Page .2-1 .

2-1

.2-2 .2-3 .2-4 .2-5

2.

2-5 2-1 2-2 2-3 2-4 COOLING

Troubleshootjng Generaldescription Servicingofwaterpump Servicing

SYSTEM

ofradiator ofthermostat

2-5 2-5 2-6 2-8 2-9 2.9

1. 1-1

LUBRICATING Generai

SYSTEM

description

MAIN

OIL

GALLERY

The lubricating system is of the full-flow filter type and is arranged as illustrated in Fig. 2-1. The engine oil pumped out from the oil pump
is primarily filtered through the full-flow type oil filter before it is fed into the oil gallery for lubricating the vitaJ engine parts. On model equipped with the oil cooler. the engine oil fed. past the oil filter and oil cooler. into the oil gallery .

"'AIN BAC

I ~A~ ~

@ OIL

PUMP
.ve I VAI I

2-2 LUBRICATING

SYSTEM ANO COOLING

SYSTEM

(1)

Main data and specifications

Lubricating system Oil pump type Delivery (Pump speed 1000 r.p.m., Pressure cf delivery: 4 kg/cm2, Oil temperature; 50C, Engine oil; SAE 30) :
Oil filter type I Relief valve opening 'pressure -Overflow valve opening pressure-

Pressurized circulation Trochoid type

type

13.0 ill/min.

or more

kg/cm2 _kg/cm2

Paper element type full-tlow tilter 5.76.3 (C240) 0.8 -1.2 (Pressure of difference at which

Overflow

valve opens)

Oil cooler type Relief valve opening pressure

O.il pressure unit actuating pressure

kg/cm2
kg/Cm2

External type. water-cooled oil cooler 1.3- 1.7 (Pressure of difference at which Relief valve opens)
0.3 -0.5

1-2

Servicing

of oil pump

assembly

(2)

3 -t::::>

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 13. 14. 15. 16. 17. 18.

SHAFT PINION PIN ROTOR PIN VANE COVER BOL T BOL T WASHER BOL T WASHER OIL PIPE SPACER STRAINER BOL T

Inspectjon and correction 1) Inspection of vane, rotor and pinion gear. Check these parts for wear or damage and replace with new ones as necessary. 2) Check the clearance between the vane, rotor and cover. If the measured value is beyond the value indicating need for servicing, repiace the rotor and vane.

17

FIG.2-2

Measuring tools: Feeler gauge square (1) Disassembly and reassembly 1) .Disconnect the oil pipe. 2) Remove the gauze filter case and pump cover, then remove the vane. 3) Pull out the pin retajning the pinion and remove the pinion from the rotor shaft. 4) Remove the pin and rotor. 5) Remove the rotor shaft. 6) To reassembfe, reverse the disassembly procedure. 7) When reassembfy operation is completed, check that the rotor shaft turns smoothly.

3) Check the clearance between the rotor and vane. 11 the measured value is beyond the value indicating need far servicing, replace the rotor using a kit.

LUBRICATING

SYSTEM

ANO COOLING

SYSTEM 2.3

1-3

Servicing

of oil filter

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

FIG.2-4 4) Check the clearance between the vane and pump body. If the clearance is excessive. repiace the entire pump assembly.
4

I 5--0
5) Check the clearance between the ratar shaft and pump body. If the measured value is beyond the value indicating need far servicing, replace the entire pump assembly.

OILFILTER CARTRIDGE NUT OIL COOLER STUD PACKING PACKING BODY PIN PACKING PLUG VALVE SPRING WASHER PLUG BOL T

6--0 7
11

12

10~

,I~
/ ~15

13

14

FIG. 2-6

(1)

Disassembly
1) Drain the

and reassembly
;.. oil filter by removing the drain plug.

2) Remove

the

oil filter

assembly

from

the

engine. 3) Remove the filter element assembly. 4) Remove the relief valve and overf(ow valve. 5) To reassemble. follow the disassembly procedure in reverse order.

FIG.2-5

NOTE: Apply a thin ccat cf engine cii t c the cil filter O ring. Install the filter assembly and tighten it finger tight.

2-4 LUBRICATING

SYSTEM

ANO COOLING

SYSTEM

(2)

Inspection 1) Check the relief valve and overflow valve visually for damage paying attention to the joining face. then check- for smoothness of operation. Replace the entire valve assembly if found to be at fault. 2) To check relief valvEf opening pressure. pro.ceed as follows: Co~nect an oil pipe with oil ; pressure gauge to a part of t.he oi~ gallery ~ near theo:( filter and take reading gauge when the relief valve ope~s. of the

FIG.2-8

f~,_~ "!,"",c",, ""","""", """'~'""

~-",~

,;I!,,""

7&;~;;;

..=
~

~I

,.
~~~~

a
~

I l~~,

FIG.2-7

1-4

Servicing

cf

cil

cccler

Integrai water cooled oil cooler is made standard equipment. This regulates lubricant oil temperature to normal, thus preventing oil deterioration and increase endurance of engine. has sufficient power even under severe condition. This oil cooler has 5 stage fins at oil filter body. the upper part of which is installed cartridge type oil filter element. The oil cooler and the oil filter have respective safety valve. thus when the element or fin is choked up bypass is opened through the cooler or filter and ensure the engine Iubrication. The safety valve of oil cooler is fit to the filter body, and if the oil cooler stopped, oil can flow through the filter without passing oil

FIG. 2 -9 cooler. While the safety valve of oil filter is built in the oil filter element. and if the oil filter element is stopped. oil can flow the oil gallery without passing the element. Oil will flow through the oil pump, the oil cooler fin, after being heat-exchanged with cooling water in the oil cooler. pass through the oil filter element and to the oil gallery of the cylinder body gallery without passing through the element. Cooling water goes through the intake of the cylinder head then go into and circulate through the oil cooler and goes to the back of the engine. and join returned water from the heater at 3 way connector in going back to the water pump.

LUBRICATING

SYSTEM

AND COOLING

SYSTEM 2-5

(2)

Cleaning and inspection 1) Make the cleaner by diluting 10% of Mobilso( A with 90% of Keros.ene. 2) Fili the oil port of cooler with cleaner and leave it in for approximately 10 hours. 3) Remove 113 of cleaner from the element. plying compressed air (2 kglcm2) into the element from the oil port. 4) Repeat the above steps more than 5 times. (Number of cleaning cycles should be adjusted according to the condition of the element.)

NOTE:

Cleaner is inflammable. Se sure ta use cleaner under adequate ventilatian and wear a mask and gaggles far pratectian.

5) When cleaning is campleted, check ttle element tar cracking or damage. . FilI the ail caale.r with.water and plug ane af the Q.iJparts. Apply. campressed air ihta the ail caaler trcm ?-nather ail part and check far water leakage. ---

1-5

Trouble

shooting
CAUSE Use of wrong oil Oil seals or gaskets detective Piston rings or ring grooves worn Piston rings sticking Valve stem oil controllers. valve guides or valve stems worn Cylinder liners worn Use of wrong Oil Relief valve sticking
Restrictions in oil pump gauze Oil pump driven rotor or drive rotor worn Oil pipe cracked. broken or filter CORRECTION

COMPLAINT
Oil consumption t 00 high

Drain and refill with specified oil Correct Replace piston rings or pistons Replace piston rings or pistons Replace oil controllers. valves or valve guides Replace cylinder liners Drain and refill with specified oil Replace relief valve or oil pump assembly crean or replace gauze filter Replace oil pump assembly Correct or replace
Replace oil pump assembly Install undersize bearings

Oil pressure t 00 low

loosely connected Oil pump defective Crankshaft bearings or connectingrod bearings worn excessively Oil pressure gauge defective

Replace
Replace Replace filter cartridge piston rings or hone specified oi

Oil deteriorates quickly

Restrictions Gases leaking

in oil filter

Use of wrong Oil does not reach valve system

oil

cylinders Drain and refill with

Oil ports in cylinder block and cylinder head clogged Oil ports in rocker arm shaft clogged Oil ports brackets Oil ports in rocker clogged in rocker arm shaft arms clogged

Clean or correct Clean or correct

Clean or correct

Clean

or

correct

2.
2-1

COOLING Generai

SYSTEM description
the coolant reaches normal operating tem-

The cooling system consists basically of the radiator. water pump. cooling fan and thermostat. To facilitate quick normalization of the engine after cold starting. the cooling system incorporates a thermostat. so that the coolant is bypassed into the water pump without being cooled at the radiator before

perature. When the coolant temperature reaches 82C, the thermostat valve begins to open (the valve opens wide at 95C), cjrculating the coolant through the radiator for efficient engine cooling.

2-6

LUBRICATING

SYSTEM

ANO

COOLING

SYSTEM

Waxpellet

thermostat

Thermostat

housing

Cylinder
... o

head

(O
-o (O a:

c cc -:01 C O O U

Cyl. body oil codler chamber

Water pump FIG.2-10

(1) Main data and specifications
Water pump ooooo.o speed 3000 r.p.m.) (pump

Waterpumptype Oelivery

Impeller type 60ill/min. or more

Thermostat Thermostattype Valve opening

000 temperature.

0..00000.. .o. ..

Waxpellet

type 76C

2-2
Il \
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. FAN CENTER PUMP BOOV SETSCREW. SPRING WASHER SCREW PLUG BEARING NUT THROWER SEALNUT IMPELLER GASKET COVER SCREW

Service

tools:

Feeler gauge, square, scale.

bench

press,

";.~'ij~ "~.o ~' !~;.f~~~. #~!.".i;' ~[~;~~~;,

(1)

Di5a55embly 1) Remove the bolt fixing the rear cover to the bodyand remove the rear cover, then IOO5en the bearing unit 5et 5CreW. 2) Remove the pulley center. 3) Remove the impeller and 5haft from the impeller sjde of the body using a bench press. NOTE: Avaid the use af a hammer or other impact taal far impefler removal as the impeller is iran cast and liable ta break.

FIG.2-12

5) Install the rear cover. NOTE: Apply adhesive compound faces of the gasket.

to both

6) Install the fan center in position. NOTE: Press the fan center into position So that the distance between the fan fitting face of the fan center and pump .body face is 111 + 0.3 mm.

FIG.2-19 NOTE: 1. It is important to allow a sufficient time for the valve to open when checking the valve lift or valve opening temperature because reaction of the thermostat to variation in temperature is somewhat sluggish (it takes 3-5 minutes for the thermostat to work in response to a change in temperature). 2. Be sure to position a piece of wood under the thermostat or hold the thermostat in suspension in water to prevent effect of direct heat when checking the thermostat. 3. Stir constantly to even out temperature of water during the testi ng. {3) Installation Install the thermostat so that its. circumference is in good contact with the thermostat housing and then. piace the water outlet pipe. NOTE: Discard used gasket and install new one. Replacement intervals The waxpel1et type thermostat

FIG.2-17 7) Rotate the pump with hand and see if it turns smoothly. NOTE: Discard used water pump gasket and install new one.

2-3
{4) (1) Removal Take out the 2 nuts fixing the water outtet pipe and remove the outlet pipe. then remove the thermostat (2) from the housing.

contains.

as its

Inspection 1) Discard the thermostat and install a new one if the valve is not correctly seated at normal room temperature. 2) Check the valve opening temperature and

name implies. wax to attain smooth controlling of the valve operation but when a leakage has developed the valve is closed by the action of the spring and the entire coolant is bypassed for circulation within the engine and can cause engine overheatjng. It is therefore, recommended that the thermostat be replaced with a new one periodically according to the conditions under placed every 50.000-70.000 km). It is also advisable to remove the thermostat assembly and check for trouble when the engine is running hot and a thermostat failure is suspected.

valve lift by heating the thermostat in water. Replace the thermostat with a new one if the measured viates from the standard range.

gradualty assembly value de-

LUBRICATING

SYSTEM

ANO

COOLING

SYSTEM

2-9

check far trauble when the engine is running hat and a thermastat failure is suspected.

2-4
(1)

Servicing

of radiator

Inspection If the pressure valve is de.fective and the cooling water is not pressurized, not only air bubb(es will be formed within the cooling system and invite lowering of cooling efficiency but also the boiling point of the cooling water will qe lowered nearly to 100C. . , 1) Inspection of radiator filler cap. Check the rubber gasket and reaf spring of the filler cap for abnarmal contact and weakening. AIso check the pressure valve and vacuum valve opening pressure and replace the filler cap as necessary. 2) Inspectian of radiator far leaks. Check the radiatar for leaks and replace if faund to be defective. Ta test far 'eaks proceed as follows: Submerge the radiator into water with the inlet and autlet plugged and apply air pressure of 1 kg/cm2 inta the radiatar and see if air bubbles arise.

3} Flashing of cooling system. Formation of rust and scales in the water passages of the cooling system will invite a considerable reduction in the cooling efficiency. and to prevent this. clean the internai part of the cooling system by using an essential radiator cleaner or other radiator chemicals. The rate of r.eduction in the cooling efficiency due to fo~ling will be as follows, assuming that the cooling efficiency of a clean cooling system i$ 100 percent (%}. When layer of scales is about- 0.42 mm in thickness 75% When layer of scales is about 0.65 mm in thickness 50% 4} Inspection of radiator core. Check the cooling fins for bending and distortion as bent or distored cooling fins will prevent smoo1.hcflow of air and cause engine overheating. If the cooling fins are found to be bent. straighten them out carefully to prevent separating them from the water tubes. Check the radiator core for presence of oil. dirt and other foreign matters and clean as necessary to maintain normal cooling efficiency.

2-5

Trouble

shooting
CAUSE
-Cooling water level t 00 low

COMPLAINT Engine overheating

CORRECTION Replenish, check for leakage and correct as necessary Replace filfer cap assembly Adjust or replace fan belt Replace fan belt Replace thermostat assembly

Radiator cap pressure valve spring weakened Fan belt loosened or broken Fan belt slipping Thermostat defective (valve not opening) Water pump defective Restrictions in water passages due to accumulation of scales Injection timing incorrect Restrictions in radiatDr core Gases leaking into water jacket due to broken cylinder head qasket
Engine over-cooling Thermostat detective (valve not closing completely) Ambient temperature

too low Correct or replace Retighten clips or replace

'requent replenishment is needed

Radiatorleaking Radiator hoses loosely

connected weakened or broken

hoses

or damaged Radiator cap valve spring Water pump leaking Heater hoses loosely Cylinder Cylinder head gasket

connected leaking

Replace filler cap assembly Replace water pump assembly Retighten or replace hoses Check cylinder head and replace gasket Replace cylinder head or

head or cylinderblock

cracked

Cooling

system

noisy

Water pump bearing detectve Fan loosely titted or bent Fan out ot balanced Fan belt detective

~~ Replace water pump assembly Retighten or replace fan assembly Replace B!!-place fan assembly fan ?elt-