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LU-12
< REMOVAL AND INSTALLATION >
OIL COOLER
CAUTION:
Perform this step when engine is cold.
4. Remove oil filter. Refer to LU-9, "
Removal and Installation".
5. Remove connector bolt, and remove oil cooler.
INSTALLATION
Installation is in the reverse order of removal, paying attention to the following:
Confirm that no foreign objects are adhering to the sealing surfaces of the oil cooler and oil pan.
InspectionINFOID:0000000006289623
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
the valve by prying it out using a suitable tool. Install a new valve in place by tapping it in.
INSPECTION AFTER INSTALLATION
1. Check engine oil and engine coolant levels and add engine oil and engine coolant. Refer to LU-7, "Inspec-
tion" and CO-8, "Inspection".
2. Start the engine, and check for l eaks of engine oil or engine coolant.
3. Stop the engine and wait for 10 minutes.
4. Check the engine oil level and engine coolant level again. Refer to LU-7, "
Inspection" and CO-8, "Inspec-
tion"
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OIL PUMPLU-13
< REMOVAL AND INSTALLATION >
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OIL PUMP
Exploded ViewINFOID:0000000006289624
Removal and InstallationINFOID:0000000006289625
REMOVAL
NOTE:
Do not remove the engine assembly to perform this procedure.
1. Disconnect battery cable from
negative terminal. Refer to PG-165, "
Exploded View".
2. Drain engine oil. Refer to LU-8, "
Draining".
3. Drain engine coolant from radiator. Refer to CO-8, "
Draining".
CAUTION:
Perform this step when engine is cold.
Never spill engine coolant on drive belts.
4. Remove the following components and related parts: Air cleaner case assembly and air duct. Refer to EM-27, "
Exploded View".
Drive belt auto tensioner and idler pulley. Refer to EM-26, "
Exploded View".
Fan shroud. Refer to CO-13, "
Exploded View".
Cooling fan, fan coupling and fan bracket. Refer to CO-16, "
Exploded View".
Front under cover. Refer to EXT-25, "
Exploded View".
Protector A and B. Refer to SCS-32, "
FRONT TUBE ASSEMBLY : Exploded View".
Front suspension rear cross member. Refer to TM-205, "
2WD : Exploded View" (2WD models) or TM-
208, "4WD : Exploded View" (4WD models).
Steering gear assembly. Refer to ST-41, "
Exploded View".
Front final drive assembly. Refer to DLN-162, "
Exploded View".
Power steering oil pump. Refer to ST-48, "
Exploded View".
Alternator, alternator bracket and alternator stay. Refer to CHG-25, "
Exploded View".
Oil pan (lower) and oil strainer. Refer to EM-54, "
Exploded View".
Oil pan (upper). Refer to EM-57, "
Exploded View".
Electric throttle control actuator. Refer to EM-30, "
Exploded View".
Radiator hoses. Refer to CO-13, "
Exploded View".
Water suction hose and water suction pipe. Refer to CO-20, "
Exploded View".
Water pump pulley. Refer to CO-18, "
Exploded View".
Rocker cover. Refer to EM-33, "
Exploded View".
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
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LU-14
< REMOVAL AND INSTALLATION >
OIL PUMP
5. Remove the oil pump drive spacer. Hold and remove the flat space of the oil pump drive spacer bypulling it forward.
6. Remove the oil pump. Refer to LU-13, "
Exploded View".
INSTALLATION
1. Install the oil pump.
2. Install the oil pump drive spacer as follows:
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 each part is aligned and tap lightly until it reaches the end.
3. Installation of the remaining components is in the reverse order of removal.
Disassembly and AssemblyINFOID:0000000006289626
DISASSEMBLY
1. Remove oil pump cover.
2. Remove inner rotor and outer rotor from oil pump body.
3. Remove the regulator valve plug, regulator valve spring and regulator valve.
ASSEMBLY
Installation is in the reverse order of removal.
NOTE:
Install the oil pump inner rotor and outer rotor with the punched
marks on the oil pump cover side.
InspectionINFOID:0000000006289627
INSPECTION AFTER DISASSEMBLY
Clearance of Oil Pump Parts
KBIA2512E
KBIA2490E
PBIC0144E
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OIL PUMPLU-15
< REMOVAL AND INSTALLATION >
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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. (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.Body to outer rotor
(position 1)
: Refer to
LU-17, "
OilPump".
Inner rotor to outer
rotor tip (position 2) : Refer to
LU-17, "
OilPump".
PBIC0139E
Body to inner rotor
(position 3) : Refer to
LU-17, "OilPump".
Body to outer rotor
(position 4) : Refer to
LU-17, "
OilPump".
PBIC0140E
PBIC0141E
PBIC0142E
Inner rotor to brazed portion of housing clearance : Refer to LU-17, "OilPump".
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LU-16
< REMOVAL AND INSTALLATION >
OIL PUMP
(Clearance) = D1 (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.
INSPECTION AFTER INSTALLATION
1. Check the engine oil level. Refer to LU-7, "Inspection"
2. Start the engine and check for engine oil leaks.
3. Stop the engine and wait 10 minutes.
4. Check the engine oil level and adjust the engine oil level as required. Refer to LU-7, "
Inspection".
Regulator valve
to oil pump cover
: Refer to
LU-17, "
RegulatorVa l v e".
PBIC0143E
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SERVICE DATA AND SPECIFICATIONS (SDS)
LU-17
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Periodical Maintenance SpecificationINFOID:0000000006289628
ENGINE OIL CAPACITY (APPROXIMATE)
Unit: (US qt, Imp qt)
Engine Oil PressureINFOID:0000000006289629
Unit: kPa (kg/cm2, psi)
*: Engine oil temperature at 80
°C (176 °F)
Oil PumpINFOID:0000000006289630
Unit: mm (in)
Regulator ValveINFOID:0000000006289631
Unit: mm (in)
Drain and refill With oil filter change 6.5 (6-7/8, 5-3/4)
Without oil filter change 6.2 (6-4/8, 5-1/2)
Dry engine (engine overhaul) 7.6 (8, 6-3/4)
Engine speed Approximate discharge pressure* Idle speed More than 98 (1.0, 14)2,000 rpm More than 294 (3.0, 43)
Oil pump body to oil pump outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079)
Oil pump inner rotor to oil pump outer rotor tip clearance Below 0.180 (0.0071)
Oil pump body to oil pump inner rotor axial clearance 0.030 - 0.070 (0.0012 - 0.0028)
Oil pump body to oil pump outer rotor axial clearance 0.030 - 0.090 (0.0012 - 0.0035)
Oil pump 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)
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MA-1
MAINTENANCE
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CONTENTS
MAINTENANCE
PREPARATION .............
...............................3
PREPARATION .............................................. .....3
Special Service Tool ........................................... ......3
Commercial Service Tool ..........................................3
PERIODIC MAINTENANCE ..........................4
GENERAL MAINTENANCE ........................... .....4
Explanation of General Maintenance .................. ......4
PERIODIC MAINTENANCE ................................6
Introduction of Periodic Maintenance .................. ......6
Schedule 1 ................................................................6
Schedule 2 ................................................................8
RECOMMENDED FLUIDS AND LUBRI-
CANTS ................................................................
10
Fluids and Lubricants .......................................... ....10
Engine Oil Recommendation ..................................10
Anti-Freeze Coolant Mixture Ratio ..........................11
ENGINE MAINTENANCE ...................................12
DRIVE BELTS ....................................................... ....12
DRIVE BELTS : Exploded View ..............................12
DRIVE BELTS : Checking .......................................12
DRIVE BELTS : Tension Adjustment .....................12
ENGINE COOLANT ............................................... ....12
ENGINE COOLANT : Inspection .............................12
ENGINE COOLANT : Draining ................................13
ENGINE COOLANT : Refilling ................................13
ENGINE COOLANT : Flushing ...............................15
RESERVOIR TANK CAP ..........................................15
RESERVOIR TANK CAP : Inspection ................. ....15
RADIATOR ............................................................ ....16
RADIATOR : Inspection ..........................................16
FUEL LINES .......................................................... ....16
FUEL LINES : Inspection ........................................17
AIR CLEANER FILTER ......................................... ....17
AIR CLEANER FILTER : Removal and Installation
....
17
ENGINE OIL ........................................................... ....17
ENGINE OIL : Draining ............................................17
ENGINE OIL : Refilling ............................................17
OIL FILTER ............................................................ ....18
OIL FILTER : Removal and Installation ...................18
SPARK PLUG ........................................................ ....18
SPARK PLUG : Removal and Installation ...............19
SPARK PLUG : Inspection ......................................19
EVAP VAPOR LINES ............................................ ....20
EVAP VAPOR LINES : Inspection ...........................20
CHASSIS MAINTENANCE ...............................21
EXHAUST SYSTEM . ..................................................21
EXHAUST SYSTEM : Inspec tion ............................21
A/T FLUID .............................................................. ....21
A/T FLUID : Inspection ............................................21
TRANSFER FLUID ................................................ ....21
TRANSFER FLUID : Inspection ..............................21
TRANSFER FLUID : Draining .................................21
TRANSFER FLUID : Refilling ..................................22
FRONT PROPELLER SHAFT: 2F P15 ................. ....22
FRONT PROPELLER SHAFT: 2F P15 : Inspec-
tion ...........................................................................
22
REAR PROPELLER SHAFT: 2F P26 .................... ....23
REAR PROPELLER SHAFT: 2F P26 : Inspection ....23
REAR PROPELLER SHAFT: 2S1410 ................... ....23
REAR PROPELLER SHAFT: 2S1410 : Inspection ....23
FRONT DIFFERENTIAL GEAR OIL: R180A ........ ....24
FRONT DIFFERENTIAL GEAR OIL: R180A : In-
spection ...................................................................
24
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MA-2
FRONT DIFFERENTIAL GEAR OIL: R180A :
Draining ..................................................................
24
FRONT DIFFERENTIAL GEAR OIL: R180A : Re-
filling .......................................................................
25
REAR DIFFERENTIAL GEAR OIL: R230 ............. ...25
REAR DIFFERENTIAL GEAR OIL: R230 : Inspec-
tion ..........................................................................
25
REAR DIFFERENTIAL GEAR OIL: R230 : Drain-
ing ...........................................................................
25
REAR DIFFERENTIAL GEAR OIL: R230 : Refill-
ing ...........................................................................
26
WHEELS (BONDING WEIGHT TYPE) .....................26
WHEELS (BONDING WEIGHT TYPE) : Adjust-
ment ..................................................................... ...
26
BRAKE FLUID LEVEL AND LEAKS ........................27
BRAKE FLUID LEVEL AND LEAKS : Inspection ...28
BRAKE LINES AND CABLES ............................... ...28
BRAKE LINES AND CABLES : Inspection .............28
BRAKE FLUID ....................................................... ...28
BRAKE FLUID : Bleeding Brake System ................28
DISC BRAKE ......................................................... ...30
DISC BRAKE : Inspection ......................................30
DISC BRAKE : Front Disc Brake ............................31
DISC BRAKE : Rear Disc Brake .............................31
STEERING GEAR AND LINKAGE ........................ ...31
STEERING GEAR AND LINKAGE : Inspection ......31
POWER STEERING FLUID AND LINES ............... ...32
POWER STEERING FLUID AND LINES : Inspec-
tion ..........................................................................
32
AXLE AND SUSPENSION PARTS ...........................32
AXLE AND SUSPENSION PARTS : Inspection .. ...32
DRIVE SHAFT ........................................................ ...33
DRIVE SHAFT : Inspection .....................................33
BODY MAINTENANCE .....................................34
LOCKS, HINGES AND HOOD LATCH .................. ...34
LOCKS, HINGES AND HOOD LATCH : Lubricat-
ing ...........................................................................
34
SEAT BELT, BUCKLES, RETRACTORS, AN-
CHORS AND ADJUSTERS ................................... ...
34
SEAT BELT, BUCKLES, RETRACTORS, AN-
CHORS AND ADJUSTERS : Inspection .................
34
SERVICE DATA AND SPECIFICATIONS
(SDS) .......... ................................................
35
SERVICE DATA AND SPECIFICATIONS
(SDS) .............................................................. ...
35
DRIVE BELTS ........................................................ ...35
DRIVE BELTS : Drive Belts ....................................35
ENGINE COOLANT ............................................... ...35
ENGINE COOLANT :
Periodical Maintenance Specification ....................
35
ENGINE OIL ........................................................... ...35
ENGINE OIL : Periodical Maintenance Specifica-
tion ..........................................................................
35
SPARK PLUG ........................................................ ...35
SPARK PLUG : Spark Plug ....................................35
ROAD WHEEL ....................................................... ...35
ROAD WHEEL : Road Wheel .................................35
Revision: 2010 May2011 QX56