Page 2357 of 3061

LU-12
< SERVICE INFORMATION >
OIL COOLER
OIL COOLER
Removal and InstallationINFOID:0000000003531558
CAUTION:
Be careful not to burn yourself, as the engine oil and engine coolant are hot.
REMOVAL
1. Remove engine front undercover using power tool.
2. Disconnect water hoses, pinching hoses near oil cooler to prevent engine coolant from spilling.
CAUTION:
Do not spill engine coolant on the drive belt.
3. Remove oil filter. Refer to LU-11, "
Removal and Installation".
CAUTION:
Do not spill engine oil on the drive belts.
4. Remove connector bolt, and remove oil cooler.
INSPECTION AFTER REMOVAL
Oil Cooler
Check oil cooler for cracks. Check oil cooler for clogging by blowing compressed air through engine coolant
inlet. If necessary, replace oil cooler assembly.
Relief Valve
Inspect relief valve for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove
valve by prying it out using a suitable tool. Install a new valve in place by tapping it.
INSTALLATION
Installation is in the reverse order of removal, paying attention to the following:
WBIA0790E
1. Oil pan 2. Water hose 3. Water pipe
4. Water hose 5. Oil cooler bolt 6. Oil filter
7. Oil cooler 8. O-ring 9. Relief valve
10. Water hose 11. Connector pipe 12. Gasket
Page 2358 of 3061
OIL COOLER
LU-13
< SERVICE INFORMATION >
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• Confirm that no foreign objects are adhering to the sealing sur-
faces of the oil cooler or oil pan.
• Tighten the connecting bolt after aligning the stopper on the oil pan
side with protrusion of the oil cooler.
INSPECTION AFTER INSTALLATION
1. Check levels and add engine oil and engine coolant. Refer to LU-8, "Inspection".
2. Start the engine, and check for leaks of engine oil and engine coolant.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level and engine coolant level again.
KBIA2500E
Page 2359 of 3061
LU-14
< SERVICE INFORMATION >
OIL PUMP
OIL PUMP
Removal and InstallationINFOID:0000000003531559
REMOVAL
1. Remove front cover. Refer to EM-38, "Removal and Installation".
2. Remove the oil pump drive spacer.
3. Remove the oil pump.
INSTALLATION
Installation is in the reverse order of removal, paying attention of the following:
• When inserting the oil pump drive spacer, align the crankshaft key
and the flat face of the inner rotor.
• If they are not aligned, rotate the oil pump inner rotor by hand.
• Make sure that the each part is aligned and tap lightly until it
reaches the end.
INSPECTION AFTER INSTALLATION
• Start the engine, and check for leaks of engine oil.
• Stop engine and wait 10 minutes.
• Check level and add engine oil as required. Refer to LU-8, "
Inspection".
WBIA0415E
1. Oil pump body 2. Outer rotor 3. Inner rotor
4. Oil pump cover 5. Oil pump drive spacer 6. Regulator valve
7. Regulator spring 8. Regulator plug
KBIA2512E
KBIA2490E
Page 2360 of 3061

OIL PUMP
LU-15
< SERVICE INFORMATION >
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Disassembly and AssemblyINFOID:0000000003531560
DISASSEMBLY
1. Remove oil pump cover.
2. Remove inner rotor and outer rotor from oil pump body.
3. Remove the regulator plug, regulator spring and regulator valve.
INSPECTION AFTER DISASSEMBLY
Clearance of Oil Pump Parts
• Measure radial clearance using a suitable tool.
• Measure side clearance using suitable tools.
• Calculate the clearance between inner rotor and oil pump body as
follows.
1. Measure the outer diameter of protruded portion of inner rotor
(position 5) using suitable tool.
2. Measure the inner diameter of oil pump body to brazed portion
(position 6) using suitable tool.
3. Calculate the clearance using the following formula.Body to outer rotor (position 1)
: 0.114 - 0.200 mm (0.0045 - 0.0079 in)
Inner rotor to outer rotor tip (position 2)
: Below 0.180 mm (0.0071 in)
PBIC0139E
Body to inner rotor (position 3)
: 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Body to outer rotor (position 4)
: 0.030 - 0.090 mm (0.0012 - 0.0035 in)
PBIC0140E
PBIC0141E
PBIC0142E
Page 2361 of 3061
LU-16
< SERVICE INFORMATION >
OIL PUMP
• (Clearance) = (Inner diameter of oil pump body) - (Outer diameter of inner rotor)
Regulator Valve Clearance
Check regulator valve to oil pump cover clearance using the following formula.
• (Clearance) = D
1 (Valve hole diameter) - D2 (Outer Diameter of
valve)
CAUTION:
• Coat regulator valve with engine oil.
• Check that it falls smoothly into the regulator valve hole by its
own weight.
ASSEMBLY
Installation is in the reverse order of removal.
NOTE:
Install the inner rotor and outer rotor with the punched marks on the
oil pump cover side.Inner rotor to brazed portion of housing
clearance
: 0.045 - 0.091 mm (0.0018 - 0.0036 in)
Regulator valve to oil pump cover
: 0.040 - 0.097 mm (0.0016 - 0.0038 in)
PBIC0143E
PBIC0144E
Page 2362 of 3061

SERVICE DATA AND SPECIFICATIONS (SDS)
LU-17
< SERVICE INFORMATION >
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SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and LimitINFOID:0000000003531561
OIL PRESSURE
Unit: kPa (kg/cm2
, psi)
OIL PUMP
Unit: mm (in)
REGULATOR VALVE
Unit: mm (in)
ENGINE OIL CAPACITY (APPROXIMATE)
Unit: (US qt, Imp qt)
Engine speed
rpm Approximate discharge oil pressure
Idle speed
2,000More than 98 (1.0, 14)
More than 294 (3.0, 43)
Body to outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079)
Inner rotor to outer rotor tip clearance Below 0.180 (0.0071)
Body to inner rotor side clearance 0.030 - 0.070 (0.0012 - 0.0028)
Body to outer rotor side 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 to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)
Drain and refillWith oil filter change 6.2 (6 1/2, 5-1/2)
Without oil filter change 5.9 (6-1/4, 5-1/4)
Dry engine (engine overhaul) 7.6 (8, 6-3/4)
Page 2363 of 3061

MA-1
MAINTENANCE
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CONTENTS
MAINTENANCE
SERVICE INFORMATION ............................2
PRECAUTIONS ...................................................2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
2
PREPARATION ...................................................3
Special Service Tool .................................................3
Commercial Service Tool ..........................................3
GENERAL MAINTENANCE ................................4
General Maintenance ................................................4
PERIODIC MAINTENANCE ................................6
Introduction of Periodic Maintenance ........................6
Maintenance for Off-road Driving (4WD only) ...........6
Schedule 1 ................................................................6
Schedule 2 ................................................................8
RECOMMENDED FLUIDS AND LUBRI-
CANTS ................................................................
10
Fluids and Lubricants ..............................................10
SAE Viscosity Number ............................................10
ENGINE MAINTENANCE ...................................12
Checking Drive Belts ...............................................12
Changing Engine Coolant .......................................12
Checking Fuel Line .................................................15
Changing Fuel Filter ................................................15
Changing Engine Air Cleaner Filter .........................15
Changing Engine Oil ................................................16
Changing Oil Filter ...................................................16
Changing Spark Plugs .............................................18
Checking EVAP Vapor Line .....................................19
CHASSIS AND BODY MAINTENANCE ...........20
Changing In-cabin Microfilter ...................................20
Checking Exhaust System .......................................21
Checking Automatic Transmission Fluid (ATF) .......21
Changing Automatic Transmission Fluid (ATF) .......23
Changing Transfer Fluid ..........................................23
Checking Transfer Fluid ..........................................24
Checking Propeller Shaft .........................................24
Checking Final Drive Oil ..........................................24
Changing Final Drive Oil ..........................................25
Balancing Wheels ....................................................25
Tire Rotation ............................................................27
Checking Brake Fluid Level and Leaks ...................27
CheckingBrake Line and Cables .............................27
Checking Disc Brake ...............................................27
Checking Steering Gear and Linkage ......................28
Checking Power Steering Fluid and Line ................28
Checking Axle and Suspension Parts .....................29
Lubricating Locks, Hinges and Hood Latches .........30
Checking Seat Belts, Buckles, Retractors, An-
chors and Adjusters .................................................
30
Page 2365 of 3061
PREPARATION
MA-3
< SERVICE INFORMATION >
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PREPARATION
Special Service ToolINFOID:0000000003533857
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolINFOID:0000000003533858
Tool number
(Kent-Moore No.)
Tool nameDescription
KV10115801
(J-38956)
Oil filter cap wrenchRemoving and installing oil filter
a: 64.3 mm (2.531 in)
KV991J0010
(J-23688)
Engine coolant refractometerChecking concentration of ethylene glycol in
engine coolant
KV991J0070
(J-45695)
Coolant refill toolFilling cooling system
NT375
WBIA0539E
LMA053
(Kent-Moore No.)
Tool nameDescription
Power toolLoosening bolts and nuts
Spark plug wrench Removing and installing spark plug
PBIC0190E
S-NT047