ENGINE LUBRICATION & GI

COOLING SYSTEMS
MA

MODIFICATION NOTICE:
SECTION LC EM

EC
I The TB42S engine has been replaced with the TB45S engine.
For the TB45S engine specifications other than those described here, refer to TB45E engine.
I The ZD30DDTi engine has been added. FE

CL

CONTENTS MT

TB45S ENGINE COOLING SYSTEM..........................................9

Cooling Circuit .............................................................9
AT
ENGINE COOLING SYSTEM..........................................2
System Check............................................................10
Cooling Circuit .............................................................2
Water Pump ...............................................................11 TF
Thermostat.................................................................12
ZD Water Outlet...............................................................13
ENGINE LUBRICATION SYSTEM ..................................3 Radiator .....................................................................14 PD
Lubricating Circuit ........................................................3 Cooling Fan (Crankshaft driven) ...............................15
Oil Pressure Check......................................................4 SERVICE DATA AND SPECIFICATIONS (SDS) ..........16
Engine Lubrication System........................................16 FA
Oil Pump ......................................................................5
Oil Jet...........................................................................7 Engine Cooling System .............................................16
Oil Cooler.....................................................................8 RA

BR

ST

RS

BT

HA

EL

SE

IDX

LC-1
ENGINE COOLING SYSTEM TB45S

Cooling Circuit

SLC269B

LC-2
ENGINE LUBRICATION SYSTEM ZD

Lubricating Circuit GI

MA

EM

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX
SLC361B

LC-3
ENGINE LUBRICATION SYSTEM ZD

Oil Pressure Check

WARNING:
I Be careful not to burn yourself, as the engine and oil may
be hot.
I Oil pressure check should be done in “Neutral” gear posi-
tion.
1. Check oil level.
2. Remove oil pressure switch.

SLC694A

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 speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)
Idle speed More than 147 (1.47, 1.5, 21)
2,000 More than 539 (5.39, 5.5, 78)
4,000 More than 736 (7.36, 7.5, 107)

JLC362B

If difference is extreme, check oil passage and oil pump.

6. Install oil pressure switch with sealant.
Oil pressure switch:
: 13 - 17 N⋅m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)

LC-4
ENGINE LUBRICATION SYSTEM ZD

Oil Pump GI
REMOVAL AND INSTALLATION
Refer to “TIMING GEAR” in EM section. MA
DISASSEMBLY AND ASSEMBLY
EM

EC

FE

CL

MT

AT
JLC363B
TF
I When installing oil pump, apply new engine oil to gears.
PD

FA

RA

BR
I When installing the inner and outer gear, face mating mark
toward the oil pump cover as shown (left). ST

RS

BT

JLC364B
HA

EL

SE

IDX

LC-5
ENGINE LUBRICATION SYSTEM ZD
Oil Pump (Cont’d)
OIL PUMP INSPECTION
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
0.114 - 0.200
Body to outer gear radial clearance q
1
(0.0045 - 0.0079)
Inner gear to outer gear tip clearance q
2 Less than 0.180 (0.0071)
0.05 - 0.09
Body to inner gear axial clearance q
3
(0.0020 - 0.0035)
JLC365B
0.050 - 0.105
Body to outer gear axial clearance q
4
(0.0020 - 0.0041)
Inner gear to brazed portion of housing 0.045 - 0.091
clearance q5 (0.0018 - 0.0036)
Regulator valve to oil pump cover 0.040 - 0.097
clearance q6 (0.0016 - 0.0038)

I If the tip clearance (q

2 ) exceeds the limit, replace gear set.
I If body to gear clearances (q1 ,q
3 ,q4 ,q 5 ) exceed the limit,
replace oil pump body assembly.

JLC366B

JLC367B

REGULATOR VALVE INSPECTION

1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls smoothly
into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump cover.

4. Check regulator valve to oil pump cover clearance.

Clearance:
q
6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump cover.

SLC369B

LC-6
ENGINE LUBRICATION SYSTEM ZD
Oil Pump (Cont’d)
OIL PRESSURE RELIEF VALVE AND BYPASS VALVE GI
INSPECTION (For oil cooler)
1. Inspect oil pressure relief valve for movement, cracks and
breaks by pushing the ball. If replacement is necessary, remove
MA
valve by prying it out with suitable tool.
Install a new valve in place by tapping it.
EM

2. Check oil pressure relief valve to oil cooler housing clearance. EC

Clearance:
q
C : 0.032 - 0.068 mm (0.0013 - 0.0027 in)
If it exceeds the limit, replace oil cooler housing. FE

CL

MT
SLC371B
AT
Oil Jet
INSPECTION (For timing chain) TF
Make sure that the holes are not clogged. Clean them with a wire
if necessary.
Drive oil jet into place after positioning alignment mark on. PD

FA

SLC385B
RA
INSPECTION (For piston)
1. Push cut-off valve of oil jet bolt with a clean resin or brass rod BR
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 ST
wire if necessary.

RS

FEM124 BT
When installing oil jet, align oil jet’s boss with hole on cylin-
der block. HA
Oil jet:
: 30 - 39 N⋅m (3.0 - 4.0 kg-m, 22 - 28 ft-lb)
EL

SE

FEM125
IDX

LC-7
ENGINE LUBRICATION SYSTEM ZD
Oil Jet (Cont’d)
OIL FILTER
The oil filter is an element type. Refer to “Changing Oil Filter” in MA
section.

Oil Cooler

JLC370B

REMOVAL AND INSTALLATION

1. Drain engine oil and coolant.
Remove catalyst and turbocharger. Refer to “CATALYST AND
TURBOCHARGER” in EM section.
2. Remove bolts A to C then remove oil cooler assembly.
I Do not remove “D” nuts when removing oil cooler assem-
bly.
Bolt length:
A: 20 mm (0.79 in)
B: 45 mm (1.77 in)
JLC381B C: 65 mm (2.56 in)
3. Installation is in reverse order of removal.
I Do not spill coolant on the drive belt.

INSPECTION
1. Check oil cooler for cracks.
2. Check oil cooler for clogging by blowing through coolant inlet.
If necessary, replace oil cooler assembly.

LC-8
ENGINE COOLING SYSTEM ZD

Cooling Circuit GI

MA

EM

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX
JLC372B

LC-9
 ENGINE COOLING SYSTEM ZD

System Check
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
Wrap a thick cloth around the cap. Slowly turn it a quarter turn
to allow built-up pressure to escape. Carefully remove the cap
by turning it all the way.

CHECKING COOLING SYSTEM HOSES

Check hoses for the following:
I Improper attachment
I Leaks
I Cracks
I Damage
I Chafing
I Deterioration

CHECKING COOLING SYSTEM FOR LEAKS

To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
CAUTION:
Higher pressure than specified may cause radiator damage.

SLC134B

CHECKING RADIATOR CAP

To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)

SLC135B

Pull the negative pressure valve to open it.

Check that it closes completely when released.

SMA967B

LC-10
ENGINE COOLING SYSTEM ZD

Water Pump GI
CAUTION:
I When removing water pump assembly, be careful not to MA
get coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit. EM
I Always replace with new gasket.
I After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
Refer to MA section.

EC

FE

CL

MT

AT

TF

PD

FA

RA

JLC373B
BR

REMOVAL AND INSTALLATION ST

1. Drain coolant from radiator and cylinder block.
Refer to MA section (“Changing Engine Coolant”, “ENGINE
MAINTENANCE”). RS
2. Remove radiator upper hose.
3. Remove radiator shroud.
4. Remove cooling fan. BT
5. Remove drive belt. Refer to MA section, “Checking Drive Belt”.
6. Remove insulator.
7. Remove vacuum pipe.
HA
8. Remove TDC sensor. Refer to TDC sensor removal and instal-
lation in “TIMING GEAR”.
9. Remove fan coupling with water pump.
EL
10. Install in the reverse order of removal.
SE

IDX

LC-11
 ENGINE COOLING SYSTEM ZD
Water Pump (Cont’d)
INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
2. Check for rough operation due to excessive end play.
CAUTION:
Do not disassemble water pump coupling assembly.

SLC374B

Thermostat

JLC380B

REMOVAL AND INSTALLATION

1. Drain engine coolant. Refer to MA section, “Changing Engine
Coolant”.
2. Remove left side battery. (If so equipped)
3. Remove radiator upper hose.
4. Remove radiator shroud.
5. Remove intake air duct, inlet pipe.
6. Remove harness and connectors.
7. Install in reverse order of removal.
I After installation, run engine for a few minutes and check
JLC384B for leaks.
I Be careful not to spill coolant in engine compartment. Use
a rag to absorb coolant.

LC-12
 ENGINE COOLING SYSTEM ZD
Thermostat (Cont’d)
INSPECTION GI
1. Check valve seating condition at ordinary temperatures. It
should seat tightly.
2. Check valve opening temperature and maximum valve lift. MA
Tropical type and Standard type
Gulf standard and Australia Frigid type EM
model model
Valve opening tem-
76.5 (170) 82 (180) 88 (190)
perature °C (°F)
SLC695A Maximum valve lift
10/90 (0.39/194) 10/95 (0.39/203) 10/100 (0.39/212)
mm/°C (in/°F) EC
3. Then check if valve closes at 5°C (9°F) below valve opening
temperature. FE

CL

MT

AT
Water Outlet
INSPECTION TF
Visual inspection for water leaks. If there is leakage, replace gas-
ket.
PD

FA

SLC377B
RA

BR

ST

RS

BT

HA

EL

SE

IDX

LC-13
ENGINE COOLING SYSTEM ZD

Radiator

JLC378B

REMOVAL AND INSTALLATION

1. Remove under cover.
2. Drain engine coolant. Refer to MA section, “Changing Engine
Coolant”.
3. Remove air cleaner case, air duct and resonator.
4. Remove battery (right side).
5. Move window washer tank.
6. Remove radiator shroud (lower).
7. Remove radiator shroud (front).
8. Disconnect radiator hose (upper and lower).
9. Disconnect reservoir tank hose.
10. Disconnect A/T oil cooler hose (Only A/T models).

LC-14
ENGINE COOLING SYSTEM ZD
Radiator (Cont’d)
11. Remove radiator. GI
12. After repairing or replacing radiator, install all removed parts in
reverse order of removal.
MA
Cooling Fan (Crankshaft driven)
DISASSEMBLY AND INSTALLATION EM

EC

FE

JLC379B
CL

I Do not release the drive belt tension by removing the fan/water MT

pump pulley.
I Fan coupling cannot be disassembled and should be replaced
as a unit. If front mark qF is present, install fan so that side AT
marked q F faces the front.
I Proper alignment of these components is essential. Improper
alignment will cause them to wobble and may eventually cause TF
the fan to separate from the water pump causing extensive
damage.
PD

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX

LC-15
 SERVICE DATA AND SPECIFICATIONS (SDS) ZD

Engine Lubrication System

Oil pressure check Oil pump
Unit: mm (in)
Engine speed Approximate discharge pressure
0.114 - 0.200
rpm kPa (bar, kg/cm2, psi) Body to outer gear radial clearance q
1
(0.0045 - 0.0079)
Idle speed More than 147 (1.47, 1.5, 21)
Inner gear to outer gear tip clearance q
2 Less than 0.180 (0.0071)
2,000 More than 539 (5.39, 5.5, 78)
0.05 - 0.09
Body to inner gear axial clearance q
3
4,000 More than 736 (7.36, 7.5, 107) (0.0020 - 0.0035)

0.050 - 0.105
Body to outer gear axial clearance q
4
(0.0020 - 0.0041)

Inner gear to brazed portion of housing 0.045 - 0.091

clearance q5 (0.0018 - 0.0036)

Regulator valve to oil pump cover clear- 0.040 - 0.097

ance q
6 (0.0016 - 0.0038)

Engine Cooling System

Radiator Thermostat
Unit: kPa (bar, kg/cm2, psi)
Tropical type Standard type
78 - 98
Cap relief pressure
(0.78 - 0.98, 0.8 - 1.0, 11 - 14) Valve opening tem-
76.5 (170) 82 (180)
perature °C (°F)
Leakage test pressure 157 (1.57, 1.6, 23)
Valve lift More than 10/95 More than 10/95
mm/°C (in/°F) (0.39/203) (0.39/203)

LC-16