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Lubrication System

The document describes the lubrication system of an engine. It details: 1) The engine uses a fully pressurized and filtered lubrication system. 2) Troubleshooting tips are provided for issues like low/high oil pressure and leaks. 3) The procedure for replacing the engine oil and oil filter is outlined.

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dwcdisco
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0% found this document useful (0 votes)
199 views

Lubrication System

The document describes the lubrication system of an engine. It details: 1) The engine uses a fully pressurized and filtered lubrication system. 2) Troubleshooting tips are provided for issues like low/high oil pressure and leaks. 3) The procedure for replacing the engine oil and oil filter is outlined.

Uploaded by

dwcdisco
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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LU1

LUBRICATION SYSTEM

LUBRICATION SYSTEM

LU2
LUBRICATION SYSTEM

Description

DESCRIPTION
A fully pressurized, fully filtered lubrication system has been adopted for this engine.

LU3
LUBRICATION SYSTEM

Description

DESCRIPTION
A fully pressurized, fully filtered lubrication system has been adopted for this engine.

LUBRICATION SYSTEM

-Memo

LU5
LUBRICATION SYSTEM

Oil Pressure Check

TROUBLESHOOTING
Problem
Oil leakage

Low oil pressure

High oil pressure

Possible cause

Remedy

Page

Cylinder head, cylinder block or oil pump


body damaged or cracked
Oil seal faulty
Gasket faulty

Repair as necessary
Replace oil seal
Replace gasket

Oil leakage
Relief valve faulty
Oil pump faulty
Engine oil poor quality
Crankshaft bearing faulty
Connecting rod bearing faulty
Oil filler clogged

Repair as necessary
Repair relief valve
Repair oil pump
Replace engine oil
Replace bearing
Replace bearing
Replace oil filler

LU9, 17
LU9, 17
LU7
EM185, 224, 269
EM185, 224, 269
LU7

Relief valve faulty

Repair relief valve

LU9, 17

EM207, 249, 294


LU20

OIL PRESSURE CHECK


1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring
or thinning.
If the quality is poor, replace the oil.
Oil grade: API grade SG multigrade and fuelefficient
engine oil. Recommended viscosity is as
shown.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the L and F marks on
the dipstick.
If low, check for leakage and add oil up to F mark.

3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL


PRESSURE GAUGE
(a) (4AFE)
Remove the alternator and bracket.
(b) Remove the oil pressure switch.
HINT (3SGTE): Use SST.
SST 0981630010

LU6
LUBRICATION SYSTEM

Oil Pressure Check

(c) Install an oil pressure gauge.


(d) (4AFE)
Install the bracket and alternator.
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle 29 kPa (0.3 kgf/cm2, 4.3 psi)
or more
At 3,000 rpm 245 490 kPa
(2.5 5.0 kgf/cm2, 36 71 psi)

6. REINSTALL OIL PRESSURE SWITCH


(a) (4AFE)
Remove the alternator and bracket.
(b) Remove the oil pressure gauge.
(c) Apply adhesive to two or three threads of the oil
pressure switch.
Adhesive: Part No. 0883300080, THREE BOND 1344,
LOCTITE 242 or equivalent

(d) Reinstall the oil pressure switch.


HINT (3SGTE): Use SST.
SST 0981630010
(e) (4AFE)
Reinstall the bracket and alternator.
7. START ENGINE AND CHECK FOR LEAKS

LU7
LUBRICATION SYSTEM

Replacement of Engine Oil and Oil Filter

REPLACEMENT OF ENGINE OIL AND


OIL FILTER
CAUTION:

Prolonged and repeated contact with mineral oil will result


in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil
contains potentially harmful contaminants which may
cause skin cancer.
Care should be taken, therefore, when changing engine, oil
to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves
that cannot be penetrated by oil should be worn. The skin
should be thoroughly washed with soap and water, or use
waterless hand cleaner, to remove any used engine oil. Do
not use gasoline, thinners, or solvents.
In order to preserve the environment, used oil and used oil
filter must be disposed of only at designated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a container.
2. REPLACE OIL FILTER
(a) (3SGTE)
Remove the alternator ducts.
(See steps 2, 4 and 10 on pages CH7 and 8)
(b) Using SST, remove the oil filter.
SST 0922806500

(c) Clean the oil filter contact surface on the filter


mounting.
(d) Lubricate the filter rubber gasket with engine oil.

LU8
LUBRICATION SYSTEM

Replacement of Engine Oil and Oil Filter

(e) Tighten the oil filter by hand until the rubber gasket
contacts the seat of the filter mounting. Then using
SST, give it an additional 3/4 turn to seat the oil
filter.
SST 0922806500
(f) (3SGTE)
Reinstall the alternator ducts.
(See steps1, 7 and 9 on pages CH23 and 24)

3. FILL WITH ENGINE OIL


(a) Clean and install the oil drain plug with a new gasket.
Torque:
4AFE 34 Nm (350 kgfcm, 25 ftlbf)
3SGTE and 5SFE 39 Nm (400 kgfcm, 29 ftlbf)

(b) Fill with new engine oil.


Oil grade: See page LU5
Capacity:
(4AFE)
Drain and refill
w/ Oil filter change
3.2 liters (3.3 US qts, 2.8 Imp. qts)
w/o Oil filter change
3.0 liters (3.1 US qts, 2.6 Imp. qts)
Dry fill 3.7 liters (3.9 US qts, 3.3 Imp. qts)
(3SGTE)
Drain and refill
w/ oil filter change
3.9 liters (4.1 US qts, 3.4 Imp. qts)
w/o Oil filter change
3.6 liters (3.8 US qts, 3.2 Imp. qts)
Dry fill 4.3 liters (4.5 US qts, 3.8 Imp. qts)
(5SFE (w/ Oil cooler))
Drain and refill
w/ Oil filter change
4.2 liters (4.4 US qts, 3.7 Imp. qts)
w/o Oil filter change
3.8 liters (4.0 US qts, 3.3 Imp. qts)
Dry fill 4.6 liters (4.9 US qts, 4.0 Imp. qts)
(5SFE (w/o Oil cooler))
Drain and refill
w/ Oil filter change
4.1 liters (4.3 US qts, 3.6 Imp. qts)
w/o Oil filter change
3.7 liters (3.9 US qts, 3.3 Imp. qts)
Dry fill 4.5 liters (4.8 US qts, 4.0 Imp. qts)
(c) Reinstall the oil filler cap.
4. START ENGINE AND CHECK FOR LEAKS
5. RECHECK ENGINE OIL LEVEL (See page LU5)

LU9
LUBRICATION SYSTEM

Oil Pump (4AFE)

OIL PUMP (4AFE)


REMOVAL OF OIL PUMP
HINT: When repairing the oil pump, the oil pan and
strainer should be removed and cleaned.

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL


OF BATTERY
CAUTION: Work must be started after approx. 20
seconds or longer from the time the ignition switch is

turned to the LOCK position and the negative () ter


minal cable is disconnected from the battery.
2. REMOVE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE OIL (See page LU7)
5. REMOVE SUSPENSION LOWER CROSSMEMBER
(See step 24 on page EM189)
6. REMOVE FRONT EXHAUST PIPE
(See step 25 on page EM189)
7. REMOVE ENGINE MOUNTING CENTER MEMBER
(See step 31 on page EM 190)

LU10
LUBRICATION SYSTEM

Oil Pump (4AFE)

8. REMOVE OIL PAN


(a) Remove the nineteen bolts and two nuts.

(b) Insert the blade of SST between the cylinder block


and oil pan, cut off applied sealer and remove the oil
pan.
SST 0903200100
NOTICE:

Do not use SST for the oil pump body side and rear
oil seal retainer.
Be careful not to damage the oil pan flange.

9. REMOVE OIL STRAINER


Remove the two bolts, two nuts, oil strainer and gasket.

10. SUSPEND ENGINE WITH ENGINE CHAIN HOIST


11. REMOVE TIMING BELT
(See steps 2 to 15 and 17 to 20 on pages EM33 to 37)
12. REMOVE IDLER PULLEY AND CRANKSHAFT TIMING
PULLEY (See steps 21 and 22 on page EM38)

13. REMOVE OIL DIPSTICK AND DIPSTICK GUIDE


(a) Remove the dipstick.
(b) Remove the bolt, and pull out the dipstick guide.
(c) Remove the Oring from the dipstick guide.

LU11
LUBRICATION SYSTEM

Oil Pump (4AFE)

14. REMOVE OIL PUMP


(a) Remove the seven bolts.

(b) Using a plasticfaced hammer, remove the oil pump


by carefully tapping the oil pump body.

COMPONENTS

LU12
LUBRICATION SYSTEM

Oil Pump (4AFE)

DISASSEMBLY OF OIL PUMP


(See page LU11)
1. REMOVE RELIEF VALVE
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the retainer, spring and relief valve.

2. REMOVE DRIVE AND DRIVEN ROTORS


Remove the five screws, pump body cover, the drive and
driven rotors.

INSPECTION OF OIL PUMP


1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If it doesnt, replace the relief valve. If necessary, replace
the oil pump assembly.

2. INSPECT DRIVE AND DRIVEN ROTORS


A. Inspect rotor body clearance
Using a thickness gauge, measure the clearance between
the driven rotor and pump body.
Standard body clearance: 0.080 0.180 mm
(0 . 0031 0.0071 i n . )
Maximum body clearance: 0.20 mm (0.0079 in.)
If the body clearance is greater than maximum, replace
the rotors as a set. If necessary, replace the oil pump
assembly.
B. Inspect rotor tip clearance
Using a thickness gauge, measure the clearance between the
drive and driven rotor tips.
Standard tip clearance: 0.025 0.085 mm
(0. 0010 0.0033 in.)
Maximum tip clearance: 0.35 mm (0.0138 in.)
If the tip clearance is greater than maximum, replace the
rotors as a set.

LU13
LUBRICATION SYSTEM

Oil Pump (4AFE)

C. Inspect rotor side clearance


Using a thickness gauge and precision straight edge,
measure the clearance between the rotors and precision
straight edge.
Standard side clearance: 0.025 0.085 mm
(0.0010 0.0033 in.)
Maximum side clearance: 0.10 mm (0.0039 in.)
If the side clearance is greater than maximum, replace the
rotors as a set. If necessary, replace the oil pump assembly.

REPLACEMENT OF CRANKSHAFT FRONT


OIL SEAL
(See page EM207)

ASSEMBLY OF OIL PUMP


(See page LU11)
1. INSTALL DRIVE AND DRIVEN ROTORS
(a) Place the drive and driven rotors into pump body
with the marks facing the pump body cover side.

(b) Install the pump body cover with the five screws.
Torque: 10 Nm (105 kgfcm, 8 ftlbf)

2. INSTALL RELIEF VALVE


(a) Insert the relief valve, spring and retainer into the
pump body hole.
(b) Using snap ring pliers, install the snap ring.

LU14
LUBRICATION SYSTEM

Oil Pump (4AFE)

INSTALLATION OF OIL PUMP


(See page LU9)
1. INSTALL OIL PUMP
(a) Place a new gasket in position on the cylinder block.
(b) Engage the spline teeth of the oil pump drive rotor
with the large teeth of the crankshaft, and slide the
oil pump.

(c) Install the oil pump with the seven bolts.


Torque: 21 Nm (218 kgfcm, 16 ftlbf)

HINT: Each bolt length is indicated in the illustration.


Bolt length: Long bolt 35 mm (1.38 in.)
Others 25 mm (0.98 in.)

2. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK


(a) Install a new 0ring to the dipstick guide.
(b) Apply soaply water to the 0ring.
(c) Push in the dipstick guide, and install it with the
bolt.
Torque: 9.3 Nm (95 kgfcm, 82 in.lbf)

(d) Install the dipstick.

3. INSTALL CRANKSHAFT TIMING PULLEY AND IDLER


PULLEY (See steps 1 and 2 on page EM40)
4. INSTALL TIMING BELT
(See steps 3 to 6 and 8 to 21 on pages EM40 to 45)
5. REMOVE ENGINE CHAIN HOIST FROM ENGINE

6. INSTALL OIL STRAINER


Install a new gasket and the oil strainer with the two bolts
and two nuts.
Torque: 9.3 Nm (95 kgfcm, 82 in.Ibf)

LU15
LUBRICATION SYSTEM

Oil Pump (4AFE)

7. INSTALL OIL PAN


(a) Remove any old packing (FIPG) material and be
careful not to drop any oil on the contact surfaces of
the oil pan and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
Thoroughly clean all components to remove all
the loose material.
Using a nonresidue solvent, clean both sealing
surfaces.
NOTICE: Do not use a solvent which will affect the
painted surfaces.

(b) Apply seal packing to the oil pan as shown in the


illustration.
Seal packing: Part No. 0882600080 or equivalent
Install a nozzle that has been cut to a 3 5 mm
(0.12 0.20 in.) opening.
H I NT: Avoid applying an excessive amount to the surface.
Be particularly careful near oil passages.
Parts must be assembled within 5 minutes of application.
Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap.
(c) Install the oil pan with the nineteen bolts and two
nuts.
Torque: 4.9 Nm (50 kgfcm, 43 MAW)

8. INSTALL ENGINE MOUNTING CENTER MEMBER


(See step 10 on page EM216)
9. INSTALL FRONT EXHAUST PIPE
(See step 17 on page EM217)
10. INSTALL SUSPENSION LOWER CROSSMEMBER
(See step 18 on page EM218)
11. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
12. FILL WITH ENGINE OIL (See page LU8)
13. START ENGINE AND CHECK FOR LEAKS
14. RECHECK ENGINE OIL LEVEL (See page LU5)
15. INSTALL HOOD
16. INSTALL ENGINE UNDER COVERS

LU16
LUBRICATION SYSTEM

Oil Pump (3SGTE and 5SFE)

OIL PUMP (3SGTE and 5SFE)


REMOVAL OF OIL PUMP
HINT: When repairing the oil pump, the oil pan and
strainer should be removed and cleaned.

LU17
LUBRICATION SYSTEM

Oil Pump (3SGTE and 5SFE)

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL


O F BATTERY
CAUTION: Work must be started after approx. 20
seconds or longer from the time the ignition switch is
turned to the LOCK position and the negative () terminal
cable is disconnected from the battery.

2. REMOVE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE OIL (See page LU7)
5. REMOVE SUSPENSION LOWER CROSSMEMBER
3SGTE (See step 33 on page EM228)
5SFE (See step 28 on page EM274)
6. REMOVE FRONT EXHAUST PIPE
3SGTE (See step 34 on page EM229)
5SFE (See step 29 on page EM274)
7. REMOVE ENGINE MOUNTING CENTER MEMBER
3SGTE (See step 42 on page EM229)
5SFE (See step 34 on page EM275)
8. REMOVE STIFFENER PLATE
Remove the three bolts and stiffener plate.

9. (3SGTE)
DISCONNECT TURBO OIL PIPE HOSE FROM OIL PAN

10. REMOVE OIL PAN


(a) Remove the dipstick.
(b) Remove the seventeen bolts and two nuts.

LU18
LUBRICATION SYSTEM

Oil Pump (3SGTE and 5SFE)

(c) Insert the blade of SST between the cylinder block


and oil pan, cut off applied sealer and remove the oil
pa n.
SST 0903200100
NOTICE:

Do not use SST for the oil pump body side and rear
oil seal retainer.
Be careful not to damage the oil pan flange.

11. REMOVE OIL STRAINER AND BAFFLE PLATE


Remove the two bolts, two nuts, oil strainer, baffle plate
and gasket.

12. SUSPEND ENGINE WITH ENGINE CHAIN HOIST


13. REMOVE TIMING BELT
3SGTE (See steps 2 to 18 and 20 to 23 on pages EM
46 to 51)
5SFE (See steps 2 to 17 and 19 to 22 on pages EM
67 to 72)
14. REMOVE N0.2 IDLER PULLEY, CRANKSHAFT TIMING
PULLEY AND OIL PUMP PULLEY
3SGTE (See steps 25 to 27 on page EM52)
5SFE (See steps 24 to 26 on pages EM72 and 73)
15. REMOVE OIL PUMP
(a) Remove the twelve bolts.

(b) Using a plasticfaced hammer, remove the oil pump by


carefully tapping the oil pump dody.
(c) Remove the gasket.

LU19
LUBRICATION SYSTEM

Oil Pump (3SGTE and 5SFE)

COMPONENTS

DISASSEMBLY OF OIL PUMP


1. REMOVE RELIEF VALVE
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the retainer, spring and relief valve.

2. REMOVE DRIVE AND DRIVEN ROTORS


Remove the two bolts, pump body cover, 0ring, the
drive and driven rotors.

LU20
LUBRICATION SYSTEM

Oil Pump (3SGTE and 5SFE)

INSPECTION OF OIL PUMP


1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If it doesnt, replace the relief valve. If necessary, replace
the oil pump assembly.

2. INSPECT DRIVE AND DRIVEN ROTORS


A. Inspect rotor body clearance
Using a thickness gauge, measure the clearance between the
driven rotor and body.
Standard body clearance: 0.100 0.160 mm
(0.0039 0.0063 in.)
Maximum body clearance: 0.20 mm (0.0079 in.)
If the body clearance is greater than maximum, replace
the rotors as a set. If necessary, replace the oil pump
assembly.
B. Inspect rotor tip clearance
Using a thickness gauge, measure the clearance between the
drive and driven rotor tips.
Standard tip clearance: 0.040 0.160 mm
(0. 0016 0.0063 in.)
Maximum tip clearance: 0.20 mm (0.0079 in.)
If the tip clearance is greater than maximum, replace the
rotors as a set.

REPLACEMENT OF OIL PUMP OIL


SEAL
1. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal.

2. INSTALL OIL SEAL


(a) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump cover edge.
SST 0962030010 (0962730010, 0963100020)
(b) Apply MP grease to the oil seal lip.

REPLACEMENT OF CRANKSHAFT FRONT


OIL SEAL
(See page EM249)

LU21
LUBRICATION SYSTEM

Oil Pump (3SGTE and 5SFE)

ASSEMBLY OF OIL PUMP


(See page LU19)
1. INSTALL DRIVE AND DRIVEN ROTORS
(a) Place the drive and driven rotors into pump body
with the marks facing the pump body cover side.

(b) Install the pump body cover with the two bolts.
Torque: 8.8 Nm (90 kgfcm, 78 in.lbf)

2. INSTALL RELIEF VALVE


(a) Insert the relief valve, spring and retainer into the
pump body hole.
(b) Using snap ring pliers, install the snap ring.

INSTALLATION OF OIL PUMP


(See page LU16)
1. INSTALL OIL PUMP
Install a new gasket and the oil pump with the twelve
bolts.
Torque: 3SGTE 7.8 Nm (80 kgfcm, 69 in.lbf)
5SFE 8.8 Nm (90 kgfcm, 78 MAW)

HINT: Each bolt length is indicated in the illustration.


Bolt length: Long bolt 35 mm (1.38 in.)
Others 25 mm (0.98 in.)
2. INSTALL OIL PUMP PULLEY, CRANKSHAFT TIMING
PULLEY AND NO.2 IDLER PULLEY
3SGTE (See steps 1 to 3 on page EM55)
5SFE (See steps 1 to 3 on page EM75)
3. INSTALL TIMING BELT
3SGTE (See steps 5 to 8, 10 to 26 and 30 on pages
EM55 to 61)
5SFE (See steps 5 to 8 and 10 to 24 on pages EM 75
to 80)

LU22
LUBRICATION SYSTEM

Oil Pump (3SGTE and 5SFE)

4. REMOVE ENGINE CHAIN HOIST FROM ENGINE


5. INSTALL BAFFLE PLATE AND OIL STRAINER
Install a new gasket, the baffle plate and the oil strainer
with the two bolts and two nuts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)

6. INSTALL OIL PAN


(a) Remove any old packing (FIPG) material and be
careful not to drop any oil on the contact surfaces of
the oil pan and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
Thoroughly clean all components to remove all
the loose material.
Using a nonresidue solvent, clean both sealing
surfaces.
NOTICE: Do not use a solvent which will affect the

painted surfaces.
(b) Apply seal packing to the oil pan as shown in the
illustration.
Seal packing: Part No.0882600080 or equivalent
Install a nozzle that has been cut to a 3 5 mm
(0.12 0.20 in.) opening.
HINT: Avoid applying an excessive amount to the surface.
Be particularly careful near oil passages.
Parts must be assembled within 5 minutes of application.
Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap.

(c) Install the oil pan with the seventeen bolts and four
nuts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)

(d) Install the dipstick.

LU23
LUBRICATION SYSTEM

Oil Pump (3SGTE and 5SFE)

7. (3SGTE)
CONNECT TURBO OIL PIPE HOSE TO OIL PAN

8. INSTALL STIFFENER PLATE


Install the stiffener plate with the three bolts.
Torque: 37 Nm l380 kgfcm, 27 ftlbf)

9. INSTALL ENGINE MOUNTING CENTER MEMBER


3SGTE (See step 9 on page EM260)
5SFE (See step 9 on page EM304)
10. INSTALL FRONT EXHAUST PIPE
3SGTE (See step 18 on page EM261)
5SFE (See step 15 on page EM305)
11. INSTALL SUSPENSION LOWER CROSSMEMBER
3SGTE (See step 19 on page EM262)
5SFE (See step 16 on page EM306)
12. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
13. FILL WITH ENGINE OIL (See page LU8)
14. START ENGINE AND CHECK FOR LEAKS
15. RECHECK ENGINE OIL LEVEL (See page LU5)
16. INSTALL HOOD
17. INSTALL ENGINE UNDER COVERS

LU24
LUBRICATION SYSTEM

Oil Cooler (3SGTE)

OIL COOLER (3SGTE)


COMPONENTS

REMOVAL OF OIL COOLER


1. DISCONNECT CABLE FROM NEGATIVE TERMINAL
OF BATTERY
CAUTION: Work must be started after approx. 20
seconds or longer from the time the ignition switch is
turned to the LOCK position and the negative () terminal cable is disconnected from the battery.

2.
3.
4.
5.

DRAIN ENGINE COOLANT (See page CO6)


REMOVE ALTERNATOR (See page CH7)
REMOVE OIL FILTER (See page LU7)
DISCONNECT WATER BYPASS HOSE FROM OIL
COOLER

LU25
LUBRICATION SYSTEM

Oil Cooler (3SGTE)

6. REMOVE OIL COOLER


.(a) Remove the relief valve and plate washer.
(b) Remove the two nuts, oil cooler and two gaskets.
(c) Remove the 0ring from the oil cooler.

(d) Remove the bolt, and disconnect the water bypass


pipe from the oil cooler bracket.

7. REMOVE OIL COOLER BRACKET


(a) Remove the four bolts and oil cooler bracket.
(b) Remove the two 0rings from the oil cooler.

INSPECTION OF OIL COOLER


1. INSPECT RELIEF VALVE
Push the valve with a wooden stick to check if it is stuck.
If stuck, replace the relief valve.

2. INSPECT OIL COOLER


Check the oil cooler for damage or clogging.
If necessary, replace the oil cooler.

LU26
LUBRICATION SYSTEM

Oil Cooler (3SGTE)

INSTALLATION OF OIL COOLER


(See page LU24)
1. INSTALL OIL COOLER BRACKET
(a) Install two new 0rings to the oil cooler bracket.

(b) Apply a light coat of engine oil on the small 0ring.

(c) Install the oil cooler bracket with the four bolts.
Torque: 7.8 Nm (80 kgfcm, 69in.lbf)

2. INSTALL OIL COOLER


(a) Install new 0ring and gasket to the oil cooler.

(b) Temporarily install the water bypass pipe with the


bolt.

LU27
LUBRICATION SYSTEM

Oil Cooler (3SGTE)

(c) Apply a light coat of engine oil on the threads and


under the head of the relief valve.
(d) Temporarily install two new gaskets and the oil
cooler with the plate washer, relief valve and two
nuts.

(e) Tighten the relief valve.


Torque: 78 Nm (800 kgfcm, 58 ftlbf)

(f) Tighten the two nuts holding the oil cooler to the
water bypass pipe..
Torque: 12 Nm (120 kgfcm, 9 ftlbf)

(g) Tighten the bolt holding the water bypass pipe to


oil cooler bracket.
Torque: 18 Nm (180 kgfcm, 13 ftlbf)

3. CONNECT WATER BYPASS HOSE TO OIL COOLER

4. INSTALL OIL FILTER (See page LU7)


5. INSTALL ALTERNATOR (See page CH23)
6. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
7. FILL WITH ENGINE COOLANT (See page CO6)
8. START ENGINE AND CHECK FOR LEAKS
9. CHECK ENGINE OIL LEVEL (See page LU5)

LU28
LUBRICATION SYSTEM

Oil Cooler (5SFE)

OIL COOLER (5SFE)


COMPONENTS

REMOVAL OF OIL COOLER


1. DISCONNECT CABLE FROM NEGATIVE TERMINAL
OF BATTERY

CAUTION: Work must be started after approx. 20


seconds or longer from the time the ignition switch is
turned to the LOCK position and the negative () terminal cable is disconnected from the battery.

2. REMOVE RH ENGINE UNDER COVER


3. DRAIN ENGINE COOLANT (See page CO6)
4. REMOVE FRONT EXHAUST PIPE
(See step 30 on page EM274)
5. REMOVE ALTERNATOR (See page CH9)
6. REMOVE EXHAUST MANIFOLD AND CATALYTIC
CONVERTER ASSEMBLY
(See step 14 on pages EM 151 and 152)
7. REMOVE OIL FILTER (See page LU7)

LU29
LUBRICATION SYSTEM

Oil Cooler (5SFE)

8. REMOVE WATER BYPASS HOSE HEAT PROTECTOR


Remove the bolt, two nuts and heat protector.

9. DISCONNECT WATER BYPASS HOSES FROM OIL


COOLER
Disconnect the two water bypass hoses.

10. REMOVE OIL COOLER


(a) Remove the relief valve and plate washer.
(b) Remove the nut and oil cooler.
(c) Remove the 0ring and gasket from the oil cooler.

INSPECTION OF OIL COOLER


1. INSPECT RELIEF VALVE
Push the valve with a wooden stick to check if it is stuck.
If stuck, replace the relief valve.

2. INSPECT OIL COOLER


Check the oil cooler for damage or clogging.
If necessary, replace the oil cooler.

LU30
LUBRICATION SYSTEM

Oil Cooler (5SFE)

INSTALLATION OF OIL COOLER


(See page LU28)
1. INSTALL OIL COOLER
(a) Install new 0ring and gasket to the oil cooler.

(b) Apply a light coat of engine oil on the threads and


under the head of the relief valve.
(c) Temporarily install the oil cooler with the nut.
(d) Install the plate washer and relief valve.
Torque: 800 kgcm (58 ftIb, 78 Nm)

(e) Tighten the nut.


Torque: 80 kgcm (69 in.Ib, 7.8 Nm)

2. CONNECT WATER BYPASS HOSES


Connect the two water bypass hoses.

3. INSTALL WATER BYPASS HOSE HEAT PROTECTOR


Install the heat protector with the bolt and two nuts.
4. INSTALL OIL FILTER (See page LU7)
5. INSTALL EXHAUST MANIFOLD AND CATALYTIC
CONVERTER ASSEMBLY
(See step 27 on page EM182)
6. INSTALL ALTERNATOR (See page CH25)
7. INSTALL FRONT EXHAUST PIPE
(See step 15 on page EM305)
8. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
9. FILL WITH ENGINE COOLANT (See page CO6)
10. START ENGINE AND CHECK FOR LEAKS
11. CHECK ENGINE OIL LEVEL (See page LU5)
12. INSTALL RH ENGINE UNDER COVER

LU31
LUBRICATION SYSTEM

Oil Nozzles (3SGTE)

OIL NOZZLES (3SGTE)


COMPONENTS

REMOVAL OF OIL NOZZLES


1. REMOVE CRANKSHAFT (See pages EM224 to 239)
2. REMOVE OIL NOZZLES (WITH RELIEF VALVES)
Using a 5 mm hexagon wrench, remove the bolt and oil
nozzle. Remove the four oil nozzles.

INSPECTION OF OIL NOZZLES


INSPECT RELIEF VALVES (OIL NOZZLES)
Push the valve with a wooden stick to check if it is stuck.
If stuck, replace the relief valve.

INSTALLATION OF OIL NOZZLES


1. INSTALL OIL NOZZLES (WITH RELIEF VALVES)
Using a 5 mm hexagon wrench, install the oil nozzle with
the bolt. Install the four oil nozzles.
Torque: 9.1 Nm (93 kgfcm, 81 in.lbf)

2. REMOVE CRANKSHAFT (See pages EM253 to 267)

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