ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION
LC
CONTENTS
QG
ENGINE LUBRICATION SYSTEM..................................3
Precautions ..................................................................3
LIQUID GASKET APPLICATION PROCEDURE............3
Preparation ..................................................................3
SPECIAL SERVICE TOOLS........................................3
Lubrication Circuit ........................................................4
Oil Pressure Check......................................................5
Oil Pump ......................................................................5
REMOVAL AND INSTALLATION.................................5
DISASSEMBLY AND ASSEMBLY................................6
INSPECTION.............................................................7
REGULATOR VALVE INSPECTION............................7
Changing Engine Oil....................................................8
Changing Oil Filter .......................................................9
Service Data and Specifications (SDS).....................10
OIL PRESSURE CHECK..........................................10
OIL PUMP INSPECTION..........................................10
REGULATOR VALVE INSPECTION..........................10
OIL CAPACITY........................................................10
ENGINE COOLING SYSTEM........................................ 11
Precautions ................................................................ 11
LIQUID GASKET APPLICATION PROCEDURE.......... 11
Preparation ................................................................ 11
SPECIAL SERVICE TOOLS...................................... 11
Cooling Circuit ...........................................................12
System Check............................................................12
CHECKING COOLING SYSTEM HOSES...................12
CHECKING RADIATOR............................................13
CHECKING RADIATOR CAP....................................13
CHECKING COOLING SYSTEM FOR LEAKS............13
Water Pump ...............................................................14
REMOVAL AND INSTALLATION...............................14
INSPECTION...........................................................14
Thermostat .................................................................15
REMOVAL AND INSTALLATION...............................15
INSPECTION...........................................................16
Radiator .....................................................................16
COMPONENTS.......................................................16
Cooling Fan ...............................................................17
COMPONENTS.......................................................17
CONTROL SYSTEM................................................17
Changing Engine Coolant..........................................17
- DRAINING ENGINE COOLANT -............................17
- REFILLING ENGINE COOLANT -...........................18
- FLUSHING COOLING SYSTEM -............................19
Radiator (Aluminum type) ..........................................20
PREPARATION.......................................................20
DISASSEMBLY........................................................20
ASSEMBLY.............................................................21
INSPECTION...........................................................22
Overheating Cause Analysis .....................................23
Service Data and Specifications (SDS).....................24
THERMOSTAT........................................................24
RADIATOR..............................................................24
COOLANT CAPACITY..............................................24
YD
ENGINE LUBRICATION SYSTEM................................25
Precautions ................................................................25
LIQUID GASKET APPLICATION PROCEDURE..........25
Preparation ................................................................25
SPECIAL SERVICE TOOLS......................................25
Lubrication Circuit ......................................................26
Oil Pressure Check....................................................27
Oil Pump ....................................................................27
REMOVAL AND INSTALLATION...............................27
DISASSEMBLY AND ASSEMBLY..............................28
OIL PUMP INSPECTION..........................................28
REGULATOR VALVE INSPECTION..........................29
Changing Engine Oil..................................................30
Oil Filter Bracket ........................................................31
REMOVAL AND INSTALLATION...............................31
Changing Oil Filter .....................................................31
REMOVAL...............................................................32
INSTALLATION........................................................32
Oil Cooler ...................................................................33
REMOVAL AND INSTALLATION...............................33
Service Data and Specifications (SDS).....................34
OIL PRESSURE CHECK..........................................34
REGULATOR VALVE INSPECTION..........................34
OIL PUMP INSPECTION..........................................34
ENGINE OIL CAPACITY...........................................34
ENGINE COOLING SYSTEM........................................35
Precautions ................................................................35
LIQUID GASKET APPLICATION PROCEDURE..........35
Preparation ................................................................35
SPECIAL SERVICE TOOLS......................................35
Cooling Circuit ...........................................................36
System Check............................................................37
CHECKING COOLING SYSTEM HOSES...................37
CHECKING RADIATOR............................................37
CHECKING RADIATOR CAP....................................37
CHECKING COOLING SYSTEM FOR LEAKS............38
Water Pump ...............................................................38
REMOVAL AND INSTALLATION...............................38
REMOVAL...............................................................39
INSPECTION...........................................................39
INSTALLATION........................................................39
Thermostat .................................................................40
REMOVAL AND INSTALLATION...............................40
INSPECTION...........................................................41
Radiator .....................................................................41
COMPONENTS.......................................................41
REMOVAL AND INSTALLATION...............................42
Cooling Fan ...............................................................42
COMPONENTS.......................................................42
CONTROL SYSTEM................................................42
Changing Engine Coolant..........................................43
- DRAINING ENGINE COOLANT -............................43
- REFILLING ENGINE COOLANT -...........................43
- FLUSHING COOLING SYSTEM -............................45
Radiator (Aluminum type) ..........................................46
Overheating Cause Analysis .....................................46
Service Data and Specifications (SDS).....................47
THERMOSTAT........................................................47
RADIATOR..............................................................47
ENGINE COOLANT CAPACITY................................47
CONTENTS(Cont'd)
LC-2
SLC101B
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.
SMA915C
Changing Engine OilNJLC0035WARNING:
+Be careful not to burn yourself, as the engine oil is hot.
+Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine com-
ponents.
2. Stop engine and wait more than 10 minutes.
3. Remove drain plug and oil filler cap.
4. Drain oil and refill with new engine oil.
Oil specification and viscosity (Except for Europe):
+API grade SE, SF, SG, SH or SJ
+ILSAC grade GF-I & GF-II
Oil specification and viscosity (For Europe):
+API grade SG, SH or SJ
+ILSAC grade GF-I & GF-II
Refer to MA-20, ªRECOMMENDED FLUIDS AND LUBRI-
CANTSº.
Refill oil capacity (Approximate):
Unit:!(Imp qt)
With oil filter change 2.7 (2-3/8)
Without oil filter change 2.5 (2-1/4)
Dry engine (engine overhaul) 3.1 (2-3/4)
CAUTION:
+Be sure to clean drain plug and install with new washer.
Drain plug:
: 29 - 39 N´m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
+The refill capacity changes depending on the oil tempera-
ture and drain time, use these values as a reference and
be certain to check with the dipstick when changing the
oil.
ENGINE LUBRICATION SYSTEMQG
Oil Pump (Cont'd)
LC-8
Service Data and Specifications (SDS)
OIL PRESSURE CHECKNJLC0011
Engine speed
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
600 More than 98 (0.98, 1.0, 14)
2,000 More than 294 (2.94, 3.0, 43)
6,000 More than 392 (3.92, 4.0, 57)
OIL PUMP INSPECTIONNJLC0013Unit: mm (in)
Body to outer rotor radial clearance 0.250 - 0.325 (0.0098 - 0.0128)
Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)
Body to inner rotor clearance 0.030 - 0.085 (0.0012 - 0.0033)
Body to outer rotor axial clearance 0.030 - 0.090 (0.0012 - 0.0035)
Inner rotor to brazed portion of housing clear-
ance0.045 - 0.091 (0.0018 - 0.0036)
REGULATOR VALVE INSPECTIONNJLC0012Unit: mm (in)
Regulator valve to oil pump cover clearance 0.052 - 0.088 (0.0020 - 0.0035)
OIL CAPACITYNJLC0036Unit:!(Imp qt)
With oil filter change2.7 (2-3/8)
Without oil filter change2.5 (2-1/4)
Dry engine (engine overhaul)3.1 (2-3/4)
ENGINE LUBRICATION SYSTEMQG
Service Data and Specifications (SDS)
LC-10
SLC287B
JLC288B
Changing Engine OilNJLC0074WARNING:
+Be careful not to burn yourself, as the engine oil is hot.
+Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine com-
ponents.
2. Stop engine and wait more than 10 minutes.
3. Remove drain plug and oil filler cap.
4. Drain oil and refill with new engine oil.
Oil Specification and Viscosity (Except for Europe):
+API CD, CE, CF or CF-4
Oil Specification and Viscosity (For Europe):
+API grade CF-4
Refer to MA-20, ªRECOMMENDED FLUIDS AND LUBRI-
CANTSº.
Refill oil capacity (Approximately):
Unit:!(Imp qt)
Drain and refillWithout oil filter
change4.9 (4-3/8)
With oil filter
change5.2 (4-5/8)
Dry engine (engine overhaul) 6.3 (5-1/2)
CAUTION:
+Be sure to clean drain plug and install with new washer.
Drain plug:
: 29 - 39 N´m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
+The refill capacity depends on the oil temperature and
drain time. Use these specifications for reference only.
Always use the dipstick to determine when the proper
amount of oil is in the engine.
5. Check oil level.
6. Start engine and check area around drain plug and oil filter for
oil leakage.
7. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
ENGINE LUBRICATION SYSTEMYD
Changing Engine Oil
LC-30
Service Data and Specifications (SDS)
OIL PRESSURE CHECK=NJLC0048
Engine speed
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed More than 140 (1.40, 1.43, 20.3)
2,000 More than 270 (2.69, 2.75, 39.1)
4,000 More than 430 (4.29, 4.38, 62.3)
REGULATOR VALVE INSPECTIONNJLC0049Unit: mm (in)
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)
OIL PUMP INSPECTIONNJLC0050Unit: mm (in)
Body to outer rotor radial clearance 0.114 - 0.260 (0.0045 - 0.0102)
Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)
Body to inner rotor axial clearance 0.050 - 0.090 (0.0020 - 0.0035)
Body to outer rotor axial clearance 0.030 - 0.190 (0.0012 - 0.0075)
Inner rotor to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036)
ENGINE OIL CAPACITYNJLC0078Unit:!(Imp qt)
Drain and refill (Approximately)Without oil filter change 4.9 (4-3/8)
With oil filter change 5.2 (4-5/8)
Dry engine (engine overhaul)6.3 (5-1/2)
ENGINE LUBRICATION SYSTEMYD
Service Data and Specifications (SDS)
LC-34
SMA145AA
SMT512C
Changing M/T OilNJMT00861. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20, ªRECOMMENDED FLUIDS AND
LUBRICANTSº.
Capacity:
RS5F30A 2.8 - 3.0!(4-7/8 - 5-1/4 Imp pt)
RS5F70A 3.0!(5-1/4 Imp pt)
Oil level (Reference data):
RS5F30A 58 - 66 mm (2.28 - 2.60 in)
RS5F70A 75.5 - 80.5 mm (2.969 - 3.166 in)
Drain plug:
: 25 - 34 N´m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
SMA066C
CheckingNJMT0087OIL LEAK AND OIL LEVELNJMT0087S011. Check that oil is not leaking from transaxle or around it.
2. Check oil level.
Never start engine while checking oil level.
Filler plug:
: 10 - 19 N´m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
M/T OILRS5F30A, RS5F70A
Changing M/T Oil
MT-14
SMA067C
Changing M/T OilNJMT00881. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20, ªRECOMMENDED FLUIDS AND
LUBRICANTSº.
Capacity:
RS5F50A 4.5 - 4.8!(7-7/8 - 8-1/2 Imp pt)
Drain plug:
: 15 - 20 N´m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SMA066C
CheckingNJMT0089OIL LEAK AND OIL LEVELNJMT0089S01Check for oil leakage and oil level.
Never start engine while checking oil level.
Filler plug:
: 25 - 34 N´m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
M/T OILRS5F50A
Changing M/T Oil
MT-15