Page 1977 of 2267
LIQUID GASKET APPLICATION PROCEDURE
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide
for SR engine and 3.5 to 4.5 mm (0.138 to 0.177 in) wide for
QG and CD engine (for oil pan).
Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide
(in areas except oil pan).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.
SEM164 Groove Bolt holeInner
side
AEM080 GrooveInner side.
PRECAUTION
LC-2
Page 1978 of 2267

Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
Tool nameDescriptionEngine
application
SR CD QG
ST25051001*
Oil pressure gauge
NT558
PS1/4x19/inMeasuring oil
pressure
Maximum measuring
range: 2,452 kPa
(24.5 bar, 25 kg/cm
2,
356 psi)XXX
ST25052000*
Hose
NT559
PS1/4x19/inPS1/8x28/inAdapting oil
pressure gauge to
cylinder block
XXX
KV10115801 or
KV10115800
Oil filter wrench
NT362
15 faces,
Inner span: 64.3 mm (2.531 in)
(Face to opposite face)Removing oil filter
X—X
99545R2500
(KV10106S0)
Oil filter wrench
NT631
15 faces,
Inner span: 92.5 mm (3.642 in)
(Face to opposite corner)Removing oil filter
—X—
WS39930000
Tube presser
NT052
Pressing the tube of
liquid gasket
XXX
EG17650301
Radiator cap tester
adapter
NT564
Adapting radiator
cap tester to radiator
filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)XXX
*:Special tool or commercial equivalent
PREPARATION
Special Service Tools
LC-3
Page 1979 of 2267
Lubrication CircuitNCLC0003
SEM852F Oil drop
Intake camshaft
Main gallery
Chain tensioner
Relief valve
Oil filter
Oil strainerOil pumpOil jetTiming chain guideVTC Exhaust camshaft
SEM938F Oil pan Oil strainer
Oil pump
Oil filter
Main oil
gallery
Main bearingTiming chain
oil jet
Connecting rod
bearingTiming chain
Connecting rod
PistonRegulator valve
Oil pressure
relief valve
Valve timing
controller#1 Intake
camshaft journal#1 Exhaust
camshaft journal
#1 Intake
camshaft#1 Exhaust
camshaftExhaust
camshaft journal
Exhaust
camshaft
Valve lifter Valve lifterIntake
camshaftIntake
camshaft journalChain tensioner Cylinder head
oil gallery Oil passage
Oil gallery in cylinder block
By-pass passage
Oil jet
Drain
Valve timing
control solenoid
(OFF) (ON)
ENGINE LUBRICATION SYSTEMQG
Lubrication Circuit
LC-4
Page 1980 of 2267

Oil Pressure CheckNCLC0004WARNING:
Be careful not to burn yourself, as the engine and oil may
be hot.
Put gearshift lever in Neutral “N” position.
1. Check oil level.
2. Remove oil pressure switch.
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
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
600More than 98 (0.98, 1.0, 14)
2,000More than 294 (2.94, 3.0, 43)
6,000More than 392 (3.92, 4.0, 57)
If difference is extreme, check oil passage and oil pump
for oil leaks.
6. Install oil pressure switch with sealant.
Oil Pump
REMOVAL AND INSTALLATIONNCLC0005Always replace oil seal with a new one. Refer to EM sec-
tion (“OIL SEAL REPLACEMENT”).
When installing oil pump, apply engine oil to gears.
Make sure that O-ring is fitted properly.
1. Drain engine oil.
2. Remove drive belts.
3. Remove oil pan. Refer to EM section (“OIL PAN”).
4. Remove oil strainer.
5. Remove front cover. Refer to EM section (“TIMING CHAIN”).
6. Install front cover.
7. Reinstall parts in reverse order of removal.
SEM853F Oil pressure switch
Front
SLC926-A ST25051001
ST25052000
ENGINE LUBRICATION SYSTEMQG
Oil Pressure Check
LC-5
Page 1981 of 2267

DISASSEMBLY AND ASSEMBLYNCLC0006
1. Oil pump cover
2. Inner gear
3. Outer gear
4. Front cover5. Gasket
6. Oil strainer
7. Regulator valve8. Spring
9. Washer
10. Plug
INSPECTIONNCLC0007
Using a feeler gauge, check the following clearances.
Standard clearance:
Unit: mm (in)
Body to outer gear radial clearance10.250 - 0.325 (0.0098 - 0.0128)
Inner gear to outer gear tip clearance2Below 0.18 (0.0071)
Body to inner gear clearance30.030 - 0.085 (0.0012 - 0.0033)
Body to outer gear axial clearance40.030 - 0.090 (0.0012 - 0.0035)
Inner gear to brazed portion of housing
clearance50.045 - 0.091 (0.0018 - 0.0036)
SEM854FA
SEC. 135⋅150
39 - 59 (4.0 - 6.0, 29 - 43) : Lubricate with new engine oil.
: Use Genuine Liquid Gasket or equivalent.
: Do not re-use.
:N·m (kg-m; in-lb)
:N·m (kg-m, ft-lb)6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)7.8 - 12.7
(0.80 - 1.30, 69.4 - 112.8) 7.8 - 10.8 (0.80 - 1.10, 69.4 - 95.5)
SEM855F Feeler gauge
Front cover
SEM856F Straightedge
Feeler gauge Front cover
ENGINE LUBRICATION SYSTEMQG
Oil Pump (Cont’d)
LC-6
Page 1982 of 2267

If the tip clearance (2) exceeds the limit, replace gear set.
If body to gear clearances (1, 3, 4, 5) exceed the limit,
replace front cover assembly.
REGULATOR VALVE INSPECTIONNCLC0008
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 front cover assem-
bly.
4. Check regulator valve to front cover clearance.
Clearance:
6 : 0.052 - 0.088 mm (0.0020 - 0.0035 in)
If it exceeds the limit, replace front cover assembly.
Oil FilterNCLC0010The oil filter is a small, full-flow cartridge type and is provided with
a relief valve.
The new and previous oil filter designs differ from each
other and are not interchangeable.
Use Tool KV10115801 for removing oil filter.
SEM857F Inside micrometer
Front cover
Micrometer
Inner gear
SLC986AA Spring
Regulator valveWasher
Plug
SLC101B Front
cover
Regulator valve
SLC972A Oil filter body
Relief valve
Filtering paper
Screw
PackingBody
color
(gray)
Label
(red)
ENGINE LUBRICATION SYSTEMQG
Oil Pump (Cont’d)
LC-7
Page 1983 of 2267
Cooling CircuitNCLC0016
System CheckNCLC0017WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure fluid escaping 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
by turning it all the way.
CHECKING COOLING SYSTEM HOSESNCLC0017S01
Check hoses for the following:
Improper attachment
Leaks
Cracks
Damage
Loose connections
Chafing
Deterioration
SEM939F Radiator
Water inlet
Thermostat
Thermostat housing
Water pump
Cylinder block
Cylinder head
Thermostat housing
Water outletThrottle bodyEGR valveHeater Reservoir tankThermostat: CLOSED
Thermostat: OPEN
ENGINE COOLING SYSTEMQG
Cooling Circuit
LC-8
Page 1984 of 2267

CHECKING COOLING SYSTEM FOR LEAKSNCLC0017S02
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
CAUTION:
Higher pressure than specified may cause radiator damage.
CHECKING RADIATORNCLC0017S04
Check radiator for mud or clogging. If necessary, clean radiator as
follows.
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically download.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically download.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm
2,
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
CHECKING RADIATOR CAPNCLC0017S03
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78-98kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Limit
59-98kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm
2,9-14psi)
Pull the negative pressure valve to open it.
Check that it closes completely when released.
ULC015 EG17650301
SLC613-A
SMA967B
ENGINE COOLING SYSTEMQG
System Check (Cont’d)
LC-9