LUBRICATION

GENERAL .............................................................................. LU - 2
SERVICE PROCEDURE ......................................................... LU-15
OIL PUMP, OIL FILTER AND OIL STRAINER ....................... LU-16
OIL PRESSURE SWITCH ....................................................... LU-21
OIL COOLER .......................................................................... LU-22
LU-2 LUBRICATION

GENERAL
SPECIFICATIONS

Model
D4AF D4AE D4AL D4DA D4DB
Item
Lubrication method Pressure feed by oil pump Í Í Í Í
Oil pump Type Gear pump Í Í Í Í
Relief valve Type Piston valve Í Í Í Í
Oil filter
* Spin-on type oil filter Type Filter paper type Í Í Í Í
combination oil filter
Regulator valve Type - - - - -
Oil cooler Type Shell-and -tube Í Í Shell-and plate Í
(multi-plate type)

Bypass valve Type Piston valve Í Í Í Í

LUBRICATION CHART

Quality Lubrication interval

Application
Oil Q’ty Normal driving Severe driving
models API Class Temp.-Viscosity(°) condition condition
D4AF(NA) CC or higher 1) 0 ~ 40°C: 8.2 Every 5,000km Every 3,000km

SAE*30 (8.5 when by- change change

pass filter is Every 10,000km change Every 6,000km change
D4AE(TC) CD or higher 2)-10°~(above):
installed) (By pass oil filter or (By pass oil filter or
SAE 20w-40
combination oil filter combination oil filter
D4AL(TCI) 3)-15°C~(above):
installed) installed)
SAE 15w-40
D4DA(TCI) 4)-20~40°C: Every 15,000km Every 9,000km
SAE 10w-30 change change
D4DB(TCI) 5)10°C or less: 8.2

SAE 5w-30
GENERAL LU-3

SERVICE STANDARD

Nominal value Corrosion and

Correction and
Description Limit
(Basic diameter [ ]) remarks

Starter At idle 145kPa 49 kpa Adjust

(1.5 kgf/cm²) (0.5 kgf/cm²)

At maximum speed 295 to 490 kPa 195 kpa Adjust

(3 to 5 kgf/cm²) (2 kgf/cm²)

Oil pump case to gear tooth end clearance 0.10 to 0.19 0.2 Replace
Difference between oil pump 0.10 to 0.07 0.18 Replace
case depth and gear height (sinkage)

Driven gear to driven shaft clearance [20] 0.04 to 0.07 0.15 Replace
Drive gear end play 0.03 or more
Relief valve opening D4AF, D4AL 360 to 420 kPa Replace
pressure D4AE (3.7 to 4.3 kgf/cm²)

D4DA,D4DB 98 to 1176kPa
(10-12 kg/cm²)

Oil cooler Bypass valve opening D4AF, D4AL 175 to 215 kPa Replace
pressure D4AE (1.8 to 2.2 kgf/cm²)

D4DA,D4DB 243 to 441kPa

(3.5-4.3 kg/ cm²)

Bypass valve spring installed D4AF, D4AL 25 to 26 N Replace

load(length installed : 51) D4AE (2.6 to 2.7 kgf)

Opening pressure of D4DA,D4DB 559 to 617kPa Replace

regulator (5.7-6.3 kgf/ cm²)

TIGHTENING TORQUE

Description Thread size Tightening torque

Remarks
O.D. x pitch(mm) N·m (kgf·m)
Oil filter center bolt M16 x 1.5 29 to 34 ( 3 to 3.5)
Oil pump Relief valve D4AF,D4AL/E M27 x 1.5 69 (7)
Cover to case bolt D4AF,D4AL/E M8 x 1.25 20 (2)
Stiffener bolt M10 x 1.5 40 (4.1)
Oil cooler Mounting bolt M10 x 1.5 44 (4.5)
Front and rear cover bolt D4AF,D4AL/E M8 x 1.25 13 to 21 (1.3 to 2.1)
Bypass valve D4AF,D4AL/E M20 x 1.5 15 to 20 (1.5 to 2)
D4DA M16 x 1.5 20 (2)
Regulator valve D4DA M16 x 1.5 20 (2)
LU-4 LUBRICATION

TROUBLESHOOTING

Oil pressure is decreasing

Yes

No Check for oil leaks. Repair the damaged parts and

Is the oil level proper?
replenish it with oil to the proper level
Yes

No
Is the oil viscosity normal? Replace it with proper oil. Check fuel supply
Yes

Do the oil pressure switch and gauge unit No

Replace
work?
Yes

Yes
Is the filter element clogged? Replace the element
No

Is the oil strainer clogged?

Yes
Does the oil pump be jointed tight? Repair / Replace the faulty parts
Isn’t there any cracks in the pipes?
No

No
Do the relief valve and regulator valve work? Repair / Replace
Yes

Isn’t there any wear or damage in the oil pump Yes

Replace the parts
body?
No

Isn’t there any wear in the connecting rod and Yes

Repair / Replace the faulty parts
main bearing?
GENERAL LU-5

Excessive oil consumption

Yes
Check the items below for leaks Repair the leakage parts
• Oil filter
• Oil cooler
• Oil pan
• Oil pipe
• Oil cover
No

No
Isn’t there any oil leaks in the front Repair / Replace the faulty parts
and rear crankshaft oil seals?
Yes

No
Isn’t there any damage in the cooling system? Repair the oil cooler, water jacket, etc.
Yes

Check the engine bearing for wear, resulting Yes

Correct / Replace
in oil leaks.
LU-6 LUBRICATION

DESCRIPTION
The engine is lubricated by a gear-type oil pump that forces engine oil through the oil cooler and oil filter into the engine for
lubrication of various engine parts.
The illustration below shows the flow of engine oil.

<D4AF, D4AE, D4AL> <D4DA, D4DB>

Injection pump

Idler shaft

Injection pump

Oil pump
ÔTo oil cooler
Vacuum
pump
From full flow filter

From bypass filter

Oil main gellery

Oil strainer

<D4AF, D4AE, D4AL> <D4DA, D4DB>

Oil pressure switch

Oil cooler

Regulator valve

Oil main gellery To oil cooler

To oil pan

Bypass valve

JCW20001
JCW21001
GENERAL LU-7

Flow Chart of Engine Oil

<D4AF, D4AE, D4AL>

Main oil gallery

Oil pressure switch Injection Cam shaft Crankshaft

Oil filter
pump bushing main bearing
Bypass
Orifice valve Idler shaft
pushing
Vacuum Rocker bushing Connection
pump rod bearing
Oil cooler Push rod Timming Auto
Turbo
charger Connection gear timer
<D4AL> Tapper rod bearing
Oil pump

Regulator Piston cooler

valve

Oil pan

Oil strainer

<D4DA,D4DB>

Main oil gallery

Injection Crankshaft Camshaft

Oil pressure switch pushing
pump main bearing

Bypass valve Oil filter Idler gear

pushing

Auto Timing Connecting Rocker

Oil cooler Orifice
timer gear rod bearing bearing

Connecting Push Tubo

Oil pump charger
bushing rod

Relief
Regulator Vacuum
valve
valve Tapper pump

Oil jet

Piston

Oil pan
Oil strainer

JCW21002
LU-8 LUBRICATION

Oil Pump (D4AF, D4AE, D4AL) <D4AF, D4AE, D4AL>

1. The oil pump, of a gear type, is driven by the skew gear mounted Skew gear
on the camshaft.
The oil pump cover serves also as the oil filter head, requiring
no oil pipe.
Oil pump

To oil cooler

2. The camshaft skew gear and oil pump gear are lubricated by
oil sprayed from the oil hole drilled in the oil pump case.
The engine oil fed under pressure by the oil pump is delivered
to the oil cooler.

JCW21003

<D4AF, D4AE, D4AL>

Skew gear

Oil pump

JCW21004

Oil Pump (D4DA, D4DB) <D4DA, D4DB>

The oil pump, of a gear type, is driven by the crankshaft. Oil pump gear

And th oil pump has a relief valve and prevents the over pressureized
in the lubrication system. Crankshaft gear

To oil cooler
Oil pump

From oil pan

From oil strainer

Relief valve

JCW21004
GENERAL LU-9

Oil Cooler <D4AF, D4AE, D4AL>

The oil cooler is an equipment for heat exchange between the cool- Coolant

ant and oil fed under pressure from the crankcase water jacket and
oil pump, respectively.
The oil cooler has a bypass valve that opens when the element
passes less oil as it becomes clogged.
Bypass valve
To oil filter From oil pump D4AF0256

<D4DA, D4DB>

Oil Pressure switch

Oil cooler Coolant

Regulator
Valve
To oil main gellery
To oil cooler

Bypass valve

Oil filter

To oil pan
Bypass valve

JCW21007

By-pass valve's operation <D4DA, D4DB> To oil cooler

Bypass valve
When oil's viscosity is high (in cold) the by -pass valve is open and
oil goes directly to oil filter.

Oil filter

JCW21008
LU-10 LUBRICATION

Regulator valve's operation <D4AF, D4AE, D4AL>

Oil pressure in main route is over-pressurized, then regulator value

opens and part of engine oil drop to the oil pan.
Valve
To oil pan

Spring

JCW21091

<D4DA, D4DB>
To oil main
gellery Regulator valve
To oil pan

Oil filter

JCW21009

Oil Pressure Switch Operation <D4DA, D4DB>

If the engine oil pressure below the specified value is sent to the oil Oil main
gellery
main passage, the built-in relay in the oil pressure switch becomes
closed contact, then the oil pressure warning lamp on a gage turns Pressure switch

on.

JCW21010

Oil Filter To main gellery

The engine oil filtered through the full-flow filter is delivered to the
crankcase oil main gallery and returns through the crankcase to To oil pan
the oil pan.
The oil pump cover has a relief valve that reroutes the engine oil to
the oil pan when the oil pressure exceeds a predetermined level,
thus preventing the lubricating system from being overloaded.

Bypass filter

Full flow filter

Bypass valve
JCW21012
GENERAL LU-11

Lubrication of Parts
The engine oil routed from the oil filter to crankcase oil main gallery
lubricates all engine parts as detailed below before returning to the
oil pan.
1. Main Bearing and Connecting Rod Bearing
1) There is an oil passage provided from the oil main gallery
to each main bearing. The oil flows through the oil hole to
lubricate the main bearing and passes through the oil pas-
sage drilled into the crankshaft to lubricate the connecting
rod bearings.

2) On D4A(D4AF, D4AE, D4AL), the oil then passes through <D4AF, D4AE, D4AL>
the oil hole in the connecting rod to lubricate the connect- Cooling piston
Oil main gallery
ing rod small-end bushing, while spraying from the oil jet to
cool down the piston.
Main bearing
Crankshaft

Connecting
rod bearing
D4AF0259

3) For D4DA, D4DB engine, engine oil is injected inward the <D4DA, D4DB>
injector by oil jet mounted under the oil main passage of
each cylinder to cool the piston. This oil jet has a check Oil main gellery
Piston
valve which is opened/closed by the specified oil pressure,
it prevents oil flow and oil pressure from decreasing at low
pressure.
Oil jet
Check valve JCW21014

2. Camshaft <D4AF, D4AE, D4AL>

Camshaft
Camshaft bushing are lubricated by the oil flowing through the Oil main gallery
oil passages leading from the oil main gallery to each bushing.
There is an oil hole provided in the journal at the front end of
engine that serves as an oil passage to lubricate the camshaft
gear and valve mechanism.
Camshaft bushing
D4AF0261
LU-12 LUBRICATION

3. Valve Mechanism Engine oil sprayed

The engine oil that has lubricated No. 1 camshaft bushing
passes through the oil hole and pipe provided at the top por-
tion of crankcase to the cylinder head.
The engine oil then goes through the front-end rocker shaft
bracket into the rocker shaft, lubricating each rocker bushing.
At the same time, it sprays from the oil hole at top of rocker to
lubricate the surfaces over which the valve cap slides and valve
stem. The oil then passes through the push rod holes in the
cylinder head and crankcase to lubricate the tappets and cam-
shaft cams before returning to the oil pan.

D4AF0262

4. Oil jet(D4DA, D4DB)

Piston
In order to supply oil for each cylinder, the oil jet installed at the
lower part of the main oil route sprays engine oil at behind of Main oil
reservoir
the piston for cooling the piston. route
The check valve installed on the oil jet opens and closes at the
Check
specified oil pressure, and does not spray engine oil at low valve
pressure avoiding drop of the oil pressure in the main oil route.
Oil jet
SOLA185A
GENERAL LU-13

Timing Gear

<D4AF, D4AE, D4AL>

Idler gear

<D4DA,D4DB>

Camshaft
Thrust plate To oil main gellery Idler gear bush Auto timer

Power steering
pump gear
Oil pipe

Camshaft gear Timing gear

Idler gear Auto timer case
Idler shaft Bearing
oil jet
Vacuum pump

CUBLU110

Engine oil from main route goes through camshaft and idler shaft and lubricates each gear and vaccum pump. Also auto
timer forcing lubrication oil jet is in the timing gear’s case and lubricate auto timer continuously.

Injection pump <D4DA, D4DB>

Governer
Engine oil that lubricates the injection pump and governor goes
through the route of bearing cover and drops to oil pan.
Timing gear
case

Oil pipe
Timer Bearing cover
Injection pump
JCW21020
LU-14 LUBRICATION

Vacuum pump <D4AF, D4AE, D4AL>

Engine oil goes through the route of timing gear case and lubri-
cates the vane, and then goes back to oil pan.

JCW21020

<D4DA, D4DB>
To camshaft
Oil main gellery
Timing
gear case

To crankshaft
Vacuum pump JCW21021

Turbo charger
Engine oil in main route lubricates the bearing in bearing housing.
Turbo charger is installed on both side of turbine wheel shaft.
Bearing housing

Piston ring Piston ring

Bearing

A: To oil main gellery

B: To oil pan
JCW21022

Oil pressure switch Plunger

When oil pressure is over 0.5kg/cm at oil hole pressure sensor,
2 Spring

spring in the sensor is pushed that circuit is opened and oil pres-
sure warning lamp is turned off.
Oil hole
But when the oil pressure is below 0.5kg/cm2, circuit becomes in
contact by spring force and then oil pressure warning lamp
Oil pressure switch
illuminates.
Diaphragm EENG003A
SERVICE PROCEDURES LU-15

SERVICE PROCEDURES
Oil filler cap
Engine oil replacement and oil pressure measurement.
1. Engine oil replacement.
1) Remove the drain plug and drain oil from the engine oil pan
after warming up the engine.
2) Apply new oil to the engine after tightening the specified
torque to the drain plug.

Drain plug

CW21-025

2. Oil pressure measurement <D4AF, D4AE, D4AL>

With the oil pressure switch removed and pressure gauge
installed, warm up the engine until the oil temperature reaches
70°C to 90°C.
Measure the oil pressure at idle and maximum speeds. If the
At idle
measurement is below the limit, overhaul the lubricating system. NV 145 kPa (1.5 kgf/cm²)
L 49 kPa (0.5 kgf/cm²)
At maximum speed
Standard value Limit Result NV 295 to 490 kPa (3 to 5 kg/cm²)
L 195 kPa (2 kgf/cm²) D4AF0266
Idle 145kPa(1.5kg/cm2) 49kPa(0.5kg/cm2)

Maximum 294~490kPa 196kPa Inspection

<D4DA, D4DB>
speed (3~5kg/cm2) (2kg/cm2)

CUBLU005
LU-16 LUBRICATION

OIL PUMP, OIL FILTER AND OIL STRAINER

Removal and installation
Oil Pump and Oil Filter

<D4AF, D4AE, D4AL>

Oil pump housing

Apply a thin coat of engine

oil before installating

Relief valve

Oil filter

JCW21028

Remove the oil filter using a oil filter wrench (Commecially avail- <D4AF, D4AE, D4AL>
able tool).

Filter wrench
(Commecially
available tool)
JCW21029

<D4DA, D4DB>

Filter wrench
(Commecially
available tool)

JCW21030
OIL PUMP, OIL FILTER AND OIL STRAINER LU-17

OIL STRAINER AND OIL PUMP

<D4AF, D4AE, D4AL>

Apply sealant
(THREEBOND No. 1207C or
equivalent) to mounting surfaces
40 Nm and mount within 3 minutes
(4.1 kgf·m)
2

1 Cut off tip segment

3 of the nozzle
∅2

Evenly apply along

1. Stiffner curved surface
2. Oil pan
3. Oil strainer D4AF0269

<D4DA, D4DB>

3
2

1 34~44N·m (3.5~4.5kgf·m)

1. Drain plug Sealant (THREEBOND

5 4
2. Stiffner No. 1707 For equivalent)
3. Bolt
4. Oil pan
6
5. Oil strainer
6. O-ring

NOTE
Replace the gasket and seal
with new ones after
removal.

JCW21032

CAUTION:
1. When applying sealant to the oil pan surfaces, make sure that the surfaces are free from oil and grease.
2. Sealant must be applied evenly.
3. After installing the oil pan, ensure that there is no shift.
4. Never attempt to start the engine within one hour after the oil pan is installed.
5. If the oil pan attaching bolt has been loosened, be sure to apply new sealant.
LU-18 LUBRICATION

OIL PUMP
Disassembly, Inspection and Reassembly

<D4AF, D4AE, D4AL>

Gear tooth end to case clearance

NV 0.10 to 0.19 mm
Wear
L 0.2 mm Wear, damage
Make sure end play
3 after installation

Difference between gear and case

height (sinkage)
NV 0.01 to 0.07 mm
L 0.18 mm

4
20 N·m
Gear to shaft clearance
(2 kgf·m)
BD 20 mm
NV 0.04 to 0.07 mm
L 0.15 mm
2
70 N·m(7 kgf·m)
Valve opening pressure
NV 360 to 420 kPa
(3.7 to 4.3 kgf/cm²)

1
17.7~21.6N·m(1.8~2.2kgf·m)

Disassembly sequence
1. Oil filter BD ... Basic Diameter
2. Relief valve NV ... Nominal Value
3. Oil pump coved L ... Limit
4. Driven gear
5. Oil pump case assembly

NOTE:
1. The gear is a shrink fitted onto the shaft of the oil pump case
assembly and do not attempt to disassemble more than the
illustration.
2. Before reassembly, be sure to apply engine oil to parts.
JCW21033
OIL PUMP, OIL FILTER AND OIL STRAINER LU-19

<D4DA, D4DB>

Crank case

Crankshaft gear

10

Driven gear

3
4
5
6

2
9

8
7

Disassembly sequence
1. Oil pump assembly
2. Bolt
3. Snap ring
4. Relief valve
5. Spring
6. Seat
7. Oil pump cover
8. Driven gear assembly
9. Oil pump case assembly
10. O-ring

Assembly sequence
Reverse procedure of disassembly
JCW21034
LU-20 LUBRICATION

1. Measure the drive and driven gear tooth end to oil pump case
clearance. If the measurement exceeds the limit, replace the
parts.

D4AF0273

2. Measure the difference between the drive and driven gears

tooth end height and the oil pump case depth. If the limit is
exceeded, replace the parts.

D4AF0274

3. Measure the play in the diameter direction of the driven gear to

check for driven gear to shaft clearance. If clearance exceeds
the limit, replace the parts.

D4AF0275

4. Measure the load at installed length of the relief valve spring. If

the load is far beyond the nominal value, replace the parts.

D4AF0276

Oil jet (D4DA, D4DB)

Installation of oil jet and check valve Check valve
Insert the locating pin of the oil jet into the hole on the crankcase 29N·m(3.0kgf·m)

and tighten the check valve to specified torque.

NOTE Oil jet
The check valve cannot be reused. Use therefore, a new check
valve.
EMGGN01A
Tightening torque : 29 N·m(3.0 kgf·m)
OIL PRESSURE SWITCH LU-21

OIL PRESSURE SWITCH

Inspection
1. Connect a tester(ohm range) between the terminal and the
body of the switch to check for continuity. The switch is normal
if there is continuity. If there is no continuity, replace the switch.

ECLA013C

2. Insert a thin rod in the oil hole of the switch and push it in lightly.
The switch is normal if no continuity is detected(infinite resis-
tance on the tester). If there is continuity, replace the switch. Thin rod

3. Apply a 0.5 kg/cm2 pressure to the oil hole.

The switch is normal if there is no continuity.
Also check for air leaks. If any air leaks are detected, the cause
may be a broken diaphragm. Replace the switch if it leaks. ECLA013D

Installation <D4AF, D4AE, D4AL>

Apply sealant to threads of oil pressure switch and tighten it to the

specified torque.
Tightening torque : 15~22 Nm (1.5~2.2 kgf·m)

Oil
pressure
switch
EENG002A

<D4DA, D4DB>

Oil pressure
switch

EENG001A
LU-22 LUBRICATION

OIL COOLER 1

Removal and Installation Apply engine oil to

prevent damage
Remove the oil cooler after removing the exhaust manifold.
When installing the oil cooler, align it with the oil pump mounting
surface.

3 44Nm
(4.5 kgf·m)

1. Heat insulator
2. Water pipe
3. Oil cooler
D4AF0285
OIL COOLER LU-23

Disassembly, Inspection and reassembly Cleaning

1. Check the oil path and bypass valve of the oil cooler element
for carbon deposits and sludge formation. If contaminated, wash
in a cleaning oil.
2. If the element and cover are seriously scald, wash referring to
Section "Cleaning of Cooling System" GROUP 25.

<D4AF, D4AL, D4AE>

Scale: 13 to 21N·m
Wash (Radipet-7 or equivalent) (1.3 to 2.1 kgf·m)
Clogged oil hole:
Wash in cleaning oil
Align mark on shell with
notch in element Scale, clogged oil hole
3

13 to 21N·m Matchmark
(1.3 to 2.1 kgf·m) (Align with notch in water pipe)

Install load
(installed length: 51
NV 25 to 26N
(2.6 to 2.7 kgf)

5
15 to 20N·m
Valve opening pressure (1.5 to 2 kgf·m)
NV 175 to 215 kPa
(1.8 to 2.2 kgf/cm²)

NV .. Nominal Value
Disassembly sequence
1. Front cover
2. Rear cover
3. Element
4. Shell
5. Bypass valve

For assembly, reverse the order of disassembly D4AF0286

LU-24 LUBRICATION

<D4DA, D4DB>

15
2

5 8
6
9 14

4
1 13 3
Crank case
11
10
12

Disassembly sequence
1. Oil filter 6. Oil pressure switch 11. Plug
2. Oil cooler 7. Plug 12. Spring
3. Nut 8. Spring 13. Bypass valve
4. O-ring 9. Regulator valve 14. Oil cooler body
5. Oil cooler element 10. Drain plug 15. Gasket
D4AF0286

Cleaning
1. Check the carbon deposit or dirt on the oil route and oil cooler
element's biy-pass valve.
2. Cleanse if water scale deposit is found on element and oil cooler
cover.

Inspection of the oil cooler element

1. Cap the outlet of oil cooler element and connect hose to en-
gine oil inlet then immerse it in the water as shown in picture.
2. Apply air pressure (3 kg/ cm²) and check the leakage. A

3. If any leakage is detected, preplace the oil cooler element.

5

B JCW21042