ENGINE LUBRICATION &
COOLING SYSTEMS
CONTENTS
SERVICE DATA AND SPECIFICATIONS (SDS) ............2
Engine Lubrication System..........................................2
Engine Cooling System ...............................................2
TROUBLE DIAGNOSES AND CORRECTIONS.............4
Engine Lubrication System..........................................4
Engine Cooling System ...............................................5
ENGINE LUBRICATION SYSTEM ..................................6
Lubrication Circuit ........................................................6
SECTION LC
Oil Pressure Check (On-vehicle service) ....................8
Oil Pump (H series engine) .........................................9
Oil Pump (TD27 engine)............................................10
ENGINE COOLING SYSTEM........................................12
Cooling Circuit ...........................................................12
Cooling System Inspection ........................................13
Thermostat.................................................................14
SPECIAL SERVICE TOOLS..........................................15
 SERVICE DATA AND SPECIFICATIONS (SDS)

Engine Lubrication System

GENERAL SPECIFICATIONS TIGHTENING TORQUE
Lubrication method Pressed feed flow H series engine
Oil pump Spur gear type N⋅m kg-m ft-lb in-lb

Oil filter Full flow and cartridge type Oil pump mount-
16 - 18 1.6 - 1.9 12 - 13 —
ing bolt

Oil pump cover

INSPECTION AND ADJUSTMENT bolt
6.9 - 8.8 0.7 - 0.9 — 61 - 78

Oil pump Oil pan bolt 6.4 - 7.4 0.65 - 0.76 — 57 - 65

H series engine Oil pan drain

20 - 39 2.0 - 4.0 15 - 28 —
Unit: mm (in) plug

Pump gear to pump body clear-

Less than 0.40 (0.0157) TD27 engine
ance

Pump gear backlash Less than 0.50 (0.0197) N⋅m kg-m ft-lb
Pump gear vertical clearance Less than 0.30 (0.0118) Oil pump fixing bolt 13 - 18 1.3 - 1.9 10 - 13

Oil cooler securing bolt 16 - 20 1.6 - 2.1 12 - 15

TD27 engine Oil filter bracket fixing bolt 16 - 20 1.6 - 2.1 12 - 15
Unit: mm (in)
Oil jet bolt (for piston) 30 - 39 3.0 - 4.0 22 - 28
Gear side clearance 0.05 - 0.13 (0.0020 - 0.0051)
Oil pump relief valve 30 - 49 3.0 - 5.0 22 - 36
Gear backlash 0.07 - 0.11 (0.0028 - 0.0043)
Oil cooler short valve 30 - 49 3.0 - 5.0 22 - 36
Oil pump bushing clearance Less than 0.15 (0.0059)
Regular valve 30 - 49 3.0 - 5.0 22 - 36
Oil pump bushing inside diameter 13.012 - 13.098 (0.5123 - 0.5157)
Drive gear shaft outside diameter 12.974 - 12.992 (0.5108 - 0.5115)

Oil pressure
Unit: kPa (bar, kg/cm2, psi)

Engine H20-II, H25 TD27

Approximate dis-
charge pressure

Idle speed 98 (0.98, 1.0, 14) 98 (0.98, 1.0, 14)

333 - 372 294 - 441

3,000 rpm (3.33 - 3.73, 3.4 - 3.8, (2.94 - 4.41, 3.0 - 4.5,
48 - 54) 43 - 64)

Engine Cooling System

GENERAL SPECIFICATIONS
Cooling method Water-cooled, forced circulation
Water pump Centrifugal type

Thermostat Wax-pellet type

LC-2
 SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Cooling System (Cont’d)
INSPECTION AND ADJUSTMENT TIGHTENING TORQUE
Radiator H series engine
Unit: kPa (bar, kg/cm2, psi)
N⋅m kg-m ft-lb
Cap relief pressure 88 (0.88, 0.9, 13)
Water pump
16 - 18 1.6 - 1.9 12 - 13
Leakage test pressure 88 (0.88, 0.9, 13) bolt

Limit 147 (1.47, 1.5, 21) Water inlet bolt 16 - 18 1.6 - 1.9 12 - 13

Thermostat TD27 engine

Frigid type Standard type N⋅m kg-m ft-lb in-lb

Valve opening temperature °C (°F) 88 (190) 82 (180) Water pump

8/100 8/95 M8 16 - 20 1.6 - 2.1 12 - 15 —

Max. valve lift mm/°C (in/°F)
(0.31/212) (0.31/203)
M10 31 - 41 3.1 - 4.2 23 - 30 —

Water pump Thermostat housing

16 - 20 1.6 - 2.1 12 - 15 —
bolt
Fan belt deflection
[When pushing with a force of 98 N (10 kg, 22 Water outlet bolt 16 - 20 1.6 - 2.1 12 - 15 —
11 - 13 (0.43 - 0.51)
lb)] Fan securing bolt 6.9 - 8.8 0.7 - 0.9 — 61 - 78
mm (in)
Cylinder block drain
20 - 29 2.0 - 3.0 15 - 21 —
plug

Water temperature
20 - 29 2.0 - 3.0 15 - 21 —
sensor

LC-3
 TROUBLE DIAGNOSES AND CORRECTIONS

Engine Lubrication System

Condition Probable cause Corrective action

Oil leakage Damaged or cracked pump body cover. Replace.

Oil leakage from gasket and oil seal. Replace.

Oil leakage from regulator valve. Tighten or replace.

Oil leakage from blind plug. Replace.

Decreased oil pressure Lack of oil in engine oil pan. Correct.

Dirty oil strainer. Clean or replace.

Damaged or worn pump rotors. Replace.

Malfunctioning regulator. Replace.

Use of poor quality engine oil. Replace.

Warning light remains “on” - engine running Decreased oil pressure. Previously mentioned.
Oil pressure switch unserviceable. Replace.

Electrical fault. Check circuit.

Noise Excessive backlash in pump rotors. Replace.

LC-4
 TROUBLE DIAGNOSES AND CORRECTIONS

Engine Cooling System

Condition Probable cause Corrective action

Water leakage Damaged radiator seams. Repair.

Water leakage from water pump shaft seal. Replace as pump assembly.

Water leakage from water temperature gauge. Tighten.

Loose joints. Tighten.

Damaged cylinder head gasket. Replace.

Check engine oil for contamination.

Cracked cylinder block. Replace.

Check engine oil in crankcase for mixing with water by pull-
ing oil level gauge.
Cracked cylinder head. Replace.

Loose cylinder head bolts. Tighten.

Poor circulation Restriction in system. Check hoses for crimps, and clear the system of rust and
sludge by flushing radiator.

Insufficient coolant. Replenish.

Inoperative water pump. Replace.

Loose fan belt. Adjust.

Inoperative thermostat. Replace.

Corrosion Excessive impurity in water. Use soft, clean water (rain water is satisfactory).
Infrequent flushing and draining of system. Cooling system should be drained and flushed thoroughly.

Overheating Faulty thermostat. Replace.

Radiator fin choked with mud, chaff, etc. Clean out air passage thoroughly by using air compressed
air.

Incorrect ignition and valve timing. Adjust.

Dirty oil and sludge in engine. Flush engine and refill oil.

Inoperative water pump. Replace.

Loose fan belt. Adjust.

Restricted radiator. Flush radiator.

Inaccurate temperature gauge. Replace.

Impurity in water. Use soft, clean water.

Overcooling Faulty thermostat. Replace.

Inaccurate temperature gauge. Replace.

Noise Squeak at water pump mechanical seal. Use suitable water pump seal lubricant.

Damaged or worn water pump bearing. Replace as pump assembly.

LC-5
 ENGINE LUBRICATION SYSTEM

Lubrication Circuit
H SERIES ENGINE

LCM0007

LC-6
 ENGINE LUBRICATION SYSTEM
Lubrication Circuit (Cont’d)
TD27 ENGINE

LCM0008

LC-7
ENGINE LUBRICATION SYSTEM

Oil Pressure Check (On-vehicle service)

WARNING:
I Be careful not to burn yourself, as the engine and oil may
be hot.
I Oil pressure check should be done in “Neutral” gear posi-
tion.

1. Check oil level.

2. Remove oil pressure switch.

LCM0017

3. Install pressure gauge.

4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
Unit: kPa (bar, kg/cm2, psi)

Engine H20-II, H25 TD27

Approximate discharge
pressure
Idle speed 98 (0.98, 1.0, 14) 98 (0.98, 1.0, 14)
333 - 372 294 - 441
LCM0018 3,000 rpm (3.33 - 3.73, 3.4 - 3.8, (2.94 - 4.41, 3.0 - 4.5,
48 - 54) 43 - 64)

If difference is extreme, check oil passage and oil pump for oil
leaks.
6. Install oil pressure switch.
Use proper liquid sealant.
Oil pressure switch:
: 10 - 12 N⋅m (1.0 - 1.3 kg-m, 87 - 112 in-lb)

LC-8
ENGINE LUBRICATION SYSTEM

Oil Pump (H series engine)

DISASSEMBLY AND ASSEMBLY

LCM0011

INSPECTION
1. Inspect the following for wear or damage.
I Pump body and cover
I Pump gears
I Drive spindle
Pump gears and body are not serviced separately. If pump
gears or body are damaged or worn, replace drive shaft set or
entire oil pump assembly.

2. Using a feeler gauge, check the following clearance.

If it exceeds the limit, replace drive shaft set or entire oil pump
assembly.
Pump gear to pump body:
Less than 0.40 mm (0.0157 in)
Pump gear backlash:
Less than 0.3 - 0.4 mm (0.012 - 0.016 in)
Pump gear vertical clearance:
Less than 0.30 mm (0.0118 in)

LCM0012

LC-9
ENGINE LUBRICATION SYSTEM
Oil Pump (H series engine) (Cont’d)
3. Check oil pressure regulator valve spring.
If damaged, replace valve set or pump assembly.

LCM0013

Oil Pump (TD27 engine)

LCM0021

INSPECTION
1. Inspect pump body, gears and drive shaft for wear and dam-
age.
2. Using a feeler gauge and fuse wire, check the following clear-
ances.
Gear side clearance:
0.05 - 0.13 mm (0.0020 - 0.0051 in)

SLC966

Gear backlash:
0.07 - 0.11 mm (0.0028 - 0.0043 in)

SLC967

LC-10
ENGINE LUBRICATION SYSTEM
Oil Pump (TD27 engine) (Cont’d)
3. Measure inside diameter “A” of bushing.
A: 13.012 - 13.098 mm (0.5123 - 0.5157 in)

SLC968

4. Measure outside diameter “B” of drive gear shaft.

B: 12.974 - 12.992 mm (0.5108 - 0.5115 in)
5. Calculate oil pump bushing clearance.
Oil pump bushing clearance: A − B
Less than 0.15 mm (0.0059 in)

LCM0019

If it exceeds the limit, replace oil pump bushing or entire oil

pump assembly.

LC-11
ENGINE COOLING SYSTEM

Cooling Circuit

LCM0015

LC-12
 ENGINE COOLING SYSTEM

Cooling System Inspection

WARNING:
To avoid serious personal injury, never remove radiator cap
quickly when engine is hot. Sudden release of cooling system
pressure is very dangerous. If it is necessary to remove radia-
tor cap when radiator is hot, cover the cap with waste cloth
and turn cap slowly counterclockwise to the first stop. After all
pressure in the cooling system is released, turn cap passing
the stop and remove it.
CHECKING HOSES
Check hoses for proper attachment, leaks, cracks, damage, loose
connections, chafing and deterioration.

CHECKING RADIATOR CAP

Apply pressure to radiator cap by means of a cap tester to see if it
is satisfactory.
Radiator cap relief pressure:
88 kPa (0.88 bar, 0.9 kg/cm2, 13 psi)

SLC613

CHECKING COOLING SYSTEM FOR LEAKS

Apply pressure to the cooling system by means of a tester to check
for leakage.
Testing pressure:
88 kPa (0.88 bar, 0.9 kg/cm2, 13 psi)
Limit:
147 kPa (1.47 bar, 1.5 kg/cm2, 21 psi)
CAUTION:
Higher than the specified pressure may cause radiator dam-
age.
SMA990A

LC-13
 ENGINE COOLING SYSTEM
Cooling System Inspection (Cont’d)
FAN BELT DEFLECTION AND DAMAGE
Inspection
I Press the intermediate point between the fan pulley and the
alternator pulley [approx. 98 N (10 kg, 22 lb)] to check the fan
belt deflection.
Belt deflection: 11 - 13 mm (0.43 - 0.51 in)
I Check the fan belt for cracks or damage.
Adjustment and replacement
I Adjust the fan belt tension by the alternator’s adjustment posi-
LCM0016 tion.
I If the belt is damage, replace with a new one.

LCM0020

Thermostat
INSPECTION
1. Check for valve seating condition at ordinary temperatures. It
should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Valve opening temperature °C (°F) 82 (180)
Max. valve lift mm/°C (in/°F) 8/95 (0.31/203)

SLC343
3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.

LC-14
 SPECIAL SERVICE TOOLS

Tool number
Description
Tool name
ST25051001
Oil pressure gauge

NT558

ST25052000 Adapting oil pressure gauge to cylinder block

Hose

NT559

EG17650301 Adapting radiator cap tester to radiator filler

Radiator cap tester adapter neck

NT781

LC-15
 Service Bulletin
Issue : SB 0408
Date : August 2004

Applied model: All

Subject: Coolant/Antifreeze used for aluminum radiators and/or other aluminum parts.

Introduction:
We have received several complaints for leaking of radiators.
After investigation of several radiators, it was found that most of the radiators were leaking
because of internal corrosion.
This internal corrosion was caused due to the fact that the coolant/antifreeze is not meeting the
specification for aluminum radiators.

During the investigation it was found that when mixing concentrate coolant/antifreeze with tap
water, the corrosion protection is reduced and will cause internal corrosion, even though the
coolant/antifreeze supplier describes on the label that mixing with tap water is allowed.

Instruction (for all models):

• Use ready-mix coolant/antifreeze which is suitable for aluminum radiator and engine.
o Coolant/antifreeze specifications: Ethylene glycol base

SB0408-Coolant spec.doc Page 1 of 1 2/14/2008