FUEL SYSTEM
1. When disconnecting the high pressure fuel line, a
large amount of gasoline will spill out, so observe the
following procedures:
(a) Put a container under the connection.
(b) Slowly loosen the connection.
(c) Disconnect the connection.
(d) Plug the connection with a rubber plug.
2. When connecting the flare nut or union bolt on the
high pressure pipe union, observe the following proce±
dures:
Union Bolt Type:
(a) Always use a new gasket.
(b) Tighten the union bolt by hand.
(c) Tighten the union bolt to the specified torque.
Torque: 29 N±m (300 kgf±cm, 22 ft±lbf)
Flare Nut Type:
(s) Apply alight coat of engine oil to the flare and tighten
the flare nut by hand.
(b) Using SST, torque the flare nut.
SST 09631±22020
Torque:
28 N±m (285 kgf±cm, 21 ft±lbf) for fuel pump side
30 N±m (310 kgf±cm, 22 ft±lbf) for others
HINT: Use a torque wrench with a fulcrum length of
30 cm (11.81 in.).
3. Observe the following precautions when removing
and installing the injectors.
(a) Never reuse the O±ring.
(b) When placing a new O±ring on the injector, take care
not to damage it in any way.
(c) Coat a new 0± ring with spindle oil or gasoline before
installing±never use engine, gear or brake oil.
4. Install the injector to delivery pipe and intake manifold
as shown in the illustration.
± 5S±FE ENGINEMFI/SFI SYSTEMEG1±175
RADIATOR
The radiator performs the function of cooling the coolant which has passed through the water
jacket and become hot, and it is mounted in the front of the vehicle. The radiator consists of an
upper tank and lower tank, and a core which connects the two tanks. The upper tank contains the
inlet for coolant from the water jacket and the filler inlet. It also has a hose attached through
which excess coolant or steam can flow. The lower tank has an outlet and drain cock for the
coolant. The core contains many tubes through which coolant flows from the upper tank to the
lower tank as well as to cooling fins which radiate heat away from the coolant in the tubes. The
air sucked through the radiator by the electric fan, as well as the wind generated by the vehicle's
travel, passes through the radiator, cooling the coolant. Models with automatic transmission
include an automatic transmission fluid cooler built into the lower tank of the radiator. A fan with
an electric motor is mounted behind the radiator to assist the flow of air through the radiator. The
fan operates when the engine coolant temperature becomes high in order to prevent it from be-
coming too high.
RADIATOR CAP
The radiator cap is a pressure type cap which seals the radiator, resulting in pressurization of the
radiator as the coolant expands. The pressurization prevents the coolant from boiling even when
the engine coolant temperature exceeds 100°C (212°F). A relief valve (pressurization valve) and a
vacuum valve (negative pressure valve) are built into the radiator cap. The relief valve opens and
lets steam escape through the overflow pipe when the pressure generated inside the cooling sys-
tem exceeds the limit (coolant temperature: 110±120°C (230±248°F), pressure; 58.8103.0 kpa
(0.6±1.05 kgf/cm
2, 8.5±14.9 psi). The vacuum valve opens to alleviate the vacuum which develops
in the cooling system after the engine is stopped and the engine coolant temperature drops. The
valve's opening allows the coolant in the reservoir tank to return to the cooling system.
RESERVOIR TANK
The reservoir tank is used to catch coolant which overflows from the cooling system as a result
of volumetric expansion when the coolant is heated. The coolant in the reservoir tank returns to
the radiator when the coolant temperature drops, thus keeping the radiator full at all times and
avoiding needless coolant loss.
Check the reservoir tank level to learn if the coolant needs to be replenished.
WATER PUMP
The water pump is used for forced circulation of coolant through the cooling system. It is
mounted on the front of the cylinder block and driven by a timing belt.
THERMOSTAT
The thermostat has a wax type bypass valve and is mounted in the water inlet housing. The
thermostat includes a type of automatic valve operated by fluctuations in the engine coolant
temperature. This valve closes when the engine coolant temperature drops, preventing the
circulation of coolant through the engine and thus permitting the engine to warm up rapidly. The
valve opens when the engine coolant temperature has risen, allowing the circulation of coolant.
Wax inside the thermostat expands when heated and contracts when cooled. Heating the wax
thus generates pressure which overpowers the force of the spring which keeps the valve closed,
thus opening the valve. When the wax cools, its contraction allows the force of the spring to take
effect once more, closing the valve. The thermostat in this engine operates at a temperature of
82C (180F).
± 5S±FE ENGINECOOLING SYSTEMEG1±239
2. CHECK ENGINE COOLANT QUALITY
There should not be any excessive deposits of rust or
scales around the radiator cap or radiator filler hole,
and the engine coolant should be free from oil.
If excessively dirty, replace the engine coolant.
3. REPLACE ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not
remove It while the engine and radiator are still hot, as
fluid and steam can be blown out under pressure.
(b) Drain the engine coolant from the radiator drain cock
and engine drain plug. (Engine drain plug at the right
rear of cylinder block.)
(c) Close the drain cock and plug.
Torque (Engine drain plug):
13 N±m (130 kgf±cm, 9 ft±lbf)
(d) Slowly fill the system with coolant.
Use a good brand of ethylene±glycol base
coolant and mix it according to the
manufacturer 's directions.
Using engine coolant which includes more than
5096 ethylene±glycol (but not more than 7096) is
recommended.
NOTICE:
wDo not use a alcohol type coolant.
wThe engine coolant should be mixed with demineral±
ized water or distilled water.
Capacity (w/ Heater):
8.3 liters (6.7 US qts, 5.5 Imp.qts)
(a) Reinstall the radiator cap.
(f) Warm up the engine and check for leaks.
(g) Recheck the engine coolant level and refill as neces±
sary.
COOLANT CHECK AND
REPLACEMENT
1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
TANK
The engine coolant level should be between the
ºLOWº and ªFULLº lines.
If low, check for leaks and add engine coolant up to
the ªFULLº line.
± 5S±FE ENGINECOOLING SYSTEMEG1±241
6. INSPECT FOR WATER LEAKS
(a) Tighten the drain cock.
(b) Plug the inlet and outlet pipes of the radiator with
SST.
SST 09230 ± 01010
(c) Using a radiator cap tester, apply pressure to the
radiator.
Test pressure:
177 kPa (1.8 kgf/cm, 26 psi) (b) Check the lock plate height (H) after completing the
caulking.
Plate height:
7.75±8.25 mm (0±3051±0.3248 in.)
If not within the specified height, adjust the stopper
bolt of the handle again and perform the caulking
again.wThe points shown in the illustration and oil cooler
near here (A/T) cannot be staked with the SST.
Use a plier or like object and be careful not to
damage the core plates. After repeating this a few times, fully caulk the lock
plate by squeezing the handle until stopped by the
stopper plate.
SST 09230 ± 01010
HINT:
wDo not stake the areas protruding around the
pipes, brackets or tank ribs.
± 5S±FE ENGINECOOLING SYSTEMEG1±257
SERVICE SPECIFICATIONS
SERVICE DATA
TORQUE SPECIFICATIONS
Valve opening temperature
Valve lift
Water bypass pipe x Water pump cover
Radiator oil cooler x Radiator lower tank Water pump x Water pump cover
No.2 idler pulley x Cylinder block Water inlet x Water pump coverRelief valve opening pressure
Water pump x Cylinder blockCylinder block x Drain plug
Water inlet x Water pump
Radiator oil cooler pipe
Radiator support boltElectric
cooling fanRotating amperage
Part tightened Radiator cap
Plate height Thermostat
Radiator
± 5S±FE ENGINECOOLING SYSTEMEG1±267
A pressure feeding lubrication system has been adopted to supply oil to the moving parts of this
engine. The lubrication system consists of an oil pan, oil pump, oil filter and other external parts
which supply oil to the moving parts in the engine block. The oil circuit is shown in the illustration
at the top of the previous page. Oil from the oil pan is pumped up by the oil pump. After it passes
through the oil filter, it is through the various oil holes in the crankshaft and cylinder block. After
passing through the cylinder block and performing its lubricating function, the oil is returned by
gravity to the oil pan. A dipstick on the center left side of the cylinder block is provided to check
the oil level.
OIL PUMP
The oil pump pumps up oil from the oil pan and feeds it under pressure to the various parts of the
engine. An oil strainer is mounted in front of the inlet to the oil pump to remove impurities. The
oil pump itself is a trochoid type pump, inside of which is a drive rotor and a driven rotor. When
the drive rotor rotates, the driven rotor rotates in the same direction, and since the axis of the
drive rotor shaft is different from the center of the driven rotor, the space between the two rotors
changes as they rotate. Oil is drawn in when the space widens and is discharged when the space
becomes narrow.
OIL PRESSURE REGULATOR (RELIEF VALVE)
At high engine speeds, the engine oil supplied by the oil pump exceeds the capacity of the engine
to utilize it. For that reason, the oil pressure regulator works to prevent an oversupply of oil.
During normal oil supply, a coil spring and valve keep the bypass closed, but when too much oil
is being fed, the pressure becomes extremely high, overpowering the force of the spring and
opening the valves. This allows the excess oil to flow through the valve and return to the oil pan.
OIL FILTER
The oil filter is a full flow type filter with a relief valve built into the paper filter element. Particles
of metal from wear, airborne dirt, carbon and other impurities can get into the oil during use and
could cause accelerated wear or seizing if allowed to circulate through the engine. The oil filter,
integrated into the oil line, removes these impurities as the oil passes through it. The filter is
mounted outside the engine to simplify replacement of the filter element. A relief valve is also
included ahead of the filter element to relieve the high oil pressure in case the filter element
becomes clogged with impurities. The relief valve opens when the oil pressure overpowers the
force of the spring. Oil passing through the relief valve bypasses the oil filter and flows directly
into the main oil hole in the engine.
± 5S±FE ENGINELUBRICATION SYSTEMEG1±269
PREPARATION
SST (SPECIAL SERVICE TOOLS)
(09627±30010) Steering Sector Shaft Bushing
Replacer09226±10010 Crankshaft Front & Rear Bearing
Replacer
(09631±00020) Handle09616±30011 Steering Worm Bearing Adjusting
Screw Wrench
RECOMMENDED TOOLS
Oil pump oil seal
Oil pump oil seal 09620±30010 Steering Gear Box Replacer Set
09090±04000 Engine Sling Device
09200±00010 Engine Adjust Kit09032±00100 Oil Pan Seat Cutter
09905±00013 Snap Ring Pliers09228±06500 Oil Filter wrench
Precision straight edge
EQUIPMENT
Oil pressure gaugeFor suspending engineCrankshaft front oil seal
Torque wrenchOil pump pulley
Oil pump
± 5S±FE ENGINELUBRICATION SYSTEMEG1±270
Engine oil (M/T)
Dry fill
Drain and refill
w/ Oil filter change
w/o Oil filter change
Engine oil (A/T)
Dry fill
Drain and refill
w/ Oil filter change
w/o Oil filter changeAPI grade SG or SH, Energy±Conserving II
mutigrade engine oil or ILSAC multigrade
engine oil and recommended viscosity oil
08833±00080 Adhesive 1344,
THREE BOND 1344,
LOCTITE 242 or equivalent
SSM (SPECIAL SERVICE MATERIALS)
3.6 liters (3.8 US qts, 3.2 Imp. qts)
3.4 liters (3.6 US qts, 3.0 Imp. qts)
08826±00080 Seal packing or equivalent4.2 liters (4.4 US qts, 3.7 Imp. qts)
4.3 liters (4.5 US qts, 3.8 imp. qts)
LUBRICANT
Oil pressure switch Oil panClassification
Capacity
Item
3.6 liters (3.8 US qts, 3.2 Imp. qts)
3.4 liters (3.6 US qts, 3.0 Imp. qts)
± 5S±FE ENGINELUBRICATION SYSTEMEG1±271