Engine Lubrication & Cooling Systems

ENGINE LUBRICATION &
COOLING SYSTEMS GI
SECTION LC MA
EM
EC
CONTENTS FE
QG COMPONENTS .......................................................17
CL
CONTROL SYSTEM ................................................17
ENGINE LUBRICATION SYSTEM..................................3 Changing Engine Coolant..........................................17
Precautions ..................................................................3 MT
- DRAINING ENGINE COOLANT - ............................17
LIQUID GASKET APPLICATION PROCEDURE ............3 - REFILLING ENGINE COOLANT - ...........................18
Preparation ..................................................................3 - FLUSHING COOLING SYSTEM -............................19
SPECIAL SERVICE TOOLS ........................................3
AT
Radiator (Aluminum type)..........................................20
Lubrication Circuit ........................................................4 PREPARATION .......................................................20
Oil Pressure Check......................................................5 DISASSEMBLY ........................................................20 AX
Oil Pump ......................................................................5 ASSEMBLY .............................................................21
REMOVAL AND INSTALLATION .................................5 INSPECTION ...........................................................22
DISASSEMBLY AND ASSEMBLY................................6 Overheating Cause Analysis .....................................23 SU
INSPECTION .............................................................7 Service Data and Specifications (SDS).....................24
REGULATOR VALVE INSPECTION ............................7 THERMOSTAT ........................................................24
Changing Engine Oil....................................................8 RADIATOR ..............................................................24 BR
Changing Oil Filter.......................................................9 COOLANT CAPACITY ..............................................24
Service Data and Specifications (SDS).....................10
OIL PRESSURE CHECK ..........................................10 YD
ST
OIL PUMP INSPECTION ..........................................10
REGULATOR VALVE INSPECTION ..........................10 ENGINE LUBRICATION SYSTEM................................25
OIL CAPACITY ........................................................10 Precautions ................................................................25 RS
ENGINE COOLING SYSTEM........................................11 LIQUID GASKET APPLICATION PROCEDURE ..........25
Precautions ................................................................11 Preparation ................................................................25
SPECIAL SERVICE TOOLS ......................................25
BT
LIQUID GASKET APPLICATION PROCEDURE ..........11
Preparation ................................................................11 Lubrication Circuit ......................................................26
SPECIAL SERVICE TOOLS ......................................11 Oil Pressure Check....................................................27 HA
Cooling Circuit ...........................................................12 Oil Pump ....................................................................28
System Check............................................................12 REMOVAL AND INSTALLATION ...............................28
CHECKING COOLING SYSTEM HOSES ...................12 DISASSEMBLY AND ASSEMBLY..............................28 SC
CHECKING RADIATOR ............................................13 OIL PUMP INSPECTION ..........................................28
CHECKING RADIATOR CAP ....................................13 REGULATOR VALVE INSPECTION ..........................29
CHECKING COOLING SYSTEM FOR LEAKS ............13 Changing Engine Oil..................................................30 EL
Water Pump ...............................................................14 Oil Filter Bracket (Separated Type)...........................31
REMOVAL AND INSTALLATION ...............................14 REMOVAL AND INSTALLATION ...............................31
INSPECTION ...........................................................14 Oil Filter Bracket (Assembled Type)..........................31 IDX
Thermostat.................................................................15 REMOVAL AND INSTALLATION ...............................32
REMOVAL AND INSTALLATION ...............................15 Changing Oil Filter (Separated Type)........................32
INSPECTION ...........................................................16 REMOVAL ...............................................................32
Radiator .....................................................................16 INSTALLATION........................................................33
COMPONENTS .......................................................16 Changing Oil Filter (Assembled Type) ......................33
Cooling Fan ...............................................................17 REMOVAL ...............................................................33
CONTENTS (Cont’d)
INSTALLATION........................................................34 LIQUID GASKET APPLICATION PROCEDURE ..........52
Oil Cooler...................................................................34 Preparation ................................................................53
REMOVAL AND INSTALLATION ...............................35 SPECIAL SERVICE TOOLS ......................................53
Service Data and Specifications (SDS).....................35 Engine Oil Inspection.................................................53
OIL PRESSURE CHECK ..........................................35 OIL LEVEL AND MUDDINESS ..................................53
REGULATOR VALVE INSPECTION ..........................35 OIL LEAKAGE .........................................................53
OIL PUMP INSPECTION ..........................................35 Oil Pressure Check....................................................54
ENGINE OIL CAPACITY ...........................................35 Oil Pump ....................................................................55
ENGINE COOLING SYSTEM........................................36 REMOVAL AND INSTALLATION ...............................55
Precautions ................................................................36 Changing Engine Oil..................................................56
LIQUID GASKET APPLICATION PROCEDURE ..........36 Changing Oil Filter.....................................................57
Preparation ................................................................36 REMOVAL ...............................................................57
SPECIAL SERVICE TOOLS ......................................36 INSTALLATION........................................................57
Cooling Circuit ...........................................................37 Oil Cooler...................................................................58
System Check............................................................38 REMOVAL ...............................................................58
CHECKING COOLING SYSTEM HOSES ...................38 INSPECTION ...........................................................59
CHECKING RADIATOR ............................................38 INSTALLATION........................................................59
CHECKING RADIATOR CAP ....................................38 ENGINE COOLING SYSTEM........................................60
CHECKING COOLING SYSTEM FOR LEAKS ............39 Precautions ................................................................60
Water Pump ...............................................................39 REMOVAL OF LIQUID GASKET ...............................60
REMOVAL AND INSTALLATION ...............................39 LIQUID GASKET APPLICATION PROCEDURE ..........60
REMOVAL ...............................................................40 Preparation ................................................................61
INSPECTION ...........................................................40 SPECIAL SERVICE TOOLS ......................................61
INSTALLATION........................................................40 System Check............................................................61
Thermostat.................................................................41 CHECKING COOLING SYSTEM HOSES ...................61
REMOVAL AND INSTALLATION ...............................41 CHECKING RADIATOR ............................................61
INSPECTION ...........................................................42 CHECKING RADIATOR CAP ....................................62
Radiator .....................................................................42 CHECKING COOLING SYSTEM FOR LEAKS ............62
COMPONENTS .......................................................42 Water Pump ...............................................................63
REMOVAL AND INSTALLATION ...............................43 REMOVAL AND INSTALLATION ...............................63
Cooling Fan ...............................................................43 REMOVAL ...............................................................63
COMPONENTS (WITHOUT COMMON RAIL) .............43 INSPECTION AFTER REMOVAL ..............................64
COMPONENTS (WITH COMMON RAIL)....................44 INSTALLATION........................................................64
CONTROL SYSTEM ................................................44 INSPECTION AFTER INSTALLATION .......................64
Changing Engine Coolant..........................................44 Radiator .....................................................................65
- DRAINING ENGINE COOLANT - ............................44 COMPONENTS .......................................................65
- REFILLING ENGINE COOLANT - ...........................45 REMOVAL ...............................................................65
- FLUSHING COOLING SYSTEM -............................46 INSTALLATION........................................................66
Radiator (Aluminum type)..........................................47 Cooling Fan ...............................................................66
PREPARATION .......................................................47 COMPONENTS .......................................................66
DISASSEMBLY ........................................................47 DISASSEMBLY ........................................................67
ASSEMBLY .............................................................48 ASSEMBLY .............................................................67
INSPECTION ...........................................................49 Changing Engine Coolant..........................................67
Overheating Cause Analysis .....................................50 - DRAINING ENGINE COOLANT - ............................67
Service Data and Specifications (SDS).....................51 - REFILLING ENGINE COOLANT - ...........................68
THERMOSTAT ........................................................51 - FLUSHING COOLING SYSTEM -............................68
RADIATOR ..............................................................51 Radiator (Aluminum type)..........................................69
ENGINE COOLANT CAPACITY ................................51 PREPARATION .......................................................69
DISASSEMBLY ........................................................69
K9K ASSEMBLY .............................................................70
INSPECTION ...........................................................71
ENGINE LUBRICATION SYSTEM................................52 Overheating Cause Analysis .....................................72
Precautions ................................................................52
REMOVAL OF LIQUID GASKET ...............................52
LC-2
ENGINE LUBRICATION SYSTEM QG
Precautions
Precautions
LIQUID GASKET APPLICATION PROCEDURE
1. Use a scraper to remove all traces of old liquid gasket from
NJLC0001
GI
mating surfaces and grooves. Also, completely clean any oil
from these areas. MA
2. 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 EM
(0.138 to 0.177 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
EC
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant. FE
CL
AEM080
MT
Preparation
SPECIAL SERVICE TOOLS AT
NJLC0002
Tool number
Description AX
Tool name
ST25051001 Measuring oil pressure

Oil pressure gauge
SU
BR
NT050
ST25052000 Adapting oil pressure gauge to cylinder block

Hose ST
RS
NT559
BT
KV10115801 Removing oil filter
Oil filter wrench HA
SC
NT772
WS39930000 Pressing the tube of liquid gasket EL

Tube presser
IDX
NT052
LC-3
Lubrication Circuit
Lubrication Circuit NJLC0003
YLC020
YLC045
LC-4
Oil Pressure Check
Oil Pressure Check NJLC0004

WARNING:
I Be careful not to burn yourself, as the engine and oil may GI
be hot.
I For M/T models, put gearshift lever in Neutral “N” posi-
tion. For A/T models, put selector lever in Park “P” posi-
MA
tion.
1. Check oil level. EM
2. Remove oil pressure switch.
SEM853F
3. Install pressure gauge.

4. Start engine and warm it up to normal operating temperature.
EC
5. Check oil pressure with engine running under no-load.
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi) FE
600 More than 98 (0.98, 1.0, 14)
2,000 More than 294 (2.94, 3.0, 43)

CL
6,000 More than 392 (3.92, 4.0, 57)
SLC926-A
MT
I If difference is extreme, check oil passage and oil pump
for oil leaks.
6. Install oil pressure switch with sealant. AT
: 13 - 17 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)
AX
SU
BR
Oil Pump ST
REMOVAL AND INSTALLATION NJLC0005
I Make sure that O-ring is fitted properly.
1. Drain engine oil. RS
2. Remove drive belts.
3. Remove oil pan. Refer to EM-27, “OIL PAN AND OIL BT
STRAINER”.
4. Remove oil strainer.
5. Remove front cover. Refer to EM-52, “TIMING CHAIN”. HA
6. Install front cover.
7. Reinstall parts in reverse order of removal.
SC
EL
IDX
LC-5
Oil Pump (Cont’d)
DISASSEMBLY AND ASSEMBLY NJLC0006
YLC022-A
1. Oil pump cover 4. Front cover 7. Spring

2. Inner rotor 5. Oil strainer 8. Washer
3. Outer rotor 6. Regulator valve 9. Plug
I When installing oil pump, apply engine oil to rotors.
I Install the inner rotor and outer rotor with the punched
marks on the oil pump cover side.
JLC307B
LC-6
Oil Pump (Cont’d)
INSPECTION NJLC0007
Using a feeler gauge, check the following clearances.
Standard clearance: GI
Unit: mm (in)
Body to outer rotor radial clearance 1 0.250 - 0.325 (0.0098 - 0.0128)

MA
Inner rotor to outer rotor tip clearance
Below 0.18 (0.0071)
2
EM
Body to inner rotor clearance 3 0.030 - 0.085 (0.0012 - 0.0033)
Body to outer rotor axial clearance 4 0.030 - 0.090 (0.0012 - 0.0035)

SEM855F
Inner rotor to brazed portion of hous-
0.045 - 0.091 (0.0018 - 0.0036)
ing clearance 5
EC
FE
CL
SEM856F
MT
I If the tip clearance (2) exceeds the limit, replace rotor set.
I If body to rotor clearances (1, 3, 4, 5) exceed the limit, AT
replace front cover assembly.
AX
SU
BR
ST
RS
BT
HA
SEM857FA
REGULATOR VALVE INSPECTION NJLC0008

SC
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring. EL
3. Coat regulator valve with engine oil.
Check that it falls smoothly into the valve hole by its own
weight.
IDX
If damaged, replace regulator valve set or front cover assem-
bly.
SLC986AA
LC-7
Oil Pump (Cont’d)
4. Check regulator valve to front cover clearance.
Clearance 6:
0.052 - 0.088 mm (0.0020 - 0.0035 in)
If it exceeds the limit, replace front cover assembly.
SLC101B
Changing Engine Oil NJLC0035

WARNING:
I Be careful not to burn yourself, as the engine oil is hot.
I Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine com-
ponents.
2. Stop engine and wait more than 10 minutes.
SMA915C 3. Remove drain plug and oil filler cap.
4. Drain oil and refill with new engine oil.
Oil specification and viscosity (Except for Europe):
I API grade SE, SF, SG, SH or SJ
I ILSAC grade GF-I & GF-II
Oil specification and viscosity (For Europe):
I API grade SG, SH or SJ
I ILSAC grade GF-I & GF-II
Refer to MA-25, “RECOMMENDED FLUIDS AND LUBRI-
CANTS”.
Refill oil capacity (Approximate):
Unit: (Imp qt)
With oil filter change 2.9 (2-1/2)
Without oil filter change 2.7 (2-3/8)
Dry engine (engine overhaul) 3.0 (2-5/8)
CAUTION:
I Be sure to clean drain plug and install with new washer.
Drain plug:
: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
I The refill capacity changes depending on the oil tempera-
ture and drain time, use these values as a reference and
be certain to check with the dipstick when changing the
oil.
LC-8
Changing Engine Oil (Cont’d)
5. Check oil level.
6. Start engine and check area around drain plug and oil filter for
oil leakage. GI
7. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
MA
EM
YLC044
Changing Oil Filter NJLC0010

The oil filter is a small, full-flow cartridge type and is provided with EC
a relief valve.
I Use Tool KV10115801 for removing oil filter.
FE
CL
ALC094
MT
1. Remove oil filter with Tool.
WARNING: AT
Be careful not to burn yourself, as the engine and the engine
oil are hot.
AX
SU
BR
SLC275B
2. Clean oil filter mounting surface on cylinder block. Coat rubber

seal of new oil filter with engine oil. ST
RS
BT
HA
SMA010
3. Screw in the oil filter until a slight resistance is felt, then tighten SC
an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil. EL
I Clean excess oil from engine.
IDX
SMA229B
LC-9
Service Data and Specifications (SDS)

OIL PRESSURE CHECK NJLC0011

rpm kPa (bar, kg/cm2, psi)
600 More than 98 (0.98, 1.0, 14)
2,000 More than 294 (2.94, 3.0, 43)
6,000 More than 392 (3.92, 4.0, 57)
OIL PUMP INSPECTION NJLC0013

Unit: mm (in)
Body to outer rotor radial clearance 0.250 - 0.325 (0.0098 - 0.0128)
Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)
Body to inner rotor clearance 0.030 - 0.085 (0.0012 - 0.0033)
Body to outer rotor axial clearance 0.030 - 0.090 (0.0012 - 0.0035)
Inner rotor to brazed portion of housing clear-

0.045 - 0.091 (0.0018 - 0.0036)
ance

Unit: mm (in)
Regulator valve to oil pump cover clearance 0.052 - 0.088 (0.0020 - 0.0035)
OIL CAPACITY NJLC0036

Unit: (Imp qt)
LC-10
ENGINE COOLING SYSTEM QG
Precautions
Precautions
NJLC0014
GI
(0.138 to 0.177 in).
SEM164F
to 3.0 mm (0.079 to 0.118 in).
EC
coolant. FE
CL
AEM080
MT
Preparation
NJLC0015
Tool number
Description AX
Tool name
EG17650301 Adapting radiator cap tester to radiator filler neck

Radiator cap tester a: 28 (1.10) dia.
adapter b: 31.4 (1.236) dia.
SU
c: 41.3 (1.626) dia.
Unit: mm (in)
BR
NT564
KV99103510 Installing radiator upper and lower tanks

ST
Radiator plate pliers A
RS
NT224
KV99103520 Removing radiator upper and lower tanks

Radiator plate pliers B BT
NT225
HA
SC
EL
IDX
LC-11
Cooling Circuit
Cooling Circuit NJLC0016
SLC317B
System Check NJLC0017

WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure fluid 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 NJLC0017S01
Check hoses for the following:
I Improper attachment
I Leaks
I Cracks
I Damage
I Loose connections
I Chafing
I Deterioration
LC-12
System Check (Cont’d)
CHECKING RADIATOR NJLC0017S04
Check radiator for mud or clogging. If necessary, clean radiator as
follows. GI
I Be careful not to bend or damage the radiator fins.
I When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, rediator shroud and horns.
MA
Then tape the harness and connectors to prevent water from
entering. EM
1. Apply water by hose to the back side of the radiator core ver-
tically download.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor. EC
4. Blow air into the back side of radiator core vertically download.
I Use compressesd air lower than 490 kPa (4.9 bar, 5 kg/cm2, FE
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out. CL
MT
CHECKING RADIATOR CAP NJLC0017S03
To check radiator cap, apply pressure to cap with a tester. AT
Radiator cap relief pressure:
Standard
AX
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit SU
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
BR
SLC613-A
Pull the negative pressure valve to open it.

Check that it closes completely when released. ST
RS
BT
HA
SMA967B
CHECKING COOLING SYSTEM FOR LEAKS NJLC0017S02

SC
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure: EL
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION: IDX
Higher pressure than specified may cause radiator damage.
SLC756AA
LC-13
Water Pump
Water Pump
SEM858FB
CAUTION:
I When removing water pump assembly, be careful not to
get coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
I After installing water pump, and check for leaks using
radiator cap tester.
1. Drain engine coolant.
Refer to LC-17, “Changing Engine Coolant”.
2. Remove drive belts and idler pulley.
SEM859F 3. Loosen water pump pulley bolts.
4. Remove water pump pulley.
5. Remove front right wheel.
6. Remove front right undercover and front right fender protector.
7. Remove water pump bolts.
8. Remove water pump.
9. Reinstall parts in reverse order of removal.
INSPECTION NJLC0019
I Check body assembly and vane for rust or corrosion.
I Check for rough operation due to excessive end play.
SEM860F
LC-14
Thermostat
Thermostat
GI
MA
EM
EC
FE
CL
SEM861FB
MT
Be careful not to spill coolant over engine compartment. Use
a rag to absorb coolant. AT
1. Drain engine coolant.
Refer to LC-17, “Changing Engine Coolant”.
2. Remove water inlet, then take out thermostat. AX
SU
BR
3. Install gum ring to thermostat.
ST
RS
BT
HA
SEM862F
4. Install thermostat with jiggle valve or air bleeder at upper side. SC

After installation, run engine for a few minutes, and check
for leaks.
EL
IDX
SEM863F
LC-15
Thermostat (Cont’d)
INSPECTION NJLC0022
1. Check for valve seating condition at normal room temperature.
It should seat tightly.
2. Check valve opening temperature and valve lift.
Valve opening temperature °C (°F) 82 (180)
Valve lift mm/°C (in/°F) More than 8/95 (0.31/203)
3. Then check if valve closes at 5°C (9°F) below valve opening

temperature.
SLC343
Radiator
COMPONENTS NJLC0025
YLC016-A
1. Reservoir tank 5. Mounting bracket 9. Oil cooler hose (A/T models)

2. Reservoir tank bracket 6. Radiator 10. Upper radiator hose
3. Reservoir hose 7. Mounting rubber 11. Cooling fan assembly
4. Radiator cap 8. Lower radiator hose
LC-16
Cooling Fan
Cooling Fan NJLC0026

COMPONENTS NJLC0026S01
GI
MA
EM
EC
FE
CL
MT
AT
AX
YLC023
SU
BR
CONTROL SYSTEM NJLC0026S02

Cooling fans are controlled by the ECM. For details, refer to
ST
EC-342 (WITH EURO-OBD) or EC-621 (WITHOUT EURO-OBD),
“DTC P1217 ENGINE OVER TEMPERATURE”. RS
BT
HA
Changing Engine Coolant NJLC0037

SC
WARNING:
To avoid the danger of being scalded, never change the cool-
ant when the engine is hot. EL
— DRAINING ENGINE COOLANT — NJLC0037S01
1. Set air conditioning system as follows to prevent coolant from IDX
remaining in the system.
a. Turn ignition switch ON and set temperature controller to maxi-
mum hot position.
b. Wait 10 seconds before turning ignition switch OFF.
LC-17
Changing Engine Coolant (Cont’d)
2. Remove lower radiator hose, and remove radiator filler cap to
drain coolant.
3. Remove reservoir tank, drain coolant, then clean reservoir
tank.
I Be careful not to allow coolant to contact drive belts.
4. Cover the exhaust tube heat shield to prevent from splashing
coolant.
SMA033D
5. Remove drain plug on cylinder block and air relief plug.

6. Check drained coolant for contaminants such as rust, corro-
sion or discoloration. If contaminated flush engine cooling
system, refer to LC-19, “FLUSHING COOLING SYSTEM”.
7. Blow the coolant around the exhaust tube heat shield.
SLC277B
SLC278B
— REFILLING ENGINE COOLANT — NJLC0037S02

1. Install reservoir tank, lower radiator hose and cylinder block
drain plug.
I Apply sealant to the thread of cylinder block drain plug.
: 35 - 44 N·m (3.50 - 4.50 kg-m, 26 - 32 ft-lb)
2. Fill radiator slowly with coolant until coolant spills from the air
relief plug, then install air relief plug.
Air relief plug:
: 6.7 - 7.8 N·m (0.68 - 0.80 kg-m, 59 - 69 in-lb)
I Use genuine Nissan anti-freeze coolant or equivalent
mixed with water (distilled or demineralized).
LC-18
Refer to MA-25, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Coolant capacity (With reservoir tank):
Unit: (Imp qt) GI
M/T 6.7 (5-7/8)
For Sedan 6.6 (5-7/8) MA

A/T
For Hatchback 6.7 (5-7/8)
EM
Reservoir tank capacity:
0.7 (5/8 Imp qt)
SMA182B I Pour coolant through coolant filler neck slowly to allow air
in system to escape.
3. Fill radiator and reservoir tank to specified level.
4. Warm up engine to normal operating temperature without
EC
radiator cap installed.
I If coolant overflows radiator filler hole, install filler cap. FE
5. Run engine at 2,500 rpm for 10 seconds and return to idle
speed with radiator cap installed.
I Repeat two or three times. CL
Watch coolant temperature gauge so as not to overheat the
engine.
SMA412B
MT
6. Stop engine and cool it down.
I Cool down using a fan to reduce the time.
I If necessary, refill radiator up to filler neck with coolant. AT
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 4 through 7 two or more times with radiator cap
installed until coolant level no longer drops. AX
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of coolant flow while SU
running engine from idle up to 3,000 rpm with heater tempera-
ture controller set at several positions between COOL and
HOT. BR
I Sound may be noticeable at heater water cock.
11. If sound is heard, bleed air from cooling system by repeating
steps 4 through 7 until coolant level no longer drops ST
I Clean excess coolant from engine.
— FLUSHING COOLING SYSTEM — NJLC0037S03
RS
1. Open air relief plug.
2. Fill radiator with water until water spills from the air relief hole, BT
then close air relief plug. Fill radiator and reservoir tank with
water and reinstall radiator cap.
3. Run engine and warm it up to normal operating temperature. HA
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water. SC
7. Repeat steps 1 through 6 until clear water begins to drain from
radiator. EL
IDX
LC-19
Radiator (Aluminum type)
Radiator (Aluminum type) NJLC0081

PREPARATION NJLC0081S01
SLC882AH
1. Attach the spacer to the tip of the radiator plate pliers A.

Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in)
wide x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A are closed dimen-
sion H′′ is approx. 7.6 mm (0.299 in).
3. Adjust dimension H′′ with the spacer, if necessary.
SLC655C
DISASSEMBLY NJLC0081S02
1. Remove tank with Tool.
SLC903
I Grip the crimped edge and bend it upwards so that Tool slips
off.
Do not bend excessively.
SLC893
LC-20
Radiator (Aluminum type) (Cont’d)
I In areas where Tool cannot be used, use a screwdriver to bend
the edge up.
Be careful not to damage tank. GI
MA
EM
SLC930
2. Make sure the edge stands straight up.

3. Remove oil cooler from tank. (A/T model only)
EC
FE
CL
SLC931
MT
ASSEMBLY NJLC0081S03
1. Install oil cooler. (A/T model only) AT
Pay attention to direction of conical washer.
AX
SU
BR
SLC894
2. Clean contact portion of tank.

ST
RS
BT
HA
SLC932
3. Install sealing rubber. SC

Push it in with fingers.
Be careful not to twist sealing rubber.
EL
IDX
SLC917A
LC-21
4. Caulk tank in specified sequence with Tool.
SLC904
SLC896
I Use pliers in the locations where Tool cannot be used.
SLC897
5. Make sure that the rim is completely crimped down.

Standard height “H”:
8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage.
Refer to Inspection.
SLC554A
INSPECTION NJLC0081S04
1. Apply pressure with Tool.
Specified pressure value:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler as well. (A/T model only)
SLC933
LC-22
2. Check for leakage.
GI
MA
EM
SLC934
Overheating Cause Analysis NJLC0028
Symptom Check items EC

Water pump malfunction Worn or loose drive belt
Thermostat stuck closed —

FE
Dust contamination or
Poor heat transfer Damaged fins paper clogging — CL
Mechanical damage
Clogged radiator cooling Excess foreign material MT

tube (rust, dirt, sand, etc.)
Cooling fan does not oper- AT

ate
Reduced air flow High resistance to fan rota- — —

tion AX
Damaged fan blades
Damaged radiator shroud — — — SU

Improper coolant mixture
— — —
Cooling sys- ratio BR
tem parts
malfunction Poor coolant quality — — —
Loose clamp ST
Cooling hose
Cracked hose
Water pump Poor sealing RS

Loose
Radiator cap
Poor sealing BT
Coolant leaks
O-ring for damage, deterio-
Insufficient coolant ration or improper fitting HA
Radiator
Cracked radiator tank
Cracked radiator core SC

Reservoir tank Cracked reservoir tank
Cylinder head deterioration EL

Exhaust gas leaks into
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration
IDX
LC-23
Overheating Cause Analysis (Cont’d)
Symptom Check items
High engine rpm under no

load
Driving in low gear for

Abusive driving
extended time
Driving at extremely high

speed
— Overload on engine
Powertrain system malfunc-
tion
Installed improper size

Except cool- wheels and tires —
ing system
parts mal- Dragging brakes
function
Improper ignition timing
Blocked bumper —
Installed car brassiere

Blocked radiator grille Mud contamination or
Blocked or restricted air paper clogging —
flow
Blocked radiator —
Blocked condenser
—
Installed large fog lamp

THERMOSTAT NJLC0029
Valve opening temperature °C (°F) 82 (180)
Valve lift mm/°C (in/°F) More than 8/95 (0.31/203)
RADIATOR NJLC0030
Unit: kPa (bar, kg/cm2, psi)
Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)

Cap reliefpressure
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure 157 (1.57, 1.6, 23)
COOLANT CAPACITY NJLC0038

Unit: (Imp qt)
M/T* 6.7 (5-7/8)
Sedan 6.6 (5-7/8)

A/T*
Hatchback 6.7 (5-7/8)
Reservoir tank 0.7 (5/8)
*: With reservoir tank
LC-24
ENGINE LUBRICATION SYSTEM YD
Precautions
Precautions
NJLC0039
GI
(0.157 to 0.197 in).
SEM164F
to 3.0 mm (0.079 to 0.118 in).
EC
coolant. FE
CL
AEM080
MT
Preparation
NJLC0040
Tool number
Description AX
Tool name
ST25051001
Oil pressure gauge
SU
BR
NT050
ST25052000 Adapting oil pressure gauge to upper oil pan

Hose ST
RS
NT559
BT
WS39930000 Pressing the tube of liquid gasket
Tube pressure HA
SC
NT052
EL
IDX
LC-25
Lubrication Circuit
Lubrication Circuit NJLC0041
YLC024
LC-26
Oil Pressure Check

WARNING:
I Be careful not to burn yourself, as the engine and oil may GI
be hot.
I Oil pressure check should be done in “Neutral position”.
MA
1. Check oil level.
2. Remove exhaust front tube.
3. Remove oil pressure switch. EM
4. Install pressure gauge.
SLC283B
5. Install exhaust front tube.
6. Start engine and warm it up to normal operating temperature.
7. Check oil pressure with engine running under no-load.
EC
rpm kPa (bar, kg/cm2, psi)
Idle speed More than 140 (1.40, 1.43, 20.3) FE

2,000 More than 270 (2.69, 2.75, 39.1)
4,000 More than 430 (4.29, 4.38, 62.3) CL

If difference is extreme, check oil passage and oil pump
JLC284B for oil leaks. MT
8. After the inspections, install the oil pressure switch as follows.
a. Remove the old sealant adhering to the switch and engine. AT
b. Apply Genuine Liquid Gasket or equivalent to the thread and
tighten.
: 13 - 17 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb) AX
SU
BR
SLC926-A
ST
RS
BT
HA
SC
EL
IDX
LC-27
Oil Pump
Oil Pump
REMOVAL AND INSTALLATION =NJLC0043
I When installing oil pump, apply engine oil to rotors.
Refer to EM-27, “Primary Timing Chain” (Without common rail) or
EM-178, “PRIMARY TIMING CHAIN” (With common rail) for
removal.
Reinstall all parts in the reverse order of removal.
DISASSEMBLY AND ASSEMBLY NJLC0044
JLC285B

I Install the inner rotor and outer rotor with the punched
marks on the pump cover side.
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
Body to outer rotor radial clearance 1 0.114 - 0.260 (0.0045 - 0.0102)
Inner rotor to outer rotor tip clearance

Below 0.18 (0.0071)
2
JLC286B Body to inner rotor axial clearance 3 0.050 - 0.090 (0.0020 - 0.0035)
Body to outer rotor axial clearance 4 0.030 - 0.190 (0.0012 - 0.0075)
Inner rotor to brazed portion of hous-

0.045 - 0.091 (0.0018 - 0.0036)
ing clearance 5
I If the tip clearance (2) exceeds the limit, replace rotor set.
I If body to rotor clearances (1, 3, 4, 5) exceed the limit,
replace oil pump body assembly.
JLC355B
LC-28
Oil Pump (Cont’d)
GI
MA
EM
JLC356B
EC
FE
CL
JLC338B
MT
1. Visually inspect components for wear and damage. AT
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls
AX
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump body. SU
BR
4. Check regulator valve to oil pump body clearance.
Clearance 6:
ST
6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump body. RS
BT
HA
JLC358B
SC
EL
IDX
LC-29
Changing Engine Oil
Changing Engine Oil NJLC0074

WARNING:
cause skin cancer; try to avoid direct skin contact with
ponents.
2. Stop engine and wait more than 10 minutes.
SLC287B 3. Remove drain plug and oil filler cap.
Oil Specification and Viscosity (Except for Europe):
I API CD, CE, CF or CF-4
Oil Specification and Viscosity (For Europe):
I API grade CF-4
CANTS”.
Refill oil capacity (Approximately):
Unit: (Imp qt)
YLC044 Without oil filter

4.9 (4-3/8)
change
Drain and refill
With oil filter
5.4 (4-3/4)
change
CAUTION:
Drain plug:
: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
I The refill capacity depends on the oil temperature and
drain time. Use these specifications for reference only.
Always use the dipstick to determine when the proper
amount of oil is in the engine.
5. Check oil level.
6. Start engine and check area around drain plug and oil filter for
oil leakage.
7. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
LC-30
Oil Filter Bracket (Separated Type)
Oil Filter Bracket (Separated Type) NJLC0075
GI
MA
EM
EC
FE
CL
JLC301BA
REMOVAL AND INSTALLATION MT

NJLC0075S01
1. Remove the undercover.
2. Steer the front wheel to the right. AT
3. Remove the right splash cover.
4. Remove the oil filter bracket bolt.
5. Reinstall all removed parts in the reverse order of removal.
AX
I Insert the top mounting bolt to the oil filter bracket beforehand,
and set the oil filter bracket to the installation location. SU
BR
Oil Filter Bracket (Assembled Type) NJLC0084 ST
RS
BT
HA
SC
EL
IDX
YLC070
LC-31
Oil Filter Bracket (Assembled Type) (Cont’d)
REMOVAL AND INSTALLATION NJLC0084S01
1. Remove the undercover.
2. Steer the front wheel to the right.
3. Remove the right splash cover.
4. Remove the oil filter bracket bolt.
I Insert the top mounting bolt to the oil filter bracket beforehand,
and set the oil filter bracket to the installation location.
Changing Oil Filter (Separated Type) NJLC0076
JLC289B
REMOVAL NJLC0076S01
1. Using a socket wrench [plane-to-plane width: 17 mm (0.67 in)],
loosen the filter body approximately four turns.
SLC428B
2. Drain the oil after matching the “DRAIN” arrow mark at the
bottom of the filter body to the protrusion on the oil filter
bracket.
I Catch the oil with a pan or cloth.
CAUTION:
I The drained oil flows over the right surface of the filter
body.
I Completely wipe clean any engine oil remaining on the
filter body or vehicle.
3. Remove the filter body, then remove the oil filter element.
JLC291B
LC-32
Changing Oil Filter (Separated Type) (Cont’d)
4. Remove the O-ring from the filter body.
I Push the O-ring in one direction, lift the slack part using
fingers, and remove the O-ring from the filter body. GI
CAUTION:
Do not use wires or flat-bladed screwdrivers etc. as they may
cause damage to the filter body. MA
EM
JLC292B
INSTALLATION NJLC0076S02
1. Completely remove all foreign objects adhering to the inside of EC
the filter body or O-ring mounting area (body side and bracket
side).
2. Install the oil filter element and O-ring to the filter body. FE
I Push the oil filter element into the filter body completely.
3. Install the filter body to the oil filter bracket.
: 20 - 24 N·m (2.0 - 2.5 kg-m, 15 - 18 ft-lb) CL
4. After warming up the engine, check for engine oil leakage.
MT
Changing Oil Filter (Assembled Type) NJLC0085
AT
AX
SU
BR
ST
RS
BT
HA
MBIB1013E
REMOVAL NJLC0085S01
SC
1. Using a socket wrench [plane-to-plane width: 17 mm (0.67 in)],
loosen the oil filter approximately four turns.
EL
IDX
SLC428B
LC-33
Changing Oil Filter (Assembled Type) (Cont’d)
2. Drain the oil after matching the “DRAIN” arrow mark at the
bottom of the oil filter to the protrusion on the oil filter bracket.
I Catch the oil with a pan or cloth.
CAUTION:
I The drained oil flows over the right surface of the oil fil-
ter.
I Completely wipe clean any engine oil remaining on the oil
filter or vehicle.
3. Remove the oil filter.
JLC291B
4. Remove the O-ring from the oil filter.

I Push the O-ring in one direction, lift the slack part using
fingers, and remove the O-ring from the oil filter.
CAUTION:
Do not use wires or flat-bladed screwdrivers etc. as they may
cause damage to the oil filter.
YLC063
1. Completely remove all foreign objects adhering to the inside of
the oil filter or O-ring mounting area (filter side and bracket
side).
2. Install O-ring to the oil filter.
3. Install the oil filter to the oil filter bracket.
: 20 - 24 N·m (2.0 - 2.5 kg-m, 15 - 18 ft-lb)
Oil Cooler NJLC0077
YLC050-B
LC-34
Oil Cooler (Cont’d)
REMOVAL AND INSTALLATION NJLC0077S01
1. Draining the coolant
Refer to LC-44, “Changing Engine Coolant”. GI
2. Remove the exhaust front tube.
MA
EM

I Confirm that no foreign objects are adhering to the installation
planes of the oil cooler or block.
EC
I Tighten the connecting bolt after aligning the stopper on the
cylinder block side with protrusion of the oil cooler. FE
CL
YLC027
MT
OIL PRESSURE CHECK AT
NJLC0048

rpm kPa (bar, kg/cm2, psi) AX
Idle speed More than 140 (1.40, 1.43, 20.3)
2,000 More than 270 (2.69, 2.75, 39.1) SU

4,000 More than 430 (4.29, 4.38, 62.3)
REGULATOR VALVE INSPECTION

BR
NJLC0049
Unit: mm (in)
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038) ST
Unit: mm (in) RS
Body to outer rotor radial clearance 0.114 - 0.260 (0.0045 - 0.0102)
Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)

BT
Body to inner rotor axial clearance 0.050 - 0.090 (0.0020 - 0.0035)
Body to outer rotor axial clearance 0.030 - 0.190 (0.0012 - 0.0075)

HA
Inner rotor to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036)
SC
ENGINE OIL CAPACITY NJLC0078
Unit: (Imp qt)

EL
Drain and refill (Approximately)
IDX
LC-35
ENGINE COOLING SYSTEM YD
Precautions
Precautions
LIQUID GASKET APPLICATION PROCEDURE NJLC0051
from these areas.
(Use Genuine Liquid Gasket.)
I For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
SEM164F
to 3.0 mm (0.079 to 0.118 in).
coolant.
AEM080
Preparation
SPECIAL SERVICE TOOLS NJLC0052
Tool number
Description
Tool name

Radiator cap tester a: 28 (1.10) dia.
adapter b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
NT564

NT224

Radiator plate pliers B
NT225
LC-36
Cooling Circuit
Cooling Circuit NJLC0053
GI
MA
EM
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
YLC068
LC-37
System Check
System Check NJLC0054

WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSES NJLC0054S01
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR NJLC0054S02
follows.
rounding parts such as cooling fan, radiator shroud and horns.
entering.
tically downward.
2. Apply water again to all radiator core surfaces once per
minute.
tor.
4. Blow air into the back side of radiator core vertically downward.
I Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71
psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.

To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
SLC755AC
Pull the negative pressure valve to open it.

Check that it closes completely when released.
I Check the radiator cap negative pressure valve for contamina-
tion or damage to the valve seat.
I Move the negative pressure valve to check for abnormalities to
the opening/shutting operation.
CAUTION:
I Be sure to perform the inspections after cooling down the
engine.
I Before connecting the radiator cap to the tester, apply
SMA967B water or LLC to the cap sealing.
LC-38
I Replace the radiator cap if abnormalities are found with the
negative pressure valve, or if the valve opening pressure is out
of the standard range. GI
MA
EM

To check for leakage, apply pressure to the cooling system with a EC
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) FE
CAUTION:
I Higher than the specified pressure may cause radiator
damage. CL
I Be sure to perform the inspections after cooling down the
engine.
MT
SLC756AA
I Use a hose adapter between the cap tester and filler neck
to prevent the radiator filler neck from deforming.
I If any abnormalities are found, repair or replace the malfunc- AT
tioning parts.
AX
SU
BR
Water Pump ST
CAUTION:
I When removing water pump assembly, be careful not to RS
get coolant on drive belt.
replaced as a unit. BT
I After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
HA
SC
EL
IDX
LC-39
Water Pump (Cont’d)
JLC294BA
REMOVAL NJLC0056
1. Remove the undercover, splash cover (right), and accessory
belt.
2. Drain engine coolant. Refer to LC-44, “Changing Engine Cool-
ant”.
3. Support the bottom of the oil pan with a floor jack etc., and
remove the right engine mount bracket (front side of the
engine).
4. Remove the water pump pulley.
I Loosen the pulley bolts after fixing the pulley using a screw-
driver etc.
5. Remove engine mount brackets.
6. Remove the water pump.
INSPECTION NJLC0057
I Check for rust and contamination adhering to the water pump
and vane.
I Turn the pump shaft by hand, and check that the pump turns
smoothly without looseness.
INSTALLATION NJLC0058
I Install the parts in the reverse order of removal.
I Install the water pump pulley with the front mark (painted white,
used to prevent errors during assembly) facing the front of the
engine. Refer to the figure above.
LC-40
Thermostat
Thermostat
GI
MA
EM
EC
FE
CL
MT
AT
AX
YLC069
SU
I Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.
BR
ant”. ST
2. Remove exhaust manifold cover.
3. Remove water inlet. RS
4. Remove thermostat.
BT
HA
5. Install thermostat with jiggle valve facing upward. SC

I Carefully install the rubber ring to the flange of the
thermostat, making sure it does not slip out of place.
6. After installation and refilling coolant, run engine for a few EL
minutes, and check for leaks.
IDX
JLC300B
LC-41
Thermostat (Cont’d)
INSPECTION NJLC0060
1. Check valve seating condition at ordinary room temperatures.
It should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Standard
Valve opening temperature Above 80.5 - 83.5°C (177 - 182°F)
Valve lift More than 9 mm/95°C

(0.354 in/203°F)
SLC252B 3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.
Radiator
COMPONENTS NJLC0083
SLC430B
LC-42
Radiator (Cont’d)
1. Remove under cover.
2. Drain coolant by removing lower radiator hose. GI
3. Disconnect radiator upper and lower hoses.
4. Remove radiator shroud. MA
5. Disconnect reservoir tank hose.
6. Remove radiator mounting bracket.
7. Remove radiator. EM
8. After repairing or replacing radiator, install any part removed in
reverse order of removal.
When filling radiator with coolant, refer to LC-44, “Changing
Engine Coolant”.
EC
FE
CL
MT
COMPONENTS (WITHOUT COMMON RAIL) AT
NJLC0064S01
AX
SU
BR
ST
RS
BT
HA
SC
EL
JLC347B IDX
LC-43
Cooling Fan (Cont’d)
COMPONENTS (WITH COMMON RAIL) NJLC0064S03
YLC056
CONTROL SYSTEM NJLC0064S04

Cooling fans are controlled by ECM. For details, refer to EC-131,
“DTC P1217 OVER HEAT” (Without common rail) or EC-894
(WITH EURO-OBD) or EC-1181 (WITHOUT EURO-OBD), “DTC
P0217 ENGINE OVER TEMPERATURE” (With common rail).
Changing Engine Coolant NJLC0079
WARNING:
To avoid the danger of being scalded, never change the cool-
ant when the engine is hot.
1. Set air conditioning system as follows to prevent coolant from
remaining in the system.
a. Turn ignition switch ON and set temperature controller to maxi-
mum hot position.
JLC295B b. Wait 10 seconds before turning ignition switch OFF.
2. Remove lower radiator hose, and remove radiator filler cap to
drain coolant.
tank.
I Be careful not to allow coolant to contact drive belts.
4. Cover the exhaust tube heat shield to prevent from splashing
coolant.
SMA033D
LC-44
5. Remove drain plug of cylinder block and air relief plug.
6. Check drained coolant for contaminants such as rust, corro-
sion or discoloration. If contaminated flush engine cooling GI
system, refer to LC-46, “FLUSHING COOLING SYSTEM”.
7. Blow the coolant around the exhaust tube heat shield.
NOTE:
MA
An asterisk (*1) in the figure means “Not installed on some
models”.
EM
JLC429B
EC
FE
CL
YLC026
MT
1. Install reservoir tank, radiator drain cock or lower radiator hose AT
and cylinder block drain plug.
I Apply sealant to the thread of cylinder block drain plugs.
: 8 - 11 N·m (0.8 - 1.2 kg-m, 70 - 104 in-lb)
AX
2. Fill radiator slowly with coolant until coolant spills from the air
relief plugs, then install air relief plugs. SU
I Location of air relief plugs
Water inlet and rear side intake manifold water tubes
3. Disconnect heater hose at engine, pour coolant into the hose BR
JLC298B so that it flows toward the heater core.
I While filling, if coolant from engine side spills out, be sure to
reconnect the heater hose. ST
I Fill coolant to the level of the radiator cap at a rate of 2 (1-3/4
Imp qt)/min or lower. RS
(Close the air relief plugs in order starting with the location from
where the coolant began spilling out.)
CAUTION: BT
If the filling rate is too fast, this could lead to air being mixed
in the coolant. Be sure to fill the coolant slowly according to
the rate indicated above. HA
I Replace the copper washer of the air bleeding plug.
Air relief plug:
: 6.7 - 7.9 N·m (0.68 - 0.81 kg-m, 59 - 70 in-lb)
SC
mixed with water (distilled or demineralized). EL
IDX
LC-45
Refer to MA-25, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Engine coolant capacity (With reservoir tank):
8.7 (7-5/8 Imp qt)
Reservoir tank capacity:
0.7 (5/8 Imp qt)
I Pour coolant through coolant filler neck slowly to allow air
in system to escape.
4. Fill radiator and reservoir tank to specified level.
5. Warm up engine to normal operating temperature without
SMA182B
I If coolant overflows radiator filler hole, install radiator cap.
I Repeat two or three times.
engine.
7. Stop engine and cool it down.
I If necessary, refill radiator up to filler neck with coolant.
SMA412B 9. Repeat steps 4 through 7 two or more times with radiator cap
installed until coolant level no longer drops.
11. Warm up engine, and check for sound of coolant flow while
ture controller set at several positions between COOL and
HOT.
I Sound may be noticeable at heater water cock.
steps 4 through 7 until coolant level no longer drops
1. Open air relief plug.
2. Fill radiator with water until water spills from the air relief hole,
3. Run engine and warm it up to normal operating temperature.
6. Drain water.
radiator.
LC-46
Radiator (Aluminum type) =NJLC0086

GI
MA
EM
EC
FE
CL
YLC057-A
MT
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in) AT
sion H′′ is approx. 7.6 mm (0.299 in). AX
SU
BR
SLC655C
DISASSEMBLY
NJLC0086S02 ST
RS
BT
HA
SLC903
I Grip the crimped edge and bend it upwards so that Tool slips SC
off.
EL
IDX
SLC893
LC-47
the edge up.
Be careful not to damage tank.
SLC930
SLC931
SLC932
2. Install sealing rubber.

SLC917A
SLC904
LC-48
GI
MA
EM
SLC896

EC
FE
CL
SLC897
MT
Standard height “H”: AT
8.0 - 8.4 mm (0.315 - 0.331 in)
AX
SU
BR
SLC554A
INSPECTION
NJLC0086S04 ST
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) RS
WARNING:
pressure, securely fasten it down with a hose clamp. BT
HA
SLC933
2. Check for leakage. SC
EL
IDX
SLC934
LC-49
Overheating Cause Analysis
Symptom Check items
Poor heat transfer Damaged fins paper clogging —
Mechanical damage
Clogged radiator cooling Excess foreign material

Cooling fan does not oper-

ate

tion
Damaged fan blades
Damaged radiator shroud — — —

— — —
ratio
Cooling sys-
tem parts Poor coolant quality — — —
malfunction Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Radiator cap
Poor sealing
Coolant leaks
O-ring for damage, dete-
rioration or improper fit-
Insufficient coolant ting
Radiator
Cracked radiator core
Cylinder head deteriora-

Exhaust gas leaks into tion
Overflowing reservoir tank
cooling system Cylinder head gasket
deterioration
LC-50
Symptom Check items
High engine rpm under GI

no load

Abusive driving
extended time MA
speed EM
tion

ing system EC
function
FE
Blocked bumper —

Blocked radiator grille
CL
Mud contamination or
flow
Blocked radiator — MT
Blocked condenser
—
AT
AX
SU
BR
Service Data and Specifications (SDS) ST

THERMOSTAT NJLC0071
Valve opening temperature Above 80.5 - 83.5°C (177 - 182°F)

RS
Valve lift More than 9.0 mm/95°C (0.354 in/203°F)
RADIATOR BT
NJLC0073
2
Unit: kPa (bar, kg/cm , psi)
Cap relief pressure

Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14) HA
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure 157 (1.57, 1.6, 23) SC

ENGINE COOLANT CAPACITY NJLC0080
Unit: (Imp qt) EL
With reservoir tank 8.7 (7-5/8)
Reservoir tank 0.7 (5/8) IDX
LC-51
ENGINE LUBRICATION SYSTEM K9K
Precautions
Precautions
REMOVAL OF LIQUID GASKET NJLC0125
I After removing the mounting bolts and nuts, separate the mat-
ing surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
I In areas where the cutter is difficult to use, use a plastic ham-
mer to lightly tap the gasket applied area.
CAUTION:
PBIC0275E
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.

1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
I Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface
with white gasoline (lighting and heating use) to remove adher-
ing moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
PBIC0003E
4. Apply the gasket without breaks to the specified location with

the specified dimensions.
I If there is a groove for the liquid gasket application, apply the
gasket to the groove.
EMA0622D
I As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes. Make
sure to read the instruction in this manual.
I Within five minutes of gasket application, install the mating
component.
I If the liquid gasket protrudes, wipe it off immediately.
I Do not retighten after the installation.
I After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
SEM159F If there are instructions in this manual, observe them.
LC-52
Preparation
Preparation
GI
Tool number
(RENAULT tool number) Description
Tool name MA
KV113C0010 Removing and installing oil filter
(Mot. 1329)
Oil filter wrench
EM
MBIB0369E
EC
KV113E0020 Measuring oil pressure
(Mot. 836-05) Use C, E, F.
Oil pressure gauge set
FE
CL
MBIB0663E
MT
(—) AT
Tube pressure
AX
NT052
SU
BR
Engine Oil Inspection NJLC0126 ST

OIL LEVEL AND MUDDINESS NJLC0126S01
I Before starting the engine, check the oil level placing vehicle
horizontally. If the engine is already started, stop it and allow RS
10 minutes before checking.
I Make sure the oil level is within the range shown in the figure.
I If it is out of range, adjust it.
BT
I Check the oil for white turbidity or remarkable contamination.
I If the oil becomes turbid and white, it is highly probable that it HA
is contaminated with coolant. Find the cause and repair.
MBIB0548E
OIL LEAKAGE NJLC0126S02 SC
Check for oil leakage around the following area.
I Oil pan
I Oil pan drain plug EL
I Oil pressure switch
I Oil filter bracket
IDX
I Vacuum pump
I Oil pump housing
I Mating surface between cylinder block and cylinder head
I Mating surface between cylinder head and rocker cover
LC-53
Engine Oil Inspection (Cont’d)
I Oil cooler
I Crankshaft oil seals

WARNING:
I Oil pressure check should be done in Neutral “N” posi-
tion.
1. Check the oil level. LC-53, “Refer to OIL LEVEL AND MUDDI-
NESS”.
2. Remove engine undercover.
3. Remove the oil pressure switch to connect the oil pressure
gauge (special service tool).
MBIB0549E
4. After warming up the engine, make sure oil pressure corre-
sponding to the engine speed is produced.
I Engine oil pressure [oil temperature is 80°C (176°F)]
5. After checking, install the oil pressure switch as follows.
a. Remove old sealant adhering to the switch and engine.
b. Apply thread sealant.
Oil pressure switch:
: 25 N·m (2.55 kg-m, 18.4 ft-lb)
6. Start engine and check for oil leakage.
LC-54
Oil Pump
Oil Pump
GI
MA
EM
EC
FE
CL
MBIB0552E
MT
1. Oil pump drive chain 2. Crankshaft sprocket 3. Oil pump assembly
AT
Removal NJLC0091S01
1. Remove the following parts. AX
I Battery ground cable
I Undercover SU
I RH front wheel
2. Remove right side splash cover.
3. Remove drive belt. Refer to EM-242, “DRIVE BELTS”. BR
4. Remove oil pan. Refer to EM-253, “OIL PAN”.
5. Remove rear oil seal retainer. Refer to EM-253, “TIMING ST
BELT”.
6. Remove oil pump drive chain. Refer to EM-288, “Disassembly
of The Bottom Engine”. RS
7. Remove oil pump assembly.
Installation NJLC0091S02 BT
Install in the reverse order of removal paying attention to the
following.
HA
SC
EL
IDX
LC-55
Changing Engine Oil
Changing Engine Oil =NJLC0095

WARNING:
cause skin cancer: try to avoid direct skin contact with
1. Put vehicle horizontally.
ponents.
MBIB0548E 3. Stop engine and wait for 10 minutes.
4. Remove drain plug and oil filler cap.
I Refer to MA-25, “RECOMMENDED FLUIDS AND LUBRI-
CANTS”.
Oil capacity (Approximate):
With oil filter
4.55 (4 Imp qt)
change
Drain and refill
Without oil filter
4.39 (3-7/8 Imp qt)
change
Dry engine (overhaul) 4.71 (4-1/8 Imp qt)
I The refill capacity depends on the oil temperature and drain

time. Use these specifications for reference only.
Always use the dipstick to the determine when the proper
CAUTION:
I The refill capacity depends on the oil temperature and
drain time. Use these specifications for reference only.
Always use the dipstick to the determine when the proper
6. Warm up engine and check area around drain plug and oil fil-
ter for oil leakage.
7. Stop engine and wait for 10 minutes.
8. Check oil level.
LC-56
Changing Oil Filter
Changing Oil Filter =NJLC0097
GI
MA
EM
EC
FE
CL
MBIB0550E
1. Oil filter 3. Oil filter bracket 4. Connecting bolt

MT
2. O-ring
AT
AX
SU
BR
REMOVAL
1.
NJLC0097S01
Using an oil filter wrench (special service too), remove oil fil-
ST
ter.
CAUTION: RS
I Be careful not to get burned when the engine and engine
oil are hot.
I When removing, prepare a shop cloth to absorb any oil BT
leakage or spillage.
I Do not allow engine oil to adhere to the drive belts.
I Completely wipe off any oil that adhere to the engine and
HA
MBIB0551E the vehicle.
SC
1. Remove foreign materials adhering to the oil filter installation
surface.
2. Install oil filter bracket to oil cooler. EL
CAUTION:
Install oil filter bracket, positioning lug in the hole of oil cooler. IDX
3. Apply engine oil to the oil seal contact surface of the new oil
filter.
SMA010
LC-57
Changing Oil Filter (Cont’d)
4. Install the oil filter to oil filter bracket.
6. Check oil level and add engine oil. Refer to LC-53, “OIL LEVEL
AND MUDDINESS”.
Oil Cooler NJLC0098
MBIB0553E
1. Cylinder block 4. O-ring 6. Connecting bolt

2. O-ring 5. Oil cooler 7. Water hose
3. Water pipe
CAUTION:
I Be careful not to get burned when the engine and engine
oil are hot.
I When removing, prepare a shop cloth to absorb any oil
leakage or spillage.
I Completely wipe off any oil that abhere to the engine and
the vehicle.
REMOVAL NJLC0098S01
ant”.
LC-58
Oil Cooler (Cont’d)
CAUTION:
Perform when engine is cold.
2. Remove oil filter and oil filter bracket. Refer to LC-57, “Chang- GI
ing Oil Filter”.
3. Remove water hoses from oil cooler.
4. Remove oil cooler. MA
INSPECTION NJLC0098S02
Check oil cooler for cracks and clogging by blowing through cool- EM
ant inlet. If necessary, replace oil cooler assembly.
Installation is in reverse order of removal. EC
I Replace the O-ring (A) of the oil cooler, positioning the lip (B)
of the seal behind the lug (C) of the oil cooler.
FE
CL
MBIB0458E
MT
I Confirm that no foreign objects are adhering to the installation
planes of the oil cooler and block. AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
LC-59
ENGINE COOLING SYSTEM K9K
Precautions
Precautions
REMOVAL OF LIQUID GASKET NJLC0122
I After removing the mounting bolts and nuts, separate the mat-
ing surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
I In areas where the cutter is difficult to use, use a plastic ham-
mer to lightly tap the gasket applied area.
CAUTION:
PBIC0275E
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.

1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
I Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface
with white gasoline (lighting and heating use) to remove adher-
ing moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
PBIC0003E
4. Apply the gasket without breaks to the specified location with

the specified dimensions.
I If there is a groove for the liquid gasket application, apply the
gasket to the groove.
EMA0622D
I As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes. Make
sure to read the instruction in this manual.
I Within five minutes of gasket application, install the mating
component.
I If the liquid gasket protrudes, wipe it off immediately.
I Do not retighten after the installation.
I After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
SEM159F If there are instructions in this manual, observe them.
LC-60
Preparation
Preparation
GI
Tool number
(RENAULT tool number) Description
Tool name MA
(—)
Tube pressure
EM
S-NT052
EC
(—) a: 28 (1.10) dia.
Radiator cap tester b: 31.4 (1.236) dia.
FE
adapter c: 41.3 (1.626) dia.
Unit: mm (in)
CL
NT564

MT
(—)
AT
NT224

(—) AX
Radiator plate pliers B
NT225
SU
BR
System Check NJLC0106 ST

WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from RS
the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape BT
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSES NJLC0106S01 HA
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR SC
NJLC0106S02
follows. EL
rounding parts such as radiator fan, radiator shroud and horns. IDX
entering.
tically downwards.
LC-61
2. Apply water again to all radiator core surface once per minute.
tor.
4. Blow air into the back side of radiator core vertically down-
wards.
I Use compressed air lower than 490 kPa (4.9 bar 5 kg/cm2, 71
psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surface once per minute
until no water sprays out.

I Make sure there is no dirt or damage on the valve seat of the
radiator cap negative-pressure valve.
I Make sure there are no unusualness in the opening and clos-
ing conditions of the negative-pressure valve.
I Pull the negative pressure valve to open it.
I Make sure it closes completely when released.
SMA967B
I Check radiator cap relief pressure.

Standard:
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit:
59 kPa (0.59 bar, 0.6 kg/cm2, 9 psi)
I When connecting the radiator cap to the tester, apply water or
LLC to the cap seal part.
I Replace the radiator cap if there is an unusualness in the
negative-pressure valve, or if the relief pressure is outside of
SLC135B
the limit.
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
WARNING:
burns could occur from high pressure engine coolant escap-
ing from the radiator.
CAUTION:
SLC134B Higher pressure than specified may cause radiator damage.
LC-62
Water Pump
Water Pump
GI
MA
EM
EC
FE
CL
MBIB0540E
MT
1. Water pump 2. Gasket 3. Cylinder block
AT
WARNING:
Never remove the radiator cap when the engine is hot. Serious AX
burns could occur from high pressure coolant escaping from
the radiator.
REMOVAL SU
NJLC0108
1. Remove the following parts.
I Battery ground cable BR
I Undercover
I RH front wheel
2. Remove right side splash cover. ST
3. Remove drive belt. Refer to EM-242, “DRIVE BELTS”.
4. Drain engine coolant. Refer to LC-67, “Changing Engine Cool- RS
ant”.
CAUTION:
Perform when engine is cold. BT
5. Remove timing belt and inner cover. Refer to EM-261, “TIM-
ING BELT”.
6. Remove the water pump.
HA
I Coolant will leak from the cylinder block, so have a receptacle
ready below. SC
CAUTION:
I Handle the water pump vane so that it does not contact
any other parts. EL
replaced as a unit.
IDX
LC-63
Water Pump (Cont’d)
INSPECTION AFTER REMOVAL NJLC0109
I Visually make sure there is no significant dirt or rusting on the
water pump body and vane.
I Make sure there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
I If there are any unusualness, replace the water pump assem-
bly.
MBIB0546E
I Install in the reverse order of removal.
INSPECTION AFTER INSTALLATION NJLC0123
I Check for engine coolant leaks using radiator cap tester. Refer
to LC-62, “CHECKING COOLING SYSTEM FOR LEAKS”.
LC-64
Radiator
Radiator
COMPONENTS =NJLC0113
GI
MA
EM
EC
FE
CL
MT
AT
AX
MBIB0535E
SU
1. Radiator upper mounting bracket 6. Radiator lower core support 12. Reservoir tank hose
(RH side) 7. Radiator 13. Bracket
2. Mounting rubber 8. Clamp 14. Reservoir tank hose BR
3. Radiator cap 9. Radiator hose (lower) 15. Reservoir tank
4. Radiator upper mounting bracket 10. Radiator hose (upper) 16. Reservoir tank cap
(LH side) 11. Radiator fan assembly ST
5. Mounting rubber
RS
WARNING:
burns could occur from high pressure coolant escaping from BT
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. HA
REMOVAL NJLC0114
1. Remove engine room cover. Refer to EM-241, “ENGINE SC
ROOM COVER”.
2. Remove air cleaner case and air duct (inlet). Refer to EM-244,
“AIR CLEANER AND AIR DUCT”. EL
3. Remove reservoir tank hose bracket bolt from radiator upper
mounting bracket (RH side).
4. Remove radiator fan motor harnesses. IDX
ant”.
LC-65
Radiator (Cont’d)
CAUTION:
Perform when engine is cold.
7. Disconnect radiator upper hose, reservoir tank hose and
mounting bracket.
8. Remove radiator and radiator fan assembly.
CAUTION:
Do not damage or scratch radiator core when removing.
I Reinstall any parts removed in reverse order of removal.
I Check for engine coolant leaks. Refer to LC-62, “CHECKING
COOLING SYSTEM FOR LEAKS”.

COMPONENTS NJLC0115S01
MBIB0536E
1. Radiator fan motors 3. Radiator fan 4. Clip

2. Radiator fan shroud
LC-66
Cooling Fan (Cont’d)
DISASSEMBLY NJLC0115S03
1. Remove radiator fan and shroud assembly.
2. Remove radiator fan as shown. GI
MA
EM
MBIB0537E
EC
FE
CL
MBIB0538E
MT
3. Remove fan motor from fan shroud.
ASSEMBLY AT
NJLC0115S04
Install in the reverse order of removal.
AX
SU
BR
Changing Engine Coolant NJLC0116 ST

WARNING:
I To avoid being scalded, never change the coolant when
the engine is hot. RS
I Wrap a thick cloth around cap and carefully remove the
cap. First, turn the cap a quarter of a turn to release
built-up pressure. Then turn the cap all the way. BT
HA

SC
2. Disconnect lower radiator hose, and remove radiator cap.
EL
tank.
4. Check drained coolant for contaminants such as rust, corro- IDX
sion or discoloration.
If contaminated, flush engine cooling system. Refer to LC-68,
“FLUSHING COOLING SYSTEM”.
MBIB0534E
LC-67
1. Install reservoir tank, radiator lower hose and radiator upper
hose.
2. Fill radiator slowly with coolant until coolant spills from radia-
tor cap holes.
CAUTION:
If the filling rate is too fast, this could lead to air being mixed
in the coolant. Be sure to fill the coolant slowly according to
the rate indicated above.
SMA182B mixed with water (distilled or demineralized).
CANTS”.
Engine coolant capacity (With reservoir tank):
6.56 (5-3/4 Imp qt)
Reservoir tank:
: 0.9 (3/4 lmp qt)
I Pour coolant through coolant filler neck slowly of less
than 2 (1-3/4 lmp qt) a minute to allow air in system to
escape.
3. Fill reservoir tank to specified level.
SMA412B 4. Warm up engine to normal operating temperature without
I If coolant overflows radiator filler hole, install filler cap.
I Repeat two or three times.
engine.
6. Stop engine and cool down to less than approximately 50°C
(122°F).
I If necessary, refill radiator up to filler neck with coolant.
8. Repeat steps 5 through 7 two or more times with radiator cap
installed until coolant level no longer drops.
10. Warm up engine, and check for sound of coolant flow while
ture controller set at several position between COOL and
WARM.
I Sound may be noticeable at heater unit.
steps 5 through 7 until coolant level no longer drops.
1. Fill radiator with water until water spills from the air relief hole,
2. Run engine and warm it up to normal operating temperature.
5. Drain water.
radiator.
LC-68
Radiator (Aluminum type) NJLC0117

GI
MA
EM
EC
FE
CL
YLC057
MT
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in) AT
sion H′′ is approx. 7.6 mm (0.299 in). AX
SU
BR
SLC655C
DISASSEMBLY
NJLC0117S02 ST
RS
BT
HA
SLC903
I Grip the crimped edge and bend it upwards so that Tool slips SC
off.
EL
IDX
SLC893
LC-69
the edge up.
Be careful not to damage tank.
SLC930
SLC931
SLC932
2. Install sealing rubber.

SLC917A
SLC904
LC-70
GI
MA
EM
SLC896

EC
FE
CL
SLC897
MT
Standard height “H”: AT
8.0 - 8.4 mm (0.315 - 0.331 in)
AX
SU
BR
SLC554A
INSPECTION
NJLC0117S04 ST
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) RS
WARNING:
pressure, securely fasten it down with a hose clamp. BT
HA
SLC933
2. Check for leakage. SC
EL
IDX
SLC934
LC-71
Overheating Cause Analysis
Symptom Check items
Poor heat transfer Damaged fins paper clogging —
Mechanical damage
Clogged radiator cooling Excess foreign material

Cooling fan does not oper-

ate

tion
Damaged fan blades
Damaged radiator shroud — — —

— — —
ratio
Cooling sys-
tem parts Poor coolant quality — — —
malfunction Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Radiator cap
Poor sealing
Coolant leaks
O-ring for damage, dete-
rioration or improper fit-
Insufficient coolant ting
Radiator
Cracked radiator core
Cylinder head deteriora-

Exhaust gas leaks into tion
Overflowing reservoir tank
cooling system Cylinder head gasket
deterioration
LC-72
Symptom Check items
High engine rpm under GI

no load

Abusive driving
extended time MA
speed EM
tion

ing system EC
function
FE
Blocked bumper —

Blocked radiator grille
CL
Mud contamination or
flow
Blocked radiator — MT
Blocked condenser
—
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
LC-73
NOTES

Engine Lubrication & Cooling Systems

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Engine Lubrication & Cooling Systems

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ENGINE LUBRICATION &

ST25051001 Measuring oil pressure

ST25052000 Adapting oil pressure gauge to cylinder block

WS39930000 Pressing the tube of liquid gasket EL

Lubrication Circuit NJLC0003

Oil Pressure Check NJLC0004

3. Install pressure gauge.

2,000 More than 294 (2.94, 3.0, 43)

1. Oil pump cover 4. Front cover 7. Spring

I When installing oil pump, apply engine oil to rotors.

Body to outer rotor radial clearance 1 0.250 - 0.325 (0.0098 - 0.0128)

Body to outer rotor axial clearance 4 0.030 - 0.090 (0.0012 - 0.0035)

REGULATOR VALVE INSPECTION NJLC0008

Changing Engine Oil NJLC0035

With oil filter change 2.9 (2-1/2)

Without oil filter change 2.7 (2-3/8)

Dry engine (engine overhaul) 3.0 (2-5/8)

Changing Oil Filter NJLC0010

2. Clean oil filter mounting surface on cylinder block. Coat rubber

Service Data and Specifications (SDS)

Engine speed Approximate discharge pressure

600 More than 98 (0.98, 1.0, 14)

2,000 More than 294 (2.94, 3.0, 43)

6,000 More than 392 (3.92, 4.0, 57)

OIL PUMP INSPECTION NJLC0013

Body to outer rotor radial clearance 0.250 - 0.325 (0.0098 - 0.0128)

Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)

Body to inner rotor clearance 0.030 - 0.085 (0.0012 - 0.0033)

Body to outer rotor axial clearance 0.030 - 0.090 (0.0012 - 0.0035)

Inner rotor to brazed portion of housing clear-

REGULATOR VALVE INSPECTION NJLC0012

OIL CAPACITY NJLC0036

With oil filter change 2.9 (2-1/2)

Without oil filter change 2.7 (2-3/8)

Dry engine (engine overhaul) 3.0 (2-5/8)

EG17650301 Adapting radiator cap tester to radiator filler neck

KV99103510 Installing radiator upper and lower tanks

KV99103520 Removing radiator upper and lower tanks

Cooling Circuit NJLC0016

System Check NJLC0017

Pull the negative pressure valve to open it.

CHECKING COOLING SYSTEM FOR LEAKS NJLC0017S02

4. Install thermostat with jiggle valve or air bleeder at upper side. SC

Valve lift mm/°C (in/°F) More than 8/95 (0.31/203)

3. Then check if valve closes at 5°C (9°F) below valve opening

1. Reservoir tank 5. Mounting bracket 9. Oil cooler hose (A/T models)

Cooling Fan NJLC0026

CONTROL SYSTEM NJLC0026S02

Changing Engine Coolant NJLC0037

5. Remove drain plug on cylinder block and air relief plug.

— REFILLING ENGINE COOLANT — NJLC0037S02

For Sedan 6.6 (5-7/8) MA

Radiator (Aluminum type) NJLC0081

1. Attach the spacer to the tip of the radiator plate pliers A.

2. Make sure the edge stands straight up.

2. Clean contact portion of tank.

3. Install sealing rubber. SC

I Use pliers in the locations where Tool cannot be used.

5. Make sure that the rim is completely crimped down.

Overheating Cause Analysis NJLC0028

Symptom Check items EC

Thermostat stuck closed —

Clogged radiator cooling Excess foreign material MT