SUBARU. 1992 SERVICE MANUAL ENGINE LUBRICATION SYSTEM WOVVVOENNS M MECHANISM AND FUNCTION 1, General .. 3, Oil Pump. 4, Oil Filter .. 5. Oil Pan & Oil 6. Oil Pressure Switch . 7. Oil Cooler .. $ SPECIFICATION AND SERVICE DATA © COMPONENT PARTS 4. Oil Pump W SERVICE PR 1. Oil Pump 2. Oil Cooler .. T TROUBLESHOOTING2 [M101 ENGINE LUBRICATION SYSTEM M MECHANISM AND FUNCTION 1. General 1. SOHC MODEL ‘The lubrication system is @ full-flow, filtering type. The pump utilizes a thin, large-diemeter trochoid design to accommodate the high engine output, It is directly riven by the crankshaft, Engine oil flow is regulated by the relief valve bi the oll pump. Itis then delivered to the journal bearings, connecting rod bearings, etc., via the oil passage (on the lower right side of the cylinder block), oil filter, and the oil gallery (on the right of the cylinder block) to provide proper lubrication. Engine oil is also fed under pressure to the cylinder head valve mechanism after the flow is regulated by the orifice provided in the oil gallery. The rocker shaft has a built-in relief valve on the end so proper oil pressure is, delivered to the hydraulic lash adjusters. The oil pan is provided with baffle plates to eliminate the effect of oil suction caused by oil level variations during operation, Unit: kPa (ka/em? os) Fig. 1 2. DOHC MODEL The lubrication system is a fulllow, filtering type. The oil pump uses a thin, large-diameter, trochoid design to. ‘match high engine output and is directly driven by the crankshaft. A water-cooled, oil cooler is located between the oil filter and cylinder block to maintain an optimum engine oil temperature and prevent the degradation of lu tion performance. Engine oil is pressure-reguleted by the relief valve inside the oil pump and is delivered to the oil cooler via ‘the oll gallery on the lower side of the right-hand cylin- der block. After engine oil is cooled by the oil cooler, it is filtered by the oil filter and is then delivered to the ci gallery inside the right-hand cylinder block, From the oil gallery, the engine oil is distributed to the left and right main galleries to lubricate the main bearings and vari- ous functional parts. Part of the oil delivered to the main bearings is delivered to the connecting rod bearings via the oil passages in the crankshaft, while part of the oll is injected into the inner walls of the cylinders and pistons for proper lubrication. ‘The valve mechanism on the cylinder head is also lubri- cated by engine oil under pressure which is regulated for the flow rate at the orifice A relief valve is built into the H.LA. gallery to deliver stabilized oil pressure to the hydraulic lash adjusters. The front camshaft bearings are lubricated by engine cil delivered through the oil galleries in the camshafts. The oil pan is provided with baffle plates, preventing oll from being drawn in by changes in the oil level.y ENGINE LUBRICATION SYSTEM {M102} 2-4 ‘ tt Unit: KPo tha/em?, pal Fig. 2ENGINE LUBRICATION SYSTEM 2-4 [M201 2. Lubrication Lines 1. SOHC MODEL aT coy, | ue tpou | Sa aH Gare 2142musnot sea spun a : g a i en [ Baar BOUL seyewses sees} uso nae 410 ees} [corms one 2 om rE (Pevy sp UIRAD fe iemenrag. 6 2 ed na 0 Ht SSS See nm ES ES Cece eee r + 2 Co El ongen potions ara < onan sone — " g = 5 2 Tenn pare prey w Pe fepcraes veneigea arenas iseuxa} 2 aww no 2 tomeeon ne pf Geezad Pores) ._[ ayaysues onoife—{ Coma) prea | exer) ones 1 | eneasmene | ven wo] _ ayeysuses oxeut| buuauindelae Ayeyeuies oe Peay spUIAD cow Ls wale ware LY prow mewn farmer], amma toner | | cw pononnn' ce ‘muet ae a Tamas, [PL semen a monet ‘arog Fae g seusnof st 3 banssesd 10 g 3 new 7 Tues) Bumeg isa ea a 9 Fig. 441300] 3. Oil Pump ENGINE LUBRICATION SYSTEM. loner rotor Front oll sal Fig. 5 ‘The trochoid oil pump utilizes an internal oil circulation design which is accomplished by an inner rotor and ‘outer rotor built into the pump body. When the inner rotor Is driven by the crankshaft, the outer rotor is rotated, changing the size of the space between the two rotors (because of the different number of teeth used ‘on the rotors). Pump cover tie val etiot spring Pog Washer Engine oil is sucked into the large space created near the inlet side. It is then carried over to the discharge port and discharged due to it being gradually pressur- ized as the space carrying it becomes smaller. Oil pre sure is regulated by the relief valve located on the dis- charge side. Excess oil is directly returried to the suc- tion port.ENGINE LUBRICATION SYSTEM 4, Oil Filter [MBBO) filter element has a special pleat design to incr effective filtering area. 5, Oil Pan & Oil Str The oil pan is joined to the cylinder block vie liquid gasket. The oll strainer is a metal net type and removes large foreign particles from the engine oil. It is located in the middle of the oil pan. The pipe from the strainer is connected to the suction port on the left side of the ‘eylinder block. Baffle plates are placed in the oil pan and the lower side of the cylinder block to stabilize the cil level and strengthen the oil pan. 6. Oil Pressure Switch A: CONSTRUCTION The oll pressure switch is located on the front right upper portion of the cylinder block, The purpose of this switch is to monitor the operation of the oll pump as ‘well as the lubriceting oil pressure when the engine is running. Pleat designed element posae 1 Contsets 4 Molded portion 2 Diaphragm 5 Terminal 3 Spring po148 Fig. 7 1) When oil pressure does not bulld up (with ignition switch “ON"}: ‘The diaphragm is pushed toward the cylinder block by spring force (equivalent to the specified oil pressure). This closes the contact point to illuminate the oil pilot famp on the instrument panel. 2) When oil pressure reaches the specified value (after engine starts): After oil pressure reaches the specified value of (14.7 kPa (0.15 kg/em?, 2.1 psi), the diaphragm, pushed by oll pressure, overcomes the spring force. This opens the contact point to tum the oil pilot lamp off.2-4 [M700] ENGINE LUBRICATION SYSTEM 7. Oil Cooler (DOHC model only) in DOHC models is of a water cooled type. It serves to maintain engine oil in proper temperature range and so prevent degradation of lubri- cating oil performance. The oll cooler use connector ol fer 2.785 Fig. &ENGINE LUBRICATION SYSTEM [s0Ag] 2-4 S$ SPECIFICATIONS AND SERVICE DATA A: SPECIFICATIONS eee SOHC oHe mem Lubrication method Forced lubrication Pump type Trochotd type. Rare aen Tenor rotor ° Outer rotor 70 (Outer rotor diameter x thicknass ‘mam (in) 78x 9 (307 x 0.35) 78% 10(3.07 x 030) Tip clesrance between inner STO (0.04 — 0.14 (0.0016 — 0.0086) febshoreal teal om (i) fin 19.18 (0.0071) Side clearance between inner STO. 0.02 — 0.07 (0.0008 — 0.0028) ot pump [Fouad pump cate mm tev UN 0.12 (0.0087), Cece clearance betwoan outer S10 0.10 — 0.175 (0.0080 — 0,006) Fotor and pump case wn Gr) ne 0:20 (0.0078), = pressure 88 kPa (1.0 kalom?, 14 pal 600 rpm | Diechargo paseo ~auenity | 42 €(64 US qt 87 imp qtlimin, | 4.6 €(4.9US at 40 imp atin, aoe (176) pressure 204 KPa (3.0 kglem, 43 pai) 5,000 rpm | Discharge 42.0 ¢ (11.10 US gal 4.0 ¢ (12.42 US gal, quantity 8.24 imp gal/min. 10.34 tmp galyin, elif valve operation pressure “480 KPa (60 ko/om®, 71 pai) | 668 KPa (6.0 kalom?, 85 psi) Type Fulltiow fter ype. Fitration area 1,000 om? (165 sain) oiltiter — [By-pese vaive opening pressure 155 kPa (1.6 ke/er, 23 ped (Outer diameter x wich am in 80x 70 (8.15 x278) Oil fiter to engine thvead size M2015 ch cooer | = Water cooled type Core dimensions rm = 83 dia. x 10 (8.66 dia, x 0.39) Rolit valve (or fydraulc lash edjustr) operation pressure 69 1a (0.7 koe, 10 psi). Type Immersed contact point type it proseure [Working voltage — wattage T2V— 8.4 W or loss switch [Warning Wiaht activation pressure 147 Wa (0.18 kale, 2.1 psi) Proof prossure ‘More than 881 Ka (10 ka/em 142 pel Oil capacty (at replacement) A5CGBUS GL 40Imoat | 626 (65US at 46 imp ad2-4 [C101] ENGINE LUBRICATION SYSTEM © COMPONENT PARTS 1, Oil Pump 4, SOHC MODEL ‘Tightening torque: Nem (kgm, fb) Th: 6.4 (0.65, 4.7) 72: 505, 3.6) 73: 10(4.0,7) 7 18 Front oll sealEl NGINE LUBRICATION SYSTEM. [C102] 2-4 2. DOHC MODEL = 71 Fig. 10 it pume ASSY 19 Outer rotor 20 Pump cover 21 Rolot valve 22 Reliet spring 23 Washer Oil pan 24 Plug Oi evel gouge 28 Front ol vee! Pump case 26 Oxing Inna rotor 27 Owing Tightening torque: Nem (kgm, ftb) Ti: 6.4 (0.65, 4.7) T2: 6 (05, 3.6) T3: 10 (1.0, 7) ‘Ta: 49-59 2706W SERVICE PROCEDURE q. Oil Pump A: REMOVAL 1) Drain engine oil 2) Drain coolant 3) Remove belt covers, drive belt and related parts. (Refer to “2-3 ENGINE”) 4) Remove belt tensioner bracket. 5) Remove water pump. 6) Remove oil pump. Insert a standard screwdriver as shown in Figure 11. Be careful not to scratch mating surfaces of cylinder block and oll pump. ENGINE LUBRICATION SYSTEM B: DISASSEMBLY 1 5-6105-06,36-43) Front ol el TE Nem (eg, feb) Be-1480 Fig. 11 Fig. 12 Remove screws which secure oil pump cover and dis- assemble oil pump, Inscribe alignment marks on inne! that they can be replaced in the ing reassembly. 1oving reliof valve, loosen plug when remov- block. id outer rotors s0 inal positions dur- ing oil pump from eyliENGINE LUBRICATION SYSTEM 4, TIP CLEARANCE Measure the tip clearance of rotors. If the clearance exceeds the limit, replace rotors as a matched set. ee Tip clearance: Standard 0.04 — 0.14 mm (0.0016 — 0.0085 In) Limit (0.18 mm (0.0071 in) Fig. 13 2, CASE CLEARANCE Measure the clearance between the outer rotor and the pump case. If the clearance exceeds the limit, replace the rotor or pump case. Case clearance: ‘Standard 0,10 — 0,176 mm (0.0039 — 0.0069 in) Limit 0.20 mm (0.0079 in) Fig. 14 3. SIDE CLEARANCE Measure clearance between oil pump inner rotor and pump cover. If the clearance exceeds the limit, replace rotor or pump ca (0.02 — 0,07 mm (0.0008 — 0.0028 in} Limit 0.12 mm (0.0047 in) 2.989) Fig. 15 4, OIL RELIEF VALVE Check the valve for fitting condition and damage, the relief valve spring for damage and deterioration. Replace the parts if defective. Relief valve spring: SOHC model Froe length mm (2.827 in) Installed length 84.7 mm (2.154 in) Load when instelled 7.08 N (7.86 kg, 17.33 tb) DOHC model Froe length 78.7 mm (2.902 in) Installed length 84.7 mm (2.154 in) Load when installed 93.2 N (95 kg, 20.9 Ib) ——— ——-_ 5. OIL PUMP CASE Check the oil pump case for worn shaft hole, clogged oll passage, worn rotor chamber, cracks, and other faults. 6. OIL SEAL Check the oil seal lips for deformation, hardening, wear, etc, and replace if defective. 132-4 {0080} ENGINE LUBRICATION SYSTEM. D: ASSEMBLY E: INSTALLATION 1) Install front oil seal. Use a new oil set ‘OIL SEAL INSTALLER (499587100) 82.069) Fig. 16 tions. 3) Install oil relief valve and relief spring. 4) Install oil pump cover. 2) Install inner and outer rotors in their origins! posi- T_5-6105~06,26-49) Inner rotor Pump cate Outer ater Raia spring ToT ~a76 (18 — 435, 5.1) Front oil T+ Nim thom, feab) 2.1480, Installation is in the reverse order of removal, Observe the following: 1) Apply fluid packing to matching surfaces of oil pump. packi Three bond 1215 of equivalent 3) Be careful not to scratch oil seal when installing oil Pump on cylinder block, Apply liquid packing to oil pressure switch threads before installation.i ENGINE LUBRICATION SYSTEM {o1co} 2-4 2, Oil Cooler (DOHC model only) A; REMOVAL 4) Remove front exhaust pipe. Refer to "2-9 Exhaust syste! 2) Remove water pipe. B: INSPECTION 1) Check that coolant passages are not clogged using ait-blow method. 2) Check mating surfaces of cylinder block. O-ring groove and oil filter for damage. C: INSTALLATION 1) Install oil cooler on cylinder block with connector pipe. 2) Install oil filter. Fig. 19 3) Romove oil filter. 4) Remove connector and remove oil cooler. e285 Tightening torque: Nem (kg-m, ft1b) 49 ~ 59 (6.0 — 6.0, 36 ~ 43) Bee7t Fig. 21 Always use @ new O-ring. 3) Install front exhaust pipe. Refer to “2-9 Exhaust system”. Fig. 202-4 17000} ENGINE LUBRICATION SYSTEM 2. prog) ENGINE LUBRICATION SYSTEM T TROUBLESHOOTING \ Before troubleshooting, make sure that the engine oil level is correct and no oil leakage exists. F rouble Possible couse Coractve ection [cracked diaphvegm or ol leekage within switch Broken spring or seized contacts i [Glogged oi fier 4 aitunction of ol by-pa86 valve a a fiter | Clean or replace. E Malfunction of ot rellf valve of oll pump | Glean or replace, 1. Waning ight remains on |) CW 9H Pressure Cogged ok pessage Sean. F Econ peracetic ln ; [cioaged oi strainer or broken pipe Cloan or replace. 4 Insufficient engine oll Replenish, : 2) No ol pressure Broken pipe of oil strainer Replace [Stuck ol pump rotor Raplace j 1) Burn-out bulb Replace 2 varring ght does net 8° |) poor contact of switch contact points Replat 3) Disconnection of wiring Repel, 1) Poor contact at terminals Repal. 8. Warning ght flickers) 2} Defective wiring hemess Repel. i momentarily. (Check forthe seme possible 3} Low oil pressure causes op listed in 12). 16