Page 959 of 1226

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
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed
3,000More than 78 (0.78, 0.8, 11)
318.7 - 424.6
(3.19 - 4.25, 3.25 - 4.33, 46.2 - 61.6)
If difference is extreme, check oil passage and oil pump for oil
leaks.
6. Install oil pressure switch with sealant.
Use proper liquid sealant.
Oil pressure switch:
:10-16Nzm (1.0 - 1.6 kg-m, 87 - 139 in-lb)
Oil Pump
REMOVAL AND INSTALLATION
1. Disconnect battery terminal.
2. Drain engine oil.
3. Drain coolant from radiator and cylinder block. Refer to MA
section (``Changing Engine Coolant'', ``ENGINE MAINTE-
NANCE'').
4. Remove radiator shroud.
5. Remove drive belts. Refer to MA section (``Checking Drive
Belts'').
6. Remove crankshaft pulley and front upper and lower belt cov-
ers. Refer to EM section (``TIMING BELT'').
7. Remove oil pan. Refer to EM section (``OIL PAN'').
8. Remove oil strainer.
9. Remove oil pump assembly.
10. Installation is in reverse order of removal.
+Before installing oil pump, remove liquid gasket from mating
surface of oil pump using a scraper.
Be sure liquid gasket in grooves is also removed.
+Remove liquid gasket from mating surface of cylinder block.
+Clean all traces of liquid gasket using white gasoline.
SLC993
ENGINE LUBRICATION SYSTEM
Oil Pressure Check (Cont'd)
LC-4
Page 962 of 1226
Oil Cooler
REMOVAL AND INSTALLATION
Install oil cooler as shown in the ®gure.
INSPECTION
1. Check oil cooler element and bracket for cracks.
2. Check coolant inlet of oil cooler for clogging by blowing through
it. Replace it if necessary.
Oil Jet
INSPECTION
1. Push cut-off valve of oil jet bolt with a clean resin or brass rod
and make sure that cut-off valve moves smoothly with proper
repulsion.
2. Make sure that the oil jet passage is not clogged. Clean with a
wire if necessary.
SLC196B
SLC015
ENGINE LUBRICATION SYSTEM
LC-7
Page 963 of 1226
When installing oil jet, align oil jet's boss with hole on cylin-
der block.
Oil jet bolt:
:30-40Nzm (3.1 - 4.1 kg-m, 22 - 30 ft-lb)
Turbocharger
+Before removing water tube, drain coolant ®rst.
+Be careful not to deform tubes.
+After installation, run engine for a few minutes, and check
for oil leakage.
SLC975
SLC197B
ENGINE LUBRICATION SYSTEM
Oil Jet (Cont'd)
LC-8
Page 965 of 1226

Pull the negative pressure valve to open it. Check that it closes
completely when released.
CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system by means of a tester to check
for leakage.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm
2, 14 psi)
CAUTION:
Use of pressure higher than the speci®ed value may cause
damage to radiator.
Water Pump
CAUTION:
+When removing water pump assembly, be careful not to
get coolant on drive belts.
+Water pump cannot be disassembled and should be
replaced as a unit.
+After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
REMOVAL
1. Drain coolant from radiator and cylinder block.
Cylinder block drain plug (Use proper sealant):
:34-44Nzm (3.5 - 4.5 kg-m, 25 - 33 ft-lb)
Refer to MA section (``Changing Engine Coolant'', ``ENGINE
MAINTENANCE'').
2. Remove radiator shroud.
3. Remove drive belts. Refer to MA section (``Checking Drive
Belts'').
4. Remove fan coupling with fan.
5. Remove water pump.
SMA967B
SMA007D
SMA003D
ENGINE COOLING SYSTEM
System Check (Cont'd)
LC-10
Page 968 of 1226
+Cut off tip of nozzle of liquid gasket at point shown in ®gure.
+Use Genuine Liquid Gasket or equivalent.
+Apply a continuous bead of liquid gasket to mating surface of
water inlet.
a. Be sure diameter of liquid gasket is within 2.0 to 3.0 mm (0.079
to 0.118 in).
b. Attach water inlet to cylinder block within ®ve minutes after
applying liquid gasket.
c. After installing water inlet, wait at least 30 minutes before re®ll-
ing coolant and starting engine.
SLC822
SLC824 Diameter of liquid gasket:
2.0 - 3.0 mm (0.079 - 0.118 in)
ENGINE COOLING SYSTEM
Thermostat (Cont'd)
LC-13
Page 969 of 1226
Radiator
REMOVAL AND INSTALLATION
1. Remove under cover.
2. Drain coolant from radiator drain plug.
3. Disconnect radiator upper and lower hoses.
4. Remove radiator lower shroud.
5. Disconnect reservoir tank hose.
6. Remove radiator.
7. After repairing or replacing radiator, install any part removed in
reverse order of removal.
Re®lling Engine Coolant
For details on re®lling engine coolant, refer to MA section (``REFILL-
ING ENGINE COOLANT'', ``Changing Engine Coolant'').
SLC198B
ENGINE COOLING SYSTEM
LC-14
Page 975 of 1226

Overheating Cause Analysis
Symptom Check items
Cooling
system parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
Ð Thermostat stuck closed Ð
Damaged ®nsDust contamination or paper
clogging
Mechanical damage
Clogged radiator cooling tubeExcess foreign material (rust,
dirt, sand, etc.)
Reduced air ¯owCooling fan does not operate
ÐÐ Fan coupling does not operate
High resistance to fan rotation
Damaged fan blades
Damaged radiator shroud Ð Ð Ð
Improper coolant mixture ratio Ð Ð Ð
Poor coolant quality Ð Ð Ð
Insufficient coolantCoolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deteriora-
tion or improper ®tting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Over¯owing reservoir tankExhaust gas leaks into cooling
systemCylinder head deterioration
Cylinder head gasket deteriora-
tion
Except
cooling
system parts
malfunctionÐ Overload on engineAbusive drivingHigh engine rpm under no load
Driving in low gear for extended
time
Driving at extremely high speed
Powertrain system malfunction
Ð Installed improper size wheels
and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air ¯owBlocked bumper Ð
Ð Blocked radiator grilleInstalled car brassiere
Mud contamination or paper
clogging
Blocked radiator Ð
Blocked condenser
Ð
Installed large fog lamp
ENGINE COOLING SYSTEM
LC-20
Page 977 of 1226

MAINTENANCE
SECTION
MA
CONTENTS
PRECAUTIONS AND PREPARATION............................1
Supplemental Restraint System (SRS) ``AIR
BAG'' and ``SEAT BELT PRE-TENSIONER''...............1
Special Service Tools ..................................................1
PRE-DELIVERY INSPECTION ITEMS............................2
GENERAL MAINTENANCE............................................3
PERIODIC MAINTENANCE............................................4
Engine Oil & Minor Service .........................................4
Engine and Emission Control Service .........................5
Chassis and Body Services.........................................6
Maintenance Under Severe Driving Conditions ..........8
RECOMMENDED FLUIDS AND LUBRICANTS.............9
Fluids and Lubricants ..................................................9
SAE Viscosity Number ..............................................10
Anti-freeze Coolant Mixture Ratio ............................. 11
ENGINE MAINTENANCE..............................................12
Checking Tightening Torque ......................................12
Checking Drive Belt ...................................................12
Changing Engine Oil..................................................13
Changing Engine Oil Filter ........................................14
Changing Engine Coolant..........................................14
Checking Cooling System .........................................16
Checking and Replacing Fuel Filter and Draining
Water .........................................................................16
Checking Fuel Lines ..................................................17
Cleaning and Replacing Air Cleaner Filter ................18
Checking Injection Nozzle .........................................18
Checking Idle Speed .................................................19
Timing Belt Replacement...........................................19
CHASSIS AND BODY MAINTENANCE.......................20
Checking Exhaust System.........................................20
Checking Clutch Fluid Level and Leaks ....................20
Checking Clutch System ...........................................20Checking M/T Oil Level and Leaks ...........................20
Changing M/T Oil.......................................................20
Checking Water Entry ................................................21
Checking Transfer Fluid Level ...................................21
Changing Transfer Fluid ............................................21
Checking Propeller Shaft ...........................................21
Greasing Nipples of Propeller Shafts ........................21
Checking Differential Gear Oil ...................................22
Changing Differential Gear Oil ..................................22
Checking Front Wheel Bearing Grease ....................22
Repacking Front Wheel Bearing and Axle Joint
Grease .......................................................................23
Checking Free-running Hub Grease .........................23
Checking Water Entry in Knuckle Flange..................23
Checking Brake Fluid Level and Leaks.....................23
Checking Brake System ............................................24
Changing Brake Fluid ................................................24
Checking Brake Booster, Vacuum Hoses,
Connections and Check Valve ..................................24
Checking Disc Brake .................................................24
Balancing Wheels ......................................................25
Tire Rotation ..............................................................25
Checking Power Steering Fluid and Lines ................26
Checking Steering Damper .......................................26
Checking Steering Gear Box and Linkage ................26
Lubricating Locks, Hinges and Hood Latches...........27
Checking Seat Belts, Buckles, Retractors,
Anchors and Adjusters...............................................27
Checking Body Corrosion ..........................................28
SERVICE DATA AND SPECIFICATIONS (SDS)..........29
Engine Maintenance ..................................................29
Chassis and Body Maintenance ................................29
MA