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ENGINE LUBRICATION &

COOLING SYSTEMS

SECTION LC

CONTENTS

ZD

TD27Ti

PRECAUTIONS AND PREPARATION . ...........................2

Liquid Gasket Application Procedure ..........................2

Special Service Tools ..................................................2

ENGINE LUBRICATION SYSTEM ..................................3

Lubricating Circuit ........................................................3

Oil Pressure Check ......................................................4

Oil Pump ......................................................................5

Oil Jet ...........................................................................7

Oil Cooler .....................................................................8

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

Cooling Circuit .............................................................9

System Check ............................................................10

Water Pump ............................................................... 11

Thermostat .................................................................12

Water Outlet ...............................................................13

Radiator .....................................................................14

Cooling Fan (Crankshaft driven) ...............................15

EGR Cooler ...............................................................16

SERVICE DATA AND SPECIFICATIONS (SDS) ..........17

Engine Lubrication System ........................................17

Engine Cooling System .............................................17

PREPARATION ..............................................................18

PRECAUTION ................................................................19

ENGINE LUBRICATION SYSTEM ................................20

Lubrication Circuit ......................................................20

Oil Pressure Check. ...................................................21

Oil Pump ....................................................................22

Oil Filter Bracket ........................................................24

Oil Cooler ...................................................................25

Oil Jet .........................................................................26

ENGINE COOLING SYSTEM ........................................27

Cooling Circuit ...........................................................27

System Inspection .....................................................28

Water Pump ...............................................................29

Thermostat .................................................................31

Radiator .....................................................................32

Cooling Fan ...............................................................33

SERVICE DATA AND SPECIFICATIONS (SDS) ..........34

Engine Lubrication System ........................................34

Engine Cooling System .............................................34

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ZD

PRECAUTIONS AND PREPARATION

Liquid Gasket Application Procedure

a.

Use a scraper to remove all traces of old liquid gasket from

mating surfaces and grooves. Also, completely clean any oil

from these areas.

b.

Apply a continuous bead of liquid gasket to mating surfaces.

(Use Genuine Liquid Gasket or equivalent.)

I

For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm

(0.138 to 0.177 in).

I

For areas except oil pan, be sure liquid gasket diameter is

2.0 to 3.0 mm (0.079 to 0.118 in).

c.

Apply liquid gasket around the inner side of bolt holes (unless

otherwise specified).

SEM164F

d.

Assembly should be done within 5 minutes after coating.

e.

Wait at least 30 minutes before refilling engine oil and engine

coolant.

AEM080

Special Service Tools

*: Special tool or commercial equivalent

Tool number

Tool name

Description

ST25051001*

Oil pressure gauge

Measuring oil pressure

Maximum measuring range:

2,452 kPa (24.5 bar, 25

kg/cm 2 , 356 psi)

NT558

ST25052000*

Hose

Adapting oil pressure gauge

to cylinder block

NT559

EG17650301

Radiator cap tester

adapter

Adapting radiator cap tester

to radiator filler neck and reser-

voir tank cap

a: 28 (1.10) dia.

b: 31.4 (1.236) dia.

c: 41.3 (1.626) dia.

Unit: mm (in)

NT564

LC-2

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ZD

ENGINE LUBRICATION SYSTEM

Lubricating Circuit

SLC361B

LC-3

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ZD

ENGINE LUBRICATION SYSTEM

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

rpm

Approximate discharge pressure

kPa (bar, kg/cm 2 , psi)

Idle speed

2,000

4,000

More than 147 (1.47, 1.5, 21)

More than 539 (5.39, 5.5, 78)

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:

:13-17N

×

m (1.25 - 1.75 kg-m,9-12ft-lb)

LC-4

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ZD

ENGINE LUBRICATION SYSTEM

Oil Pump

REMOVAL AND INSTALLATION

Refer to “TIMING GEAR” in EM section.

DISASSEMBLY AND ASSEMBLY

JLC363B

I

When installing oil pump, apply new engine oil to gears.

I

When installing the inner and outer gear, face mating mark

toward the oil pump cover as shown (left).

JLC364B

LC-5

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