LU-1
ENGINE LUBRICATION SYSTEM
B ENGINE
CONTENTS
C
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SECTION
A
LU
ENGINE LUBRICATION SYSTEM
QR
PRECAUTIONS .......................................................... 3
Precautions For Liquid Gasket ................................. 3
REMOVAL OF LIQUID GASKET .......................... 3
LIQUID GASKET APPLICATION PROCEDURE ..... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
LUBRICATION SYSTEM ............................................ 5
Lubrication Circuit .................................................... 5
System Drawing ....................................................... 6
ENGINE OIL ............................................................... 7
Inspection ................................................................. 7
ENGINE OIL LEVEL ............................................. 7
ENGINE OIL APPEARANCE ................................ 7
ENGINE OIL LEAKAGE ........................................ 7
OIL PRESSURE CHECK ...................................... 7
Changing Engine Oil ................................................ 8
OIL FILTER ................................................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
OIL PUMP ................................................................. 10
Removal and Installation ........................................ 10
Disassembly and Assembly ................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY ......................................................... 12
OIL COOLER ............................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSPECTION ...................................................... 13
INSTALLATION ................................................... 13
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 14
Standard and Limit ................................................. 14
OIL PRESSURE .................................................. 14
OIL PUMP ........................................................... 14
REGULATOR VALVE .......................................... 14
ENGINE OIL CAPACITY ..................................... 14
Tightening Torque ................................................... 14
YD22DDTi
PRECAUTIONS ........................................................ 15
Precautions For Liquid Gasket ............................... 15
REMOVAL OF LIQUID GASKET ......................... 15
LIQUID GASKET APPLICATION PROCEDURE ... 15
PREPARATION ......................................................... 16
Special Service Tools ............................................. 16
LUBRICATION SYSTEM .......................................... 17
Lubrication Circuit ................................................... 17
ENGINE OIL .............................................................. 18
Inspection ............................................................... 18
ENGINE OIL LEVEL AND MUDDINESS ............. 18
ENGINE OIL LEAKAGE ...................................... 18
ENGINE OIL PRESSURE CHECK ..................... 18
Changing Engine Oil ............................................ ... 19
OIL FILTER ............................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 21
OIL FILTER BRACKET ............................................. 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 22
OIL PUMP ................................................................. 23
Removal and Installation ........................................ 23
Disassembly and Assembly .................................... 23
DISASSEMBLY ................................................... 23
INSPECTION AFTER DISASSEMBLY ................ 23
ASSEMBLY ......................................................... 24
OIL COOLER ............................................................ 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSPECTION ...................................................... 25
INSTALLATION ................................................... 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 26
Standard and Limit .................................................. 26
OIL PRESSURE .................................................. 26
OIL PUMP ........................................................... 26
REGULATOR VALVE .......................................... 26
LU-8
[QR]
ENGINE OIL
c. After warming up the engine, check for engine oil leakage with running engine.
Changing Engine OilEBS00KO4
WARNING:
●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 engine oil. If skin contact is made, wash thoroughly
with soap or hand cleaner as soon as possible.
1. Warm up engine, put vehicle horizontally and check for engine
oil leakage from engine components.
2. Stop engine and wait for 10 minutes.
3. Remove drain plug and oil filler cap.
4. Drain engine oil.
●Install drain plug and refill with new engine oil.
Engine oil specifications and viscosity:
●API grade SG, SH, SJ or SL.
●ILSAC grade GF-I, GF-II or GF-III
●ACEA 96-A2
●Refer to MA-16, "RECOMMENDED FLUIDS AND LUBRICANTS" for further detail.
Engine oil capacity (Approximate):
Unit: (lmp qt)
CAUTION:
●Be sure to clean drain plug and install with new washer.
●The refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
●Always use the dipstick to the determine when the proper amount of engine oil is in the engine.
5. Warm up engine and check area around drain plug and oil filter for engine oil leakage.
6. Stop engine and wait for 10 minutes.
7. Check engine oil level. Refer to LU-7, "
ENGINE OIL LEVEL" . Oil pressure switch:
: 12.3 - 17.2 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)
PBIC0250E
Drain and refillWith oil filter change Approximately 3.9 (3-3/8)
Without oil filter change Approximately 3.5 (3-1/8)
Dry engine (engine overhaul)Approximately 4.5 (4)
Oil pan drain plug:
: 29.4 - 39.2 N·m (3.0 - 4.0 kg-m, 22 - 28 ft-lb)
LU-14
[QR]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS00KO9
OIL PRESSURE
*:Engine oil temperature at 80°C (176°C)
OIL PUMP
Unit: mm (in)
REGULATOR VALVE
Unit: mm (in)
ENGINE OIL CAPACITY
Unit: (Imp qt)
Tightening TorqueEBS00KOA
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)* Engine speed (rpm)
Approximate discharge pressure kPa (bar, kg/cm
2 , psi)*
Idle speed
2,000
6,000 More than 98 (0.98, 1.0, 14)
294 (2.9, 3.0, 43)
392 (3.9, 4.0, 57)
Body to outer rotor radial clearance 0.114 - 0.179 (0.0045 - 0.0070)
Inner rotor to outer rotor tip clearance Below 0.220 (0.0087)
Body to inner rotor axial clearance 0.030 - 0.070 (0.0012 - 0.0028)
Body to outer rotor axial clearance 0.060 - 0.110 (0.0024 - 0.0043)
Inner rotor to brazed portion of housing clearance 0.035 - 0.070 (0.0014 - 0.0028)
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)
With oil filter change Approximately 3.9 (3-3/8)
Without oil filter change Approximately 3.5 (3-1/8)
Dry engine (engine overhaul) Approximately 4.5 (4)
Oil pressure switch 12.3 - 17.2 (1.25 - 1.75, 9 - 12)
Oil pan drain plug 29.4 - 39.2 (3.0 - 4.0, 22 - 28)
Oil filter14.7 - 20.5 (1.5 - 2.1, 11 - 15)
Oil pump assembly 6.4 - 7.5 (0.66 - 0.76, 57 - 66)*
Oil pump cover 5.9 - 7.9 (0.60 - 0.81, 52 - 70)*
Regulator plug 39.2 - 68.6 (4.0 - 6.9, 29 - 50)
Oil cooler34.3 - 44.1 (3.5 - 4.4, 26 - 32)
Oil cooler bracket 19.6 - 23.5 (2.0 - 2.3, 15 - 17)
ENGINE OIL
LU-19
[YD22DDTi]
C
D
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MA
LUc. After warming up the engine, check for oil leakage with running engine.
Changing Engine OilEBS00B04
WARNING:
●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 engine oil. If skin contact is made, wash thoroughly
with soap or hand cleaner as soon as possible.
1. Warm up engine, put vehicle horizontally and check for engine
oil leakage from engine components.
2. Stop engine and wait for 10 minutes.
3. Remove drain plug and oil filler cap.
4. Drain engine oil.
●Install drain plug and refill with new engine oil.
Engine oil specification and viscosity:
●API grade CF-4.
●ACEA B1, B3, B4, B5
●Refer to MA-16, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
Engine oil capacity (Approximate):
●The refill capacity depends on the engine oil temperature and drain time. Use these specifications for
reference only.
Always use the dipstick to the determine when the proper amount of engine oil is in the engine.
CAUTION:
●Be sure to clean drain plug and install with new washer.
●The refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
Always use the dipstick to the determine when the proper amount of engine oil is in the
engine.
5. Warm up engine and check area around drain plug and oil filter for engine oil leakage.
6. Stop engine and wait for 10 minutes.
7. Check engine oil level. Refer to LU-18, "
ENGINE OIL LEVEL AND MUDDINESS" . Oil pressure switch:
: 13.0 - 17.0 N·m (1.4 - 1.7 kg-m, 10 - 12 ft-lb)
PBIC0527E
Drain and refillWith oil filter change
5.2 (4-5/8 Imp qt)
Without oil filter change
4.9 (4-3/8 Imp qt)
Dry engine (engine overhaul)6.3 (5-1/2 Imp qt)
Oil pan drain plug:
: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
SBIA0122E
LU-26
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS00CTZ
OIL PRESSURE
OIL PUMP
Unit: mm (in)
REGULATOR VALVE
Unit: mm (in)
OIL CAPACITY
Unit: · (Imp qt)
Tightening TorqueEBS00B0F
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)* Engine speed rpm
Approximate discharge pressure kPa (bar, kg/cm
2 , psi)
Idle speed
2,000
4,000 More than 140 (1.40, 1.43, 20.3)
More than 270 (2.69, 2.75, 39.1)
More than 430 (4.29, 4.38, 62.3)
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)
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)
With oil filter change Approximately 5.2 (4-5/8 Imp qt)
Without oil filter change Approximately 4.9 (4-3/8 Imp qt)
Dry engine (engine overhaul) Approximately 6.3 (5-1/2 Imp qt)
Oil pressure switch 13 - 17 (1.4 - 1.7, 10 - 12)
Oil pan drain plug 29 - 39 (3.0 - 4.0, 22 - 29)
Oil filter bracket20 -23 (2.0 - 2.4, 15 - 17)
Oil filter body20 - 24 (2.0 - 2.5, 15 - 18)
Oil pump assembly 6.4 - 7.4 (0.65 - 0.76, 57 - 65)*
Oil pump cover 5.9 - 7.8 (0.6 - 0.8, 52 - 69)*
Regulator plug40 - 68 (4.0 - 7.0, 29 - 50)
Water hose connector for oil cooler 25 - 31 (2.5 - 3.2, 18 - 23)
Connecting bolt20 - 29 (2.1 - 2.9, 15 - 21)
MT-10
M/T OIL
M/T OIL
PFP:KLD20
Changing M/T OilECS008BR
DRAINING
1. Start the engine and let it run to warm up the transaxle.
2. Stop the engine. Remove drain plug and drain oil.
3. Set a gasket on the drain plug and install it to the transaxle.
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
2. After refilling oil, check oil level. Assemble gasket to filler plug, then install it to transaxle body.
CAUTION:
Do not reuse gasket.
Checking M/T OilECS008BS
OIL LEAKAGE AND OIL LEVEL
●Check that oil is not leaking from transaxle or around it.
●Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Never start engine while checking oil level.
●Set a new gasket on the filler plug and install it on the transaxle.
CAUTION:
Do not reuse gasket.Drain plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
Oil grade : API GL-4
Capacity (reference)
: Approx. 2.3 (4 lmp pt)
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
SCIA0361E
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-97
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MA
B
MT
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsECS008CE
TRANSAXLE
Engine QR20DE QR25DE YD22DDTi
Transaxle model RS5F51A RS6F51A
Model code number 8H500 9H608 8H868
Number of speed 5 6
Synchromesh typeWarner
Shift pattern
5 speed
6 speed
Gear ratio 1st 3.500 3.416 3.500
2nd 1.944
3rd 1.258
4th 0.947
5th 0.772 0.733 0.772
6th — 0.630
Reverse 3.374 3.252 3.374
Number of teeth Input gear 1st 14 12 14
2nd 18
3rd 31
4th 38
5th 444544
6th — 46
Reverse 14 12 14
Main gear 1st 49 41 49
2nd 35
3rd 39
4th 36
5th 343334
6th — 29
Reverse 38
Reverse idler
gearFront 37
Rear 46 38 46
Oil capacity
(Imp pt)2.3 (4)
SCIA0821E
SCIA0955E
TF-8
TRANSFER FLUID
TRANSFER FLUID
PFP:KLD30
ReplacementEDS0004Q
DRAINING
1. Run the vehicle to warm up the transfer body sufficiently.
2. Stop the engine, and remove the drain plug to drain the transfer
oil.
3. Apply recommended sealant to drain plug. Position drain plug
on transfer and tighten to the specified torque.
FILLING
1. Remove filler plug and add gear oil until oil level reaches the
specified limit near filler plug mounting hole.
CAUTION:
Carefully fill the oil. (Fill up for approx. 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the oil level again.
3. Apply recommended sealant to filler plug. Position filler plug on
transfer and tighten to the specified torque.
InspectionEDS0004R
OIL LEAKAGE AND OIL LEVEL
1. Check oil level from filler plug mounting hole as shown in the fig-
ure.
2. Before installing filler plug, apply recommended sealant. Posi-
tion filler plug on transfer and tighten to the specified torque. Drain plug tightening torque
: 9.8 - 19.6 N·m (1.0 - 1.9 kg-m, 87 -173 in-lb)
SDIA0512E
Oil capacity
: Approx. 0.31 (1/2 lmp pt)
Drain plug tightening torque
: 9.8 - 19.6 N·m (1.0 - 1.9 kg-m, 87 -173 in-lb)
SDIA0513E
Filler plug tightening torque
: 9.8 - 19.6 N·m (1.0 - 1.9 kg-m, 87 -173 in-lb)
SDIA0513E