SPECIFICATIONS

Item Specifications
Model of lubrication Oil pump type
Oil filter type Paper-filter, spin-on type
Oil cooler type Shell and plate type (multi-plate type)
Engine oil API classification CD, CD/SF, CE, CE/SF,
CF-4 or JASO classification DH-1
Oil quantity dm3 {L} Oil pan Approx. 11 {11}
Oil filter 2.3 {2.3}

12-2
STRUCTURE AND OPERATION 12
1. Lubrication System

1 2

3 4 11 12
20 21 24 25 27
17 18
13
5 26
6 7 19
14 15

16
22 23
8
9

10 28

P42396

1 Engine oil pressure switch 15 Oil jet check valve

2 Main oil gallery 16 Piston
3 Bypass valve 17 Supply pump
4 Oil cooler 18 Air compressor
5 Engine oil bypass alarm switch 19 Timing gear
6 Full-flow filter element 20 Camshaft bushing
7 Bypass filter element 21 Rocker bushing
8 Relief valve (built in oil pump) 22 Roller
9 Oil pump 23 Valve bridge
10 Oil strainer 24 No. 1 idler shaft
11 Regulator valve 25 No. 2 idler shaft
12 Crankshaft main bearing 26 No. 3 idler shaft
13 Connecting rod bearing 27 Turbocharger
14 Connecting rod bushing 28 Oil pan

12-3
STRUCTURE AND OPERATION
2. Oil Pump
1 1 Crankshaft gear
2 Oil pump gear
3 Oil pump
4 Oil strainer
B
5 Relief valve

5 2
C A: To oil filter
B: From oil pan
C: To oil pan

Oil pump 3 is a gear type. It is driven by rotation of the crankshaft

3 via crankshaft gear 1 and oil pump gear 2.
Relief valve 5 is fitted to the oil pump. When the oil pump dis-
charge pressure exceeds a specified level, the relief valve re-
A 4 turns some of the engine oil to the oil pan, thus protecting the
B lubrication system from excessive oil pressure.

01476

12-4
 12
3. Oil Filter
1 Engine oil bypass alarm switch
A 2 Bypass filter element
B 3 Full-flow filter element
1 C
A: To oil pan
B: To oil cooler
C: From oil pump

The oil filter consists of a full-flow filter element 3 and a bypass

2 filter element 2 which are both of paper type and form one united
body.

P34244

Engine oil bypass alarm switch operation

• If the oil filter is clogged, the engine oil flow is reduced, which causes
B
1 various engine parts to seize. To prevent it, the oil filter is fitted with
an engine oil bypass alarm switch 1.
C • The engine oil bypass alarm switch 1 is activated to allow engine oil
to flow directly to the oil cooler without passing through the full-flow
filter element 3 when the oil filter is clogged. Simultaneously, the
warning lamp is lit to warn the driver of the clogged oil filter element.

P34247

12-5
STRUCTURE AND OPERATION
4. Oil Cooler
1 Oil cooler cover
2 Oil cooler element
3 Bypass valve

A: To main oil gallery

2 3
B: From oil filter

B
A
1

P34273

P Oil cooler bypass valve

When oil viscosity is high at low temperatures or the oil cooler element
1 is clogged, flow resistance increases. When this happens, bypass
3
valve 3 installed on the oil cooler opens to allow engine oil to return to
the main oil gallery without passing through the cooler.
A B
A: To main oil gallery
B: From oil filter

P34275

12-6
 12
5. Engine Oil Pressure Switch and Regulator Valve
1 Engine oil pressure switch
2 Regulator valve

A A: To main oil gallery

B B: To oil pan

P Engine oil pressure switch

When the engine oil pressure supplied to the main oil gallery lowers be-
2 low a specified level, the electrical contacts in the engine oil pressure
1 P44719 switch 1 closes. When this happens, the warning lamp in the meter
cluster illuminates, warning the driver of the oil pressure drop.

P Regulator valve
The regulator valve 2 opens when the oil pressure in the main gallery
exceeds a specified level. If it is opened, the oil is allowed to escape to
the oil pan, thereby the lubrication system being protected from exces-
sive pressure.

6. Lubrication of Related Parts

Engine oil fed to the main oil gallery lubricates the following related
parts.
1
P Main Bearing and Connecting Rod Bearing
1 Connecting rod bushing
2 Connecting rod bearing
A B 3 Crankshaft
4 4 Crankshaft main bearing

A: Oil passage
B: Main oil gallery

2
3 Oil supplied via oil passage in the crankshaft 3 flows through the con-
P44719 necting rod oil passage A to lubricate the connecting rod's small end.

12-7
STRUCTURE AND OPERATION
P Timing gear
1 No. 3 idler gear
2 2 Camshaft gear
12 1 3 No. 3 idler shaft
4 No. 2 idler gear
3 5 No. 2 idler shaft
6 Crankshaft gear
11
7 Crankshaft
A 8 No. 1 idler shaft
9 Air compressor gear
B 4 10 No. 1 idler gear
11 Crankcase
10 12 Cylinder head
5
A: Oil passage
A B: Main oil gallery

9
8 7
A

P34332

Engine oil from the main oil gallery B flows through oil passage in the crankcase 11 and cylinder head 12 to lubricate the
gear shaft bushings. The oil that has lubricated the gear shaft bushings returns to the oil pan while lubricating the gears
on the way.

12-8
 12
P Valve mechanism

2 3 4 4
7 8 9
6
1 10

11

12

A 3

P34340

1 Rocker case 8 Rocker

2 Front rocker bracket 9 Adjusting screw
3 Camshaft 10 Pad
4 Rocker shaft 11 Valve bridge
5 Cylinder head 12 Valve bridge guide
6 Roller
7 Pin A: From main oil gallery

Engine oil from the main oil gallery flows through the oil passages in the cylinder head 5, rocker case 1 and front rocker
bracket 2 and is sent to the camshaft 3 and the rocker shaft 4. The oil sent to the camshaft lubricates the camshaft jour-
nals while the oil sent to the rocker shaft lubricates the rockers 8. The oil flowing toward the rocker adjusting screw 9 lu-
bricates the valve bridge 11. After lubricating various parts, the oil returns to the oil pan.

P Check valve and oil jet

1
A 1 Piston
2 Oil jet
3 Check valve

A: Main oil gallery

An oil jet 2 is fitted in the lower part of the main oil gallery A for each
2 piston. These oil jets cool the pistons 1 by injecting oil into their cooling
3 P44757
cavity.
Each oil jet is fitted with check valve 3 that opens and closes at speci-
fied oil pressure levels. At low engine speeds, these check valves close
to maintain the required volume of oil in the lubrication system and pre-
vent reductions in oil pressure.

12-9
STRUCTURE AND OPERATION
P Turbocharger
1 1 Bearing housing
2
2 Snap ring
3 Piston ring
A 4 Bearing

A: From main oil gallery

B: To oil pan

Via an oil pipe, engine oil is delivered from the main oil gallery to the
B
bearing housing 1 to lubricate the inside of the bearing housing. At
3 each end of the turbine wheel shaft, piston ring 3 acts as an oil seal.
4 3
01488

1 2 P Supply pump
1 Supply pump
2 Air compressor
3 Oil pipe

A A: From main oil gallery

B B: To oil pan

The oil that has lubricated the supply pump 1 flows through the air com-
3 P34360 pressor 2 and the timing gear train, then returns to the oil pan.

P Air compressor
1 Piston
2 Connecting rod
3 Crankshaft
1
4 Crankcase

A: From main oil gallery

B: To oil pan
2
Engine oil from main oil gallery is jetted out toward connecting rod 2 to
3 lubricate the connecting rod big end.
The engine oil is then splashed by the rotation of crankshaft 3, lubricat-
ing piston 1 and connecting rod small end.

A
4 B
P34362

12-10
TROUBLESHOOTING 12
Symptoms

Excessive oil consumption (oil leakage)

Remarks

Engine hard to start

Low oil pressure

Overheating
Possible causes
Oil cooler element installed poorly p p p
Gasket defective p p p
O-ring defective p p p
Oil cooler
Oil cooler element clogged p p
Oil cooler element damaged p p p
Fatigue in bypass valve spring p
Oil pump malfunctioning p p
Interference between oil pump gear and oil pump case or cover p p
Oil pipe poorly fitted p p
Oil pump
Oil strainer clogged p p
Fatigue in relief valve spring p
Oil filter fitted poorly p

Oil filter Element clogged p p

O-ring defective p

Front cover assembly Front oil seal defective p Gr11

timing gear case Front cover assembly installed poorly p Gr11
Rear oil seal defective p Gr11
Flywheel housing
Gasket fitted poorly p Gr11
Fatigue in regulator valve spring p
Piston cooling oil jet(s) defective p
Oil working its way up into combustion chamber(s) p Gr11
Oil working its way down into combustion chamber(s) p Gr11
Oil viscosity too high p
Unsuitable oil quality p
Deterioration in oil p
Fuel mixed with oil p

12-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Oil Filter Replacement
T Tightening torques Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

1 Oil fiter drain plug 7.8 ± 2 {0.8 ± 0.2} –

0 Special tool
Location Tool name and shape Part No. Application

f 120 to 130

2 Oil Filter Wrench MH061537 Removing oil filter

01503

WARNING k
• Wipe up any spilled engine oil since it may cause a fire.
• Do not touch oil when the engine is hot since it can inflict se-
vere burns.
2
CAUTION k
• When pouring oil into the engine, take care not to spill any on
1 the V-belts. Contact with oil could make the V-belts slip, render-
11108 ing the cooling system less effective.

[Removal]
0: Oil Filter Wrench

0 11109

[Installation]
3 A • Clean the surface of oil filter head 3 onto which oil filter 2 is attached.
• Apply thin coat of engine oil to gasket A of oil filter 2.
• Screw the oil filter onto oil filter head 3 by hand until gasket A is
2
brought into contact with the filter head.
• Hand-tighten the oil filter further 1-1/8 to 1-3/8 turns from the point
where gasket A comes in contact with oil filter head 3.
• Install oil filter drain plug 1.
1
• After installing the oil filter, start the engine to make sure that there is
11110 no oil leakage from the section sealed by gasket A.
• Check the engine oil level and replenish if it is insufficient.

12-12
 12
2. Engine Oil Replacement
T Tightening torques Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

2 Oil pan drain plug 69 {7} –
3 Oil filter drain plug 7.8 ± 2 {0.8 ± 0.2} –

K Lubricant
Location Points of application Specified lubricant Quantity
Engine oil
Approx. 11 dm3
– Oil pan (API classification CD, CD/SF, CE, CE/
{11 L}
SF, CF-4 or JASO classification DH-1)
Engine oil
Approx. 2.3 dm3
– Oil filter (API classification CD, CD/SF, CE, CE/
{2.3 L}
SF, CF-4 or JASO classification DH-1)

WARNING k
• Wipe up any spilled engine oil since it can cause a fire.
• Do not touch oil when the engine is hot since it can inflict se-
vere burns.

1 CAUTION k
When pouring oil into the engine, take care not to spill any on
the V-belts. Contact with oil could make the V-belts slip, render-
ing the cooling system less effective.

[Draining]
• Warm up the engine, then remove oil filler cap 1.
• Remove oil pan drain plug 2 and oil filter drain plug 3. Then, drain the
3 2 P44336 engine oil.

[Filling]
• Tighten oil pan drain plug 2 and oil filter drain plug 3 to their specified
torques. Add new engine oil to the specified level.

12-13
ON-VEHICLE INSPECTION AND ADJUSTMENT
3. Oil Pressure Measurement
Service standards
Location Maintenance item Standard value Limit Remedy
49 kPa
Oil pressure (at At no-load minimum speed 145 to 295 kPa {1.5 to 3 kgf/cm2} {0.5 kgf/cm2}
– oil temperature Adjust
of 70 to 90°C) 195 kPa
At no-load maximum speed 295 to 490 kPa {3 to 5 kgf/cm2}
{2 kg/cm2}

T Tightening torque Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

Check with engine
1 Engine oil pressure switch 15 to 22 {1.5 to 2.2}
cold

K Sealant
Location Points of application Specified sealant Quantity
1 Thread of engine oil pressure switch Teflon tape Wrap around 3 1/2 turns

• Remove engine oil pressure switch 1.

2 1
2: Oil cooler

11112

• Fit adapter A onto the engine oil pressure switch mounting, then fit
PT1/8
the oil pressure gauge onto the adapter.
• Warm up the engine until the oil temperature reaches 70 to 90°C.
• Measure the oil pressure at no-load minimum speed and at no-load
maximum speed. If the measured values are below the specified
A standard values, overhaul the lubrication system.
• After taking measurements, fit engine oil pressure switch 1 and tight-
en it to the specified torque.

11113 CAUTION k
Engine oil pressure switch 1 must be fitted when the engine is
cold.

Inspection of engine oil pressure switch

B Electrical

12-14
 12

MEMO

12-15
OIL PAN AND OIL JET
P Disassembly sequence
1 Drain plug
2 Oil pan
* 3 Check valve
4 Oil jet

: Crankcase L Gr11
*
P: Locating pin
X: Non-reusable part

P Assembly sequence
Follow the disassembly sequence in re-
P verse.
4

XT3 CAUTION k
Do not tighten check valve 3 in excess of
the specified torque. Excessive tight-
ness can cause defective operation, re-
sulting in scorching of the engine.
1T
2

P44057

T Tightening torques Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

1 Drain plug 69 {7} –
3 Check valve 34 {3.5} –

K Sealant
Location Points of application Specified sealant Quantity
2 Crankcase mounting surface of oil pan THREEBOND 1207C As required

12-16
 12
R Service procedure
2 Fitting oil pan
1.5 mm • Apply sealant A to the mounting surface of oil pan 2 as illustrated.
2 A Apply the sealant evenly and without breaks.
• Within three minutes of applying sealant A, fit oil pan 2 onto the
crankcase .
*
CAUTION k
• Clean the oil pan mounting surface and ensure it is free of oily
11115 substances before applying sealant.
• Ensure that sealant A does not spread to other areas.
• After fitting oil pan 2, wait at least one hour before starting the
engine.
• Reapply sealant A to the oil pan mounting surface whenever the
mounting bolts of oil pan 2 have been loosened.

12-17
OIL PUMP AND OIL STRAINER

11
*c
3 P
6
5

1 10
9
12 8
7X
P 12
2 T4
P

13
*a
*b

P11116

P Inspection before assembly

L P12-19

P Disassembly sequence
1 Oil strainer 8 Relief valve Crankcase L Gr11
a:
*b:
2 Oil pipe 9 Relief valve spring
* Crankshaft gear L Gr11
3 Oil pump assembly 10 Washer c:
Oil pump gear
4 Bolt 11 Gear and case assembly
*P:Locating pin
5 Cover 12 Shim X: Non-reusable part
6 Driven gear assembly 13 Oil deflector
7 Ring

NOTE
• Do not remove parts 7 to 10 unless they are defective.
• Gear and case assembly 11 is an integrated unit and cannot be disassembled. If any defect is apparent, re-
place the whole unit.
• Do not remove oil strainer 1 and oil pipe 2 from oil pump assembly 3 unless they are defective. Remove those
three as a unit.

P Assembly sequence
Follow the disassembly sequence in reverse.

12-18
 12
Service standards Unit: mm
Standard value
Location Maintenance item Limit Remedy
(Basic diameter in [ ])
Clearance between drive gear shaft and inner
5, 11 [20] 0.04 to 0.07 0.15 Replace
diameter of cover
Clearance between drive gear shaft and inner
5, 6, 11 [20] 0.04 to 0.07 0.15 Replace
diameter of case and cover
Clearance between case and tooth tips of each 0.10 to 0.19 0.2
gear
6, 11 Replace
Difference between height of each gear and depth 0.06 to 0.11 0.15
of case
8 Relief valve opening pressure 1.1 ± 0.1 MPa {11 ± 1 kgf/cm2} – Replace
9 Relief valve spring load (installed length = 30 mm) 84 N {8.6 kgf} – Replace
Backlash between oil pump gear and crankshaft Adjust with
*b, *c gear 0.08 to 0.15 0.35
shim

T Tightening torques Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

4 Bolt (oil pump cover mounting) 25 ± 4.9 {2.5 ± 0.5} –

R Service procedure
P Inspection before disassembly
*c Measure the backlash between oil pump gear c and crankshaft
*
gear b. Adjust the backlash using a shim 12 if the measurement ex-
12
12 *
ceeds the limit.

*b Thickness of shims available Variation of backlash

0.1 mm 0.073 mm
0.2 mm 0.146 mm
01498

CAUTION k
Use the same thickness of shim 12 for both left and right sides.

12-19
OIL PUMP AND OIL STRAINER
5 6 11 Inspection of cover, driven gear assembly and gear and
5 6 11
case assembly
Measure the clearance between each gear shaft and the internal diam-
eters of the cover and gear and case assembly. Replace any compo-
nent whose measurement is out of specification.

01499

11 6 11 Inspection of driven gear assembly and gear and case as-

sembly
(1) Differences between gear heights and case depth
6 Replace any component whose measurement is out of specification.

01500

(2) Clearance between gear teeth tip and case

Replace any component whose measurement is out of specification.

11

6
01501

12-20
OIL FILTER 12
P Disassembly sequence
1 Oil filter drain plug
2 Oil filter L P12-12
3 O-ring
4 Engine oil bypass alarm switch
6 X B Electrical
5 Oil filter head
6 O-ring
3X
X: Non-reusable part
4T
P Assembly sequence
Follow the disassembly sequence in re-
verse.
5

T1

P34249

WARNING k
• Wipe up any spilled engine oil since it may cause a fire.
• Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION k
• When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-
belts slip, rendering the cooling system less effective.

Service standards
Location Maintenance item Standard value Limit Remedy
Engine oil bypass alarm switch valve opening +0.05
0.19 0 MPa
+0.5
{1.9 0 kgf/cm2} –
4 Replace
pressure

T Tightening torques Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

1 Oil fiter drain plug 7.8 ± 2 {0.8 ± 0.2} –
4 Engine oil bypass alarm switch 49 ± 4.9 {5.0 ± 0.5} –

K Lubricant
Location Points of application Specified lubricant Quantity
2 Oil filter gasket P12-14 Engine oil As required
6 Entire periphery of O-ring Engine oil As required

12-21
OIL COOLER
P Disassembly sequence
1 Bypass valve plug
* 2 O-ring
17X 3 Bypass valve spring
4 Bypass valve
9 5 Engine oil pressure switch
10X
6 Regulator valve L P12-24
13T 7 O-ring
11T 8 Nut
9 Oil cooler element
X 14 12 X 10 Gasket
11 Oil cooler plug
X 16 8T 12 O-ring
4 15 13 Oil cooler plug
3 14 O-ring
X2 7 X
15 Oil cooler cover
6T 16 O-ring
T1 12 11 17 Gasket
T 5T
X Crankcase assembly L Gr11
*:
X: Non-reusable part
P34270

P Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards
Location Maintenance item Standard value Limit Remedy
Bypass valve spring Free length 104.3 ± 1 – Replace
3
Installion load (installed length) 84 ± 3N {8.6 ± 0.3 kgf} – Replace
Oil cooler element air leakage (air pressure of 1000 kPa
9 0 cm3 {0 mL} – Replace
{10.2 kgf/cm2} for 15 seconds)

T Tightening torques Unit: N?m {kgf?m}

Location Parts to be tightened Tightening torque Remarks

1 Bypass valve plug 34.3 ± 4.9 {3.5 ± 0.5} –
5 Engine oil pressure switch 15 to 22 {1.5 to 2.2} –
6 Regulator valve 98 to 118 {10 to 12} –
8 Nut (oil cooler element mounting) 20 ± 4.9 {2.0 ± 0.5} –
11 Oil cooler plug 25 ± 4.9 {2.5 ± 0.5} –
13 Oil cooler plug 34.5 ± 4.9 {3.5 ± 0.5} –

12-22
 12
K Lubricant and/or sealant
Location Points of application Specified lubricant and/or sealant Quantity
5 Thread of engine oil pressure switch Teflon tape Wrap around 3 1/2 turns
7, 12
O-rings Engine oil As required
14, 16

R Service procedure
P Cleaning
• Check whether carbon deposits or sludge have accumulated in the
oil passage of oil cooler element 9 or in the oil cooler´s bypass ar-
rangement. Remove any deposits with solvent oil.
• Clean out any water scale or fur that has accumulated in the oil cool-
er element 9 or oil cooler cover 15. L Gr14

9 Inspection of oil cooler element

Plug outlet A of oil cooler element 9 and connect a hose to the oil inlet.
Then, immerse the oil cooler element in a tank of water.
B
A Apply the specified air pressure B via the hose and check that no air
leaks from the oil cooler element.
If any air leaks, replace the oil cooler element.

9
01505

12-23
REGULATOR VALVE
P Disassembly sequence
1 Snap ring
4 2 Valve
3 Spring
4 Body

P Assembly sequence
3 Follow the disassembly sequence in re-
verse.

1 2

09189

Service standards
Location Maintenance item Standard value Limit Remedy
Regulator valve spring set load (installed length =
3 76 to 80 N {7.8 to 8.2 kgf} – –
48.3 mm)
– Regulator valve opening pressure 392 ± 29 kPa {4.0 ± 0.3 kgf/cm2} – –

12-24