
+Do not use gasoline, kerosine, diesel fuel, gas oil, thinners or
solvents for cleaning skin.
+If skin disorders develop, obtain medical advice without delay.
+Where practicable, degrease components prior to handling.
+Where there is a risk of eye contact, eye protection should be
worn, for example, chemical goggles or face shields; in addi-
tion an eye wash facility should be provided.
Environmental Protection PrecautionsNLGI0001S0702Burning used engine oil in small space heaters or boilers can be
recommended only for units of approved design. The heating sys-
tem must meet the requirements of HM Inspectorate of Pollution for
small burners of less than 0.4 MW. If in doubt, check with the
appropriate local authority and/or manufacturer of the approved
appliance.
Dispose of used oil and used oil filters through authorized waste
disposal contractors to licensed waste disposal sites, or to the
waste oil reclamation trade. If in doubt, contact the local authority
for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or drains,
or into water courses.
The regulations concerning the pollution vary between
regions.
PRECAUTIONS FOR FUELNLGI0001S08Gasoline EngineNLGI0001S0804Models with three way catalyst
Unleaded premium gasoline of at least 95 octane (RON)
If premium gasoline is not available, unleaded regular gaso-
line with an octane rating of 91 (RON) may be temporarily
used, but only under the following precautions:
+Have the fuel tank filled only partially with unleaded regu-
lar gasoline, and fill up with premium unleaded gasoline
as soon as possible.
+Avoid full throttle driving and abrupt acceleration.
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will dam-
age the three way catalyst.
Diesel Engine*:NLGI0001S0805Diesel fuel of at least 50 cetane
* If two types of diesel fuel are available, use summer or winter
fuel properly according to the following temperature conditions.
+Above 7°C (20°F) ... Summer type diesel fuel.
+Below 7°C (20°F) ... Winter type diesel fuel.
CAUTION:
+Do not use home heating oil, gasoline, or other alternate
fuels in your diesel engine. The use of those can cause
engine damage.
+Do not use summer fuel at temperatures below 7°C
(20°F). The cold temperatures will cause wax to form in the
fuel. As a result, it may prevent the engine from running
smoothly.
+Do not add gasoline or other alternate fuels to diesel fuel.
PRECAUTIONS FOR AIR CONDITIONINGNLGI0001S09Use an approved refrigerant recovery unit any time the air condi-
tioning system must be discharged. Refer to HA-85, “HFC-134a
(R-134a) Service Procedure” for specific instructions.
PRECAUTIONS
Precautions (Cont’d)
GI-8

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 .....................................................................17
COMPONENTS.......................................................17
Cooling Fan ...............................................................18
COMPONENTS.......................................................18
CONTROL SYSTEM................................................19
Changing Engine Coolant..........................................19
- DRAINING ENGINE COOLANT -............................19
- REFILLING ENGINE COOLANT -...........................20
- FLUSHING COOLING SYSTEM -............................20
Overheating Cause Analysis .....................................21
Service Data and Specifications (SDS).....................22
THERMOSTAT........................................................22
RADIATOR..............................................................22
COOLANT CAPACITY..............................................22
SR
ENGINE LUBRICATION SYSTEM................................23
Precautions ................................................................23
LIQUID GASKET APPLICATION PROCEDURE..........23
Preparation ................................................................23
SPECIAL SERVICE TOOLS......................................23
Lubrication Circuit ......................................................24
Oil Pressure Check....................................................25
Oil Pump ....................................................................25
REMOVAL AND INSTALLATION...............................25
DISASSEMBLY AND ASSEMBLY..............................26
INSPECTION...........................................................26
REGULATOR VALVE INSPECTION..........................27
Changing Engine Oil..................................................28
Changing Engine Oil Filter ........................................28
Oil Filter .....................................................................29
Oil Cooler ...................................................................29
REMOVAL AND INSTALLATION...............................29
INSPECTION...........................................................30
Service Data and Specifications (SDS).....................30
OIL PRESSURE CHECK..........................................30
REGULATOR VALVE INSPECTION..........................30
OIL PUMP INSPECTION..........................................30
OIL CAPACITY........................................................30
ENGINE COOLING SYSTEM........................................31
Precautions ................................................................31
LIQUID GASKET APPLICATION PROCEDURE..........31
Preparation ................................................................31

SPECIAL SERVICE TOOL........................................31
Cooling Circuit ...........................................................32
System Check............................................................32
CHECKING COOLING SYSTEM HOSES...................32
CHECKING COOLING SYSTEM FOR LEAKS............32
CHECKING RADIATOR............................................33
CHECKING RADIATOR CAP....................................33
Water Pump ...............................................................33
REMOVAL AND INSTALLATION...............................33
INSPECTION...........................................................34
Thermostat .................................................................35
REMOVAL AND INSTALLATION...............................35
INSPECTION...........................................................36
Water Outlet ...............................................................36
INSPECTION...........................................................36
INSTALLATION........................................................36
Radiator .....................................................................37
COMPONENTS.......................................................37
Cooling Fan Control System .....................................37
Changing Engine Coolant..........................................38
- DRAINING ENGINE COOLANT -............................38
- REFILLING ENGINE COOLANT -...........................38
- FLUSHING COOLING SYSTEM -............................39
Overheating Cause Analysis .....................................40
Service Data and Specifications (SDS).....................41
THERMOSTAT........................................................41
RADIATOR..............................................................41
COOLANT CAPACITY..............................................41
YD
ENGINE LUBRICATION SYSTEM................................42
Precautions ................................................................42
LIQUID GASKET APPLICATION PROCEDURE..........42
Preparation ................................................................42
SPECIAL SERVICE TOOLS......................................42
Lubrication Circuit ......................................................43
Oil Pressure Check....................................................44
Oil Pump ....................................................................44
REMOVAL AND INSTALLATION...............................44
DISASSEMBLY AND ASSEMBLY..............................45
OIL PUMP INSPECTION..........................................45
REGULATOR VALVE INSPECTION..........................46
Changing Engine Oil..................................................47
Oil Filter Bracket ........................................................48
REMOVAL AND INSTALLATION...............................48
Changing Oil Filter .....................................................48
REMOVAL...............................................................49
INSTALLATION........................................................49
Oil Cooler ...................................................................50
REMOVAL AND INSTALLATION...............................50
Service Data and Specifications (SDS).....................51
OIL PRESSURE CHECK..........................................51
REGULATOR VALVE INSPECTION..........................51
OIL PUMP INSPECTION..........................................51
ENGINE OIL CAPACITY...........................................51
ENGINE COOLING SYSTEM........................................52
Precautions ................................................................52
LIQUID GASKET APPLICATION PROCEDURE..........52
Preparation ................................................................52
SPECIAL SERVICE TOOLS......................................52
Cooling Circuit ...........................................................53
System Check............................................................54
CHECKING COOLING SYSTEM HOSES...................54
CHECKING RADIATOR............................................54
CHECKING RADIATOR CAP....................................54
CHECKING COOLING SYSTEM FOR LEAKS............55
Water Pump ...............................................................55
REMOVAL AND INSTALLATION...............................55
REMOVAL...............................................................56
INSPECTION...........................................................56
INSTALLATION........................................................56
Thermostat .................................................................57
REMOVAL AND INSTALLATION...............................57
INSPECTION...........................................................58
Radiator .....................................................................58
COMPONENTS.......................................................58
REMOVAL AND INSTALLATION...............................59
Cooling Fan ...............................................................59
COMPONENTS.......................................................59
CONTROL SYSTEM................................................59
Changing Engine Coolant..........................................59
- DRAINING ENGINE COOLANT -............................59
- REFILLING ENGINE COOLANT -...........................60
- FLUSHING COOLING SYSTEM -............................61
Overheating Cause Analysis .....................................62
Service Data and Specifications (SDS).....................63
THERMOSTAT........................................................63
RADIATOR..............................................................63
ENGINE COOLANT CAPACITY................................63
CONTENTS(Cont'd)
LC-2

SEM164F
AEM080
Precautions
LIQUID GASKET APPLICATION PROCEDURENLLC00011. 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.)
+For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
+For areas except oil pan, be sure liquid gasket diameter is 2.0
to 3.0 mm (0.079 to 0.118 in).
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.
Preparation
SPECIAL SERVICE TOOLSNLLC0002
Tool number
Tool nameDescription
ST25051001
Oil pressure gauge
NT050
Measuring oil pressure
ST25052000
Hose
NT559
Adapting oil pressure gauge to cylinder block
KV10115801
Oil filter wrench
NT772
Removing oil filter
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
ENGINE LUBRICATION SYSTEMQG
Precautions
LC-3

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 OilNLLC0035WARNING:
+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 (For Europe):
+API grade SG, SH or SJ
+ACEA grade A1-98, A3-98
+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

SMA390C
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.
ALC094
Changing Oil FilterNLLC0010The oil filter is a small, full-flow cartridge type and is provided with
a relief valve.
+Use Tool KV10115801 for removing oil filter.
SLC275B
1. Remove oil filter with Tool.
WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.
SMA010
2. Clean oil filter mounting surface on cylinder block. Coat rubber
seal of new oil filter with engine oil.
SMA229B
3. Screw in the oil filter until a slight resistance is felt, then tighten
an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
+Clean excess oil from engine.
ENGINE LUBRICATION SYSTEMQG
Changing Engine Oil (Cont'd)
LC-9

Service Data and Specifications (SDS)
OIL PRESSURE CHECKNLLC0011
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 INSPECTIONNLLC0013Unit: 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 clearance 0.045 - 0.091 (0.0018 - 0.0036)
REGULATOR VALVE INSPECTIONNLLC0012Unit: mm (in)
Regulator valve to oil pump cover clearance 0.052 - 0.088 (0.0020 - 0.0035)
OIL CAPACITYNLLC0036Unit:!(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

SEM164F
AEM080
Precautions
LIQUID GASKET APPLICATION PROCEDURENLLC01131. 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.)
+For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
+For areas except oil pan, be sure liquid gasket diameter is 2.0
to 3.0 mm (0.079 to 0.118 in).
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.
Preparation
SPECIAL SERVICE TOOLSNLLC0114The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
Tool nameDescription
ST25052000
Hose
NT559
Adapting oil pressure gauge to cylinder block
KV10115801
Oil filter wrench
NT362
Removing oil filter
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
ENGINE LUBRICATION SYSTEMSR
Precautions
LC-23