPERRADIATORHOSE
UPPER BRACKETAND CUSHION
COOLANT
RAOIATOREngine coolant refilling and bleeding,page 10 7Leak test, page 10-9Inspect soldered joints andseams for leaks,Blow out dirt Irom betweencore fins with compressed air.lf insects, etc,, are cloggingradiator, wash them off withrow pressure water.
RESERVOIR
5x0.8mmA: ,1.4 N.m {0.45 kgf.m, 3.3 tbtftlg: 5.4 N.m (0.55 kgtm.4.0 tbf.ft)
6x1.0mm7.2 N.m (0.73 kgt.m,5.3 tbtftl
LOWERCUSHION
RADIATOR FANBADIATORFAN
DRAINPLUG
O-RINGReplace.
LOWEBRADIATORHOSE
FAN MOTOR SHROUD
Ar TOYO RADIATOR manufactured radiatorB: NIPPONDENSO manufacfared raoraror
10-2
Refer to section 14when installing.
Mt-|-4.2 f (4.4 US qt,3.7 tmp qt)*j
5.0 / (5.3 U$ q1, 4.4 16p q11*z
4.1 f (4.3 US qt, 3.6 lmp q0*3
4.31 (4.5 US qt, 3.8 tmp qt)*a
CVT4.3 f (4.5 US qt,3.8 Imp qt)
*1i D16Y5, D16Y7, D16Y8 engines
iil
Page 262 of 2189
tl
Engine Coolant Refilling and Bleeding
CAUTION: when pouring engine coolant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtrical parts or the paint. lf any coolant spills, rinse it
off immediately.
1. Slide the heater temperature control lever to maxl-
mum heat. Make sure the engine and radiator are
cool to the touch.
Remove the radiator caP.
Loosen the drain plug, and drain the coolant'
Remove the drain bolt from the cylinder block'
D16Y5. D16Y7, Dl6Yg sngines:
DRAIN PLUG
0d
I ro
78 N.m {8.0 kgl m.58lbt'ft)
6.
1.
B1642 engin€:
WASHERReplace.
DRAIN BOLT78 N m (8 0 kgf m' 58lbfft)
Apply liquid gasket to the drain bolt threads, then
reinstall the bolt with a new washer and tighten 't
securely.
Tighten the radiator drain plug securely
Remove, drain and reinstall the reservoir' Fill the
tank halfway to the MAX mark with water, then up
to the MAX mark with antitreeze.
(cont'd)
10-7
MAX MARK