ENGINE LUBRICATION &
COOLING SYSTEMS
SECTIONLC
LC
CONTENTS
PRECAUTION..................................................................2 Oil Pressure Check....................................................27
PREPARATION................................................................3 Oil Pump ....................................................................27
Special Service Tools ..................................................3 Oil Cooler...................................................................30
ENGINE COOLING SYSTEM........................................31
Cooling Circuit ...........................................................31
QG
System Check............................................................32
ENGINE LUBRICATION SYSTEM..................................4
Water Pump...............................................................33
Lubrication Circuit ........................................................4
Thermostat.................................................................34
Oil Pressure Check......................................................5
Radiator .....................................................................36
Oil Pump ......................................................................5
Oil Filter .......................................................................7
ENGINE COOLING SYSTEM..........................................8
Cooling Circuit .............................................................8
System Check..............................................................8 Overheating Cause Analysis .....................................37
Water Pump...............................................................10
Thermostat.................................................................11
QG
Radiator .....................................................................13
SERVICE DATA AND SPECIFICATIONS (SDS) ..........39
Oil Pressure Check....................................................39
SR20DE
Oil Pump Inspection ..................................................39
ENGINE LUBRICATION SYSTEM................................15 Regulator Valve Inspection........................................39
Lubrication Circuit ......................................................15 Thermostat.................................................................39
Oil Pressure Check....................................................16 Radiator .....................................................................39
Oil Pump ....................................................................17
Oil Filter .....................................................................19
SR20DE
Oil Cooler...................................................................20
Oil Pressure Check....................................................40
ENGINE COOLING SYSTEM........................................21
Oil Pump Inspection ..................................................40
Cooling Circuit ...........................................................21
Regulator Valve Inspection........................................40
System Check............................................................21
Thermostat.................................................................40
Cooling System Inspection ........................................21
Radiator .....................................................................40
Water Pump...............................................................22
Thermostat.................................................................23
CD20T
Radiator .....................................................................25
Oil Pressure Check....................................................41
CD20T
Oil Pump Inspection ..................................................41
Thermostat.................................................................41
ENGINE LUBRICATION SYSTEM ................................26
Radiator .....................................................................41
Lubrication Circuit ......................................................26
PRECAUTION
LIQUID GASKET APPLICATION PROCEDURE
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
Inner
2. Apply a continuous bead of liquid gasket to mating surfaces.
side
(Use Genuine Liquid Gasket or equivalent.)
Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide
for SR engine and 3.5 to 4.5 mm (0.138 to 0.177 in) wide for
Groove Bolt hole
QG and CD engine (for oil pan).
Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide
SEM164
(in areas except oil pan).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.
Inner side
Groove
.
AEM080
LC-2
PREPARATION
Special Service Tools
Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Engine
Tool number
application
Description
Tool name
SR CD QG
ST25051001* Measuring oil
Oil pressure gauge pressure
PS1/4x19/in
Maximum measuring
X X X
range: 2,452 kPa
(24.5 bar, 25 kg/cm2,
356 psi)
NT558
ST25052000* Adapting oil
PS1/8x28/in
Hose pressure gauge to
PS1/4x19/in cylinder block
X X X
NT559
KV10115801 or Removing oil filter
KV10115800
15 faces,
Oil filter wrench
Inner span: 64.3 mm (2.531 in)
X  X
(Face to opposite face)
NT362
99545R2500 Removing oil filter
(KV10106S0)
Oil filter wrench
15 faces,
 X 
Inner span: 92.5 mm (3.642 in)
(Face to opposite corner)
NT631
WS39930000 Pressing the tube of
Tube presser liquid gasket
X X X
NT052
EG17650301 Adapting radiator
Radiator cap tester cap tester to radiator
adapter filler neck
X X X
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
NT564
*:Special tool or commercial equivalent
LC-3
QG
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Lubrication Circuit
NCLC0003
Oil drop
Exhaust camshaft
Intake camshaft
VTC
Main gallery
Timing chain guide
Chain tensioner
Oil jet
Relief valve
Oil filter
Oil pump
Oil strainer
SEM852F
Oil passage
Oil pan Oil strainer
Oil gallery in cylinder block
By-pass passage
Oil pump Regulator valve
Oil jet
Drain
Oil pressure
Oil filter
relief valve
Cylinder head
Main oil
oil gallery
gallery
Timing chain #1 Intake #1 Exhaust Exhaust Intake
Main bearing Chain tensioner
oil jet camshaft journal camshaft journal camshaft journal camshaft journal
Connecting rod Valve timing #1 Intake #1 Exhaust Exhaust Intake
Timing chain
bearing control solenoid camshaft camshaft camshaft camshaft
(OFF) (ON)
Connecting rod
Valve timing
Valve lifter Valve lifter
controller
Piston
SEM938F
LC-4
QG
ENGINE LUBRICATION SYSTEM
Oil Pressure Check
Oil pressure switch Oil Pressure Check
NCLC0004
WARNING:
Be careful not to burn yourself, as the engine and oil may
be hot.
Put gearshift lever in Neutral  N position.
Front
1. Check oil level.
2. Remove oil pressure switch.
SEM853F
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.
ST25051001
Engine speed Approximate discharge pressure
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)
ST25052000
6,000 More than 392 (3.92, 4.0, 57)
SLC926-A
If difference is extreme, check oil passage and oil pump
for oil leaks.
6. Install oil pressure switch with sealant.
Oil Pump
REMOVAL AND INSTALLATION
NCLC0005
Always replace oil seal with a new one. Refer to EM sec-
tion ( OIL SEAL REPLACEMENT ).
When installing oil pump, apply engine oil to gears.
Make sure that O-ring is fitted properly.
1. Drain engine oil.
2. Remove drive belts.
3. Remove oil pan. Refer to EM section ( OIL PAN ).
4. Remove oil strainer.
5. Remove front cover. Refer to EM section ( TIMING CHAIN ).
6. Install front cover.
7. Reinstall parts in reverse order of removal.
LC-5
QG
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont d)
DISASSEMBLY AND ASSEMBLY
NCLC0006
SEC. 135Å"150
7.8 - 10.8 (0.80 - 1.10, 69.4 - 95.5)
7.8 - 12.7
(0.80 - 1.30, 69.4 - 112.8)
: Lubricate with new engine oil.
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
: Use Genuine Liquid Gasket or equivalent.
: Do not re-use.
: N·m (kg-m; in-lb)
39 - 59 (4.0 - 6.0, 29 - 43)
: N·m (kg-m, ft-lb)
SEM854FA
1. Oil pump cover 5. Gasket 8. Spring
2. Inner gear 6. Oil strainer 9. Washer
3. Outer gear 7. Regulator valve 10. Plug
4. Front cover
INSPECTION
NCLC0007
Using a feeler gauge, check the following clearances.
Standard clearance:
Feeler gauge
Unit: mm (in)
Body to outer gear radial clearance 1 0.250 - 0.325 (0.0098 - 0.0128)
Inner gear to outer gear tip clearance 2 Below 0.18 (0.0071)
Body to inner gear clearance 3 0.030 - 0.085 (0.0012 - 0.0033)
Front cover
Body to outer gear axial clearance 4 0.030 - 0.090 (0.0012 - 0.0035)
SEM855F
Inner gear to brazed portion of housing
0.045 - 0.091 (0.0018 - 0.0036)
clearance 5
Straightedge
Front cover
Feeler gauge
SEM856F
LC-6
QG
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont d)
If the tip clearance (2) exceeds the limit, replace gear set.
Inside micrometer
If body to gear clearances (1, 3, 4, 5) exceed the limit,
replace front cover assembly.
Front cover
Micrometer
Inner gear
SEM857F
REGULATOR VALVE INSPECTION
NCLC0008
1. Visually inspect components for wear and damage.
Spring Washer
2. Check oil pressure regulator valve sliding surface and valve
Regulator valve Plug
spring.
3. Coat regulator valve with engine oil.
Check that it falls smoothly into the valve hole by its own
weight.
If damaged, replace regulator valve set or front cover assem-
bly.
SLC986AA
4. Check regulator valve to front cover clearance.
Front
cover
Regulator valve
Clearance:
6 : 0.052 - 0.088 mm (0.0020 - 0.0035 in)
If it exceeds the limit, replace front cover assembly.
SLC101B
Oil Filter
NCLC0010
Oil filter body
The oil filter is a small, full-flow cartridge type and is provided with
Relief valve
a relief valve.
The new and previous oil filter designs differ from each
Body
Filtering paper
color
other and are not interchangeable.
(gray)
Screw
Use Tool KV10115801 for removing oil filter.
Label
(red)
Packing SLC972A
LC-7
QG
ENGINE COOLING SYSTEM
Cooling Circuit
Cooling Circuit
NCLC0016
Thermostat: CLOSED
Radiator Reservoir tank
Thermostat: OPEN
Water inlet
Thermostat
Thermostat housing Heater
Water pump EGR valve
Cylinder block Throttle body
Cylinder head
Thermostat housing
Water outlet
SEM939F
System Check
NCLC0017
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
NCLC0017S01
Check hoses for the following:
Improper attachment
Leaks
Cracks
Damage
Loose connections
Chafing
Deterioration
LC-8
QG
ENGINE COOLING SYSTEM
System Check (Cont d)
CHECKING COOLING SYSTEM FOR LEAKS
NCLC0017S02
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)
CAUTION:
EG17650301
Higher pressure than specified may cause radiator damage.
ULC015
CHECKING RADIATOR
NCLC0017S04
Check radiator for mud or clogging. If necessary, clean radiator as
follows.
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
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.
4. Blow air into the back side of radiator core vertically download.
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.
CHECKING RADIATOR CAP
NCLC0017S03
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)
SLC613-A
Pull the negative pressure valve to open it.
Check that it closes completely when released.
SMA967B
LC-9
QG
ENGINE COOLING SYSTEM
Water Pump
Water Pump
REMOVAL AND INSTALLATION
NCLC0018
SEC. 210
Gasket
17 - 24 (1.7 - 2.4, 12 - 17)
Water pump
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
Do not re-use
Water pump pulley
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
17 - 24 (1.7 - 2.4, 12 - 17)
SEM858F
CAUTION:
When removing water pump assembly, be careful not to
get coolant on drive belt.
Water pump cannot be disassembled and should be
replaced as a unit.
After installing water pump, and check for leaks using
radiator cap tester.
1. Drain coolant from radiator and cylinder block.
Drain plug
Refer to MA section ( Changing Engine Coolant ,  ENGINE
MAINTENANCE ).
2. Remove cylinder head front mounting bracket.
3. Remove drive belts and idler pulley.
4. Loosen water pump pulley bolts.
5. Remove water pump pulley.
SEM869F
6. Remove water pump bolts.
Water pump
7. Remove water pump with gasket.
8. Reinstall parts in reverse order of removal.
SEM859F
LC-10
QG
ENGINE COOLING SYSTEM
Thermostat
INSPECTION
NCLC0019
Check body assembly and vane for rust or corrosion.
Check for rough operation due to excessive end play.
SEM860F
Thermostat
REMOVAL AND INSTALLATION
NCLC0021
17 - 24 (1.7 - 2.4, 12 - 17)
SEC. 210
Thermostat housing
Bracket
Gasket
Water outlet
6.0 - 7.7
(0.61 - 0.79,
To upper radiator hose
52.9 - 68.6)
Engine front
Washer
Thermostat
Water inlet
6.7 - 7.8
(0.68 - 0.80,
59.0 - 69.4)
Do not re-use.
17 - 24 (1.7 - 2.4, 12 - 17)
6.3 - 8.3
(0.64 - 0.85,
Gum ring
: N·m (kg-m, in-lb)
55.6 - 73.8)
17 - 24 (1.7 - 2.4, 12 - 17)
: N·m (kg-m, ft-lb)
From lower radiator hose
SEM861F
Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.
Use Genuine Liquid Gasket or equivalent.
1. Drain engine coolant.
2. Remove lower radiator hose.
3. Remove water inlet, then take out thermostat.
Upper
4. Install gum ring to thermostat.
Gum ring
Jiggle valve
(top side)
Thermostat flange
SEM862F
LC-11
QG
ENGINE COOLING SYSTEM
Thermostat (Cont d)
5. Install thermostat with jiggle valve or air bleeder at upper side.
Jiggle valve position
After installation, run engine for a few minutes, and check
Thermostat
for leaks.
housing
Jiggle valve
SEM863F
Thermostat
INSPECTION
NCLC0022
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 9/95 (0.35/203)
3. Then check if valve closes at 5°C (41°F) below valve opening
temperature.
SLC343
LC-12
QG
ENGINE COOLING SYSTEM
Radiator
Radiator
COMPONENTS
=NCLC0025
4.0 - 4.5
(0.41 - 0.45,
36 - 39)
4.0 - 4.5
(0.41 - 0.45,
36 - 39)
3.8 - 4.5
(0.39 - 0.45,
34 - 39)
3.25 - 4.25
(0.34 - 0.43,
: N·m (kg-m, in-lb)
29 - 37)
NLC086
1 Reservoir tank 5 Upper radiator hose 9 Lower radiator hose

2 Reservoir hose 6 Mounting rubber 10 Cooling fan

3 Radiator cap 7 Cooling fan motor 11 Cooling fan motor shield

4 Mounting bracket 8 Radiator

LC-13
QG
ENGINE COOLING SYSTEM
Radiator (Cont d)
Cooling Fan Control System
NCLC0026
Cooling fans are controlled by the ECM. For details, refer to EC
section [TROUBLE DIAGNOSIS FOR OVERHEAT (COOLING
SYSTEM)].
Refilling Engine Coolant
NCLC0027
For details on refilling engine coolant, refer to MA section
( ENGINE MAINTENANCE ,  Changing Engine Coolant , MA-30)
LC-14
SR20DE
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Lubrication Circuit
Return
Camshaft
Feed
Relief valve Hydraulic lash adjuster
Oil filter
Oil filter bracket
Oil cooler
Oil pump
Oil pan
Oil strainer
SLC093B
Oil pan
Oil strainer
Regulator valve
Oil pump
(Built into oil pump)
Oil filter Relief valve
Relief valve
Oil cooler
(Built into oil filter)
Main gallery Chain tensioner
Main bearing Timing chain
Cylinder head oil
Connecting rod bearing gallery
Connecting rod
Oil gallery
Camshaft Hydraulic lash
journal adjuster
Oil passage
By-pass passage
Piston and cylinder
To oil pan
NLC043
LC-15
SR20DE
ENGINE LUBRICATION SYSTEM
Oil Pressure Check
.
SR20DE models Oil Pressure Check
.
WARNING:
Oil pressure
switch
Be careful not to burn yourself, as the engine and oil may
be hot.
Oil pressure check should be done in  Neutral position .
1. Check oil level.
2. Remove oil pressure switch.
.
Oil cooler
.
NLC045
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.
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)
Idle speed More than 78 (0.78, 0.8, 11)
3,200 314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 - 57)
.
SLC717A
If difference is extreme, check oil passage and oil pump for oil
leaks.
6. Install oil pressure switch with sealant.
LC-16
SR20DE
ENGINE LUBRICATION SYSTEM
Oil Pump
Oil Pump
REMOVAL AND INSTALLATION
1. Drain engine oil
2. Remove drive belts.
3. Remove cylinder head. (Refer to EM section).
4. Remove oil pan. (Refer to EM section).
5. Remove oil strainer and baffle plate.
6. Remove front cover assembly.
7. Install front cover assembly.
8. Reinstall any parts removed in reverse order of removal
DISASSEMBLY AND ASSEMBLY
SEC. 135Å"150
3.7 - 5.0 (0.38 - 0.51, 32.7 - 44.3)
6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)
Gasket
.
: N·m (kg-m, ft-lb)
16 - 19 (1.6 - 1.9, 12 - 14)
: N·m (kg-m, in-lb)
: Apply engine oil.
50 - 70 (5.1 - 7.1, 37 - 51)
NLC050
: Apply liquid gasket.
1 Oil pump cover 4 Outer gear 7 Plug

2 Front cover 5 Regulator valve 8 Regulator valve set

3 Inner gear 6 Spring 9 Oil strainer

Always replace oil seal, gasket and O-ring with new ones.
When installing oil pump, apply engine oil to inner and
outer gears.
Be sure that O-rings are properly fitted.
LC-17
SR20DE
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont d)
Feeler gauge
Straightedge
Feeler
gauge
Front cover
SLC494A SLC495A
Front
cover
Inner gear
SLC450A
SLC860A
INSPECTION
Using a feeler gauge, check the following clearances:
Unit: mm (in)
Body to outer gear clearance (radial) 1 0.114 - 0.200 (0.0045 - 0.0079)

Inner gear to outer gear tip clearance 2 Below 0.18 (0.0071)

Body to inner gear clearance 3 0.05 - 0.09 (0.0020 - 0.0035)

Body to outer gear clearance (axial) 4 0.05 - 0.11 (0.0020 - 0.0043)

Inner gear to brazed portion of housing clear- 0.045 - 0.091 (0.0018 - 0.0036)
ance 5

If the tip clearance ( 2 exceeds the limit, replace gear
)
set.
If body to gear clearances ( 1 3 4 5 exceed the
, , , )
limit, replace front cover assembly.
LC-18
SR20DE
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont d)
REGULATOR VALVE INSPECTION
Spring
Washer 1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
Regulator valve
Cap
spring.
3. Coat regulator valve with engine oil. Check that regulator valve
falls smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump cover.
SLC986AA
4. Check regulator valve to oil pump cover clearance.
Oil pump cover Regulator valve
Clearance:
6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in)

If it exceeds the limit, replace oil pump cover.
SLC451A
Oil Filter
Oil filter body
The oil filter is a small, full-flow cartridge type and is provided with
Relief valve
a relief valve.
The new and existing oil filter designs differ from each
Filtering paper
other and are not interchangeable.
Thread Use Tool KV10115801 or KV10115800 for removing oil fil-
ter.
Gasket
NLC046
LC-19
SR20DE
ENGINE LUBRICATION SYSTEM
Oil Cooler
Oil Cooler
SEC. 213
Gasket
Oil cooler
Coolant
flow
O-ring
Oil filter
Oil pressure switch
13 - 17 N·m
(1.3 - 1.7 kg-m, 9 - 12 ft-lb)
Oil cooler assembly
: Do not re-use
34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb)
: Locking sealant.
.
: N·m (kg-m, ft-lb)
NLC047
REMOVAL AND INSTALLATION
1. Drain engine oil and coolant.
2. Remove oil cooler.
3. Installation is in reverse order of removal
Be careful not to burn yourself as engine oil is hot
After installation, run engine for a few minutes and check
for oil leaks.
Do not spill coolant on drive belts.
INSPECTION
1. Check oil cooler for cracks.
2. Check oil cooler for clogging by blowing through coolant inlet.
If necessary, replace oil cooler assembly.
LC-20
SR20DE
ENGINE COOLING SYSTEM
Cooling Circuit
Cooling Circuit
YLC029
System Check
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.
Cooling System Inspection
CHECKING HOSES
Check water hoses for proper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR CAP
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)
SLC613-A
LC-21
SR20DE
ENGINE COOLING SYSTEM
Cooling System Inspection (Cont d)
Pull the negative pressure valve to open it.
Check that it closes completely when released.
SMA967B
CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with a
Hose adapter
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher than the specified pressure may cause radiator dam-
age.
.
SLC546AA
Water Pump
Drain plug
REMOVAL AND INSTALLATION
1. Drain coolant from radiator.
2. Remove cylinder block drain plug located at left front of cylin-
der block and drain coolant.
3. Remove front RH wheel and engine side cover.
8 - 12 N·m
(0.8 - 1.2 kg-m,
4. Remove drive belts.
69 - 104 in-lb)
Oil level gauge guide 5. Remove front engine mounting.
.
SLC557AA
6. Remove water pump.
SEC. 210
Liquid
CAUTION:
gasket
When removing water pump assembly, be careful not to
get coolant on drive belt.
Water pump cannot be disassembled and should be
replaced as a unit.
After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
16 - 21 N·m
Water pump
(1.6 - 2.1 kg-m,
SLC556AA
12 - 15 ft-lb)
7. Before installing, remove all traces of liquid gasket from mat-
ing surface of water pump using a scraper.
Also remove traces of liquid gasket from mating surface
of cylinder block.
SLC433A
LC-22
SR20DE
ENGINE COOLING SYSTEM
Water Pump (Cont d)
8. Apply a continuous bead of liquid gasket to mating surface of
water pump.
Liquid gasket
Use Genuine Liquid Gasket or equivalent.
9. Install any parts removed in reverse order of removal
2.0 - 3.0 mm
(0.079 - 0.118 in)
SLC434A
INSPECTION
1. Check body assembly for rust or corrosion.
2. Check for rough operation due to excessive end play.
SLC408C
Thermostat
SEC. 210
6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)
16 - 21 (1.6 - 2.1, 12 - 15)
Thermostat
6.3 - 8.3
Air relief plug
housing
(0.64 - 0.85, 55.8 - 73.5)
(if so equipped)
Thermostat
Water inlet
16 - 21
(1.6 - 2.1,
12 - 15)
16 - 21 (1.6 - 2.1, 12 - 15)
2.0 - 3.0 mm
(0.079 - 0.118 in)
2.0 - 3.0 mm
.
(0.079 - 0.118 in)
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Apply liquid gasket SLC050B
LC-23
SR20DE
ENGINE COOLING SYSTEM
Thermostat (Cont d)
REMOVAL AND INSTALLATION
Upper
Jiggle valve 1. Remove lower radiator hose and drain engine coolant.
2. Remove water inlet, then take out thermostat.
3. Before installing, remove all traces of liquid gasket from mat-
ing surface of each part using a scraper.
4. Apply a continuous bead of liquid gasket to mating surface of
each part.
Use Genuine Liquid Gasket or equivalent.
5. Install thermostat with jiggle valve or air bleeder facing upward.
SLC767 After installation, run engine for a few minutes, and check
for leaks.
Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.
INSPECTION
1. Check valve seating condition at ordinary temperatures. 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 9/95 (0.35/203)
3. Then check if valve closes at 5°C (41°F) below valve opening
SLC343
temperature.
LC-24
SR20DE
ENGINE COOLING SYSTEM
Radiator
Radiator
SEC. 214
3.8 - 4.5
(0.39 - 0.46,
3.7 - 5.0 (0.38 - 0.51, 32.7 - 44.3)
33.9 - 39.9)
2

4

3

10

1

5

11

10 12

8

4.0 - 4.5
(0.41 - 0.46,
35.4 - 39.8)
3.25 - 4.25
6

(0.33 - 0.43,
28.8 - 37.6)
9

N·m (kg-m, in-lb)
11
7
7

NLC090
1 Reservoir tank 5 Upper hose 9 Lower hose

2 Reservoir tank hose 6 Mounting rubber 10 Cooling fan

3 Radiator cap 7 Oil cooler hose (A/T models) 11 Cooling fan motor

4 Mounting bracket 8 Radiator 12 Cooling fan motor shield

Cooling fan control system
Cooling fans are controlled by the ECM. For details, refer to
EC-section ( COOLING SYSTEM ,  Diagnostic Procedure ,
EC-SR-284).
Refilling engine coolant
For details on refilling engine coolant, refer to MA section
( ENGINE MAINTENANCE ,  Changing Engine Coolant ,
MA-41).
LC-25
CD20T
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Lubrication Circuit
: Oil gallery in cylinder block
: Oil passage
: By-pass passage
Oil pump Oil filter Oil cooler
Relief valve
Relief valve
Regulator valve
Cylinder head oil gallery Turbocharger
Oil strainer
Main bearing
Crankshaft
Camshaft bracket
Hydraulic valve lifter
Connecting rod bearing
Camshaft journal
Oil feed hose
Connecting rod
Vacuum pump Cam lobe
Piston and cylinder wall
Oil return hose
Oil pan
SLC083B
LC-26
CD20T
ENGINE LUBRICATION SYSTEM
Oil Pressure Check
Oil Pressure Check
Oil filter
WARNING:
Oil pressure switch
Be careful not to burn yourself, as the engine and oil may
be hot.
Oil pressure check should be done in  Neutral gear posi-
tion.
1. Check oil level.
2. Remove oil pressure switch.
SLC461
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.
ST2051001
Engine rpm Approximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed More than 59 (0.59, 0.6, 9)
2,000 294 (2.9, 3, 43)
ST25052000
SLC926-A
If difference is extreme, check oil passage and oil pump for oil
leaks.
6. Install oil pressure switch with sealant.
Oil Pump
REMOVAL AND INSTALLATION
Rear engine gusset
1. Drain engine coolant and engine oil.
2. Remove upper radiator hose, drive belts, crank pulley, timing
belt covers and timing belt. (Refer to EM section).
3. Remove exhaust front tube, timing belt pulley and rear engine
gusset (bar type), then remove oil pan. (Refer to EM section).
SLC462A
4. Remove crankshaft position sensor (TDC).
9.2 - 10.8 N·m
Crankshaft
(0.94 - 1.10 kg-m,
position 5. Remove oil pump assembly with oil strainer.
81.4 - 95.6 in-lb)
sensor
6. Reinstall any part removed. Refill engine oil and engine cool-
(TDC)
ant.
Apply liquid gasket to oil pump.
Apply liquid gasket to oil pan.
Apply liquid gasket to both ends of oil pan oil seals.
Install oil pan, fitting oil seals in the correct position.
12 - 16 N·m
(1.2 - 1.6 kg-m,
SLC087B
9 - 12 ft-lb)
LC-27
CD20T
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont d)
DISASSEMBLY AND ASSEMBLY
SEC. 150
6 - 8 (0.6 - 0.8, 52 - 69)
Cover
Oil pump body
Regulator valve
Spring
.
Inner
gear
Shim
39 - 69
(4.0 - 7.0, 29 - 51)
Outer
Gasket
gear
Plug
N·m (kg-m, ft-lb)
N·m (kg-m, in-lb)
16 - 19 (1.6 - 1.9, 12 - 14)
: Apply engine oil
SLC097B
When installing oil pump, apply engine oil to inner and
outer gears.
Apply liquid gasket when installing oil pump onto engine.
2.5 Ä… 0.5
2.5 Ä… 0.5
(0.098 Ä… 0.020) dia. Bolt hole
(0.098 Ä…
0.020)
dia.
Unit: mm (in)
SLC566A
LC-28
CD20T
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont d)
INSPECTION
Using a feeler gauge, check the following clearances.
Unit: mm (in)
Body to outer gear clearance 1 0.114 - 0.200 (0.0045 - 0.0079)

Outer gear to inner gear clearance 2 Less than 0.18 (0.0071)

Housing to inner gear clearance 3 0.05 - 0.09 (0.0020 - 0.0035)

Housing to outer gear clearance 4 0.05 - 0.11 (0.0020 - 0.0043)

Inner gear to housing clearance 5 0.045 - 0.091 (0.0018 - 0.0036)

SLC560A
If it exceeds the limit, replace gear set or entire oil pump
assembly.
SLC561C
SLC567A
SLC568A
REGULATOR VALVE INSPECTION
Spring
1. Visually inspect components for wear and damage.
Regulator valve
Plug 2. Check oil pressure regulator valve sliding surface and valve
spring.
Shim
3. Coat regulator valve with engine oil. Check that it falls freely
into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump assembly.
SLC049B
LC-29
CD20T
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont d)
OIL PRESSURE RELIEF VALVE INSPECTION
Inspect oil pressure relief valve (indicated by arrow) for movement,
cracks and breaks by pushing the ball. If replacement is necessary,
remove valve by prying it out with a suitable tool. Install a new valve
by tapping it into place.
SLC446
Oil Cooler
SEC. 150Å"213
34 - 44
(3.5 - 4.5, 25 - 33)
.
6

Front
16 - 21
(1.6 - 2.1, 12 - 15)
16 - 21
Do not re-use
(1.6 - 2.1, 12 - 15)
N·m (kg-m, ft-lb)
SLC084B
1 Oil cooler 3 O-ring 5 Gasket

2 Connector 4 Oil filter bracket 6 Gasket

INSPECTION
1. Check oil cooler element and housing for cracks.
2. Check coolant inlet of oil cooler for clogging by blowing through
it.
Replace it if necessary.
Oil cooler
SLC465A
LC-30
CD20T
ENGINE COOLING SYSTEM
Cooling Circuit
Cooling Circuit
Bottom by-pass
Oil cooler To radiator
From
turbocharger
Thermostat
Radiator cap
Reservoir tank
Radiator
Water inlet
Thermostat
Water pump
Heater unit
Cylinder block Oil cooler
Turbocharger
Cylinder head
Water outlet
: By-pass passage
SLC085B
LC-31
CD20T
ENGINE COOLING SYSTEM
System Check
System Check
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 cap and carefully loosen it a quar-
ter turn to release built-up pressure. Then remove the cap
completely.
CHECKING COOLING SYSTEM HOSES
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR CAP
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
98 - 118 kPa
(0.98 - 1.18 bar, 1.0 - 1.2 kg/cm2, 14 - 17 psi)
Limit
59 - 118 kPa
(0.59 - 1.18 bar, 0.6 - 1.2 kg/cm2, 8.6 - 17.1 psi)
SLC613-A
Pull the negative pressure valve to open it. Check that it closes
completely when released.
SMA967B
CHECKING COOLING SYSTEM FOR LEAKS
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)
CAUTION:
Higher than the specified pressure may cause radiator dam-
age.
SLC422A
LC-32
CD20T
ENGINE COOLING SYSTEM
Water Pump
Water Pump
REMOVAL AND INSTALLATION
.
CAUTION:
. Radiator lower
.
Radiator
hose
When removing water pump assembly, be careful not to
get coolant on drive belt.
Water pump cannot be disassembled and should be
replaced as a unit.
After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
.
1. Remove radiator lower hose from radiator and drain engine
NLC040
coolant.
2. Drain engine coolant from cylinder block.
3. Remove upper radiator hose, timing belt covers, front engine
mounting bracket and timing belt. (Refer to EM section).
Drain plug
4. Remove timing belt tensioner and idler and timing belt lower
(cylinder block)
back cover.
NLC041
5. Remove water pump.
Water pump
.
SLC562AA
When installing water pump, replace the gasket with a new
one.
22 - 25 N·m (2.2 - 2.6 kg-m, 16 - 19 ft-lb)
SLC086B
INSPECTION
Check body assembly for rust or corrosion.
Check for rough operation due to excessive end play.
SLC760
LC-33
CD20T
ENGINE COOLING SYSTEM
Thermostat
Thermostat
REMOVAL AND INSTALLATION
SEC. 210-211
Water outlet
16 - 21 (1.6 - 2.1, 12 - 15)
From oil cooler
16 - 21 (1.6 - 2.1, 12 - 15)
From heater unit
Up
Thermostat
Thermostat housing
Water inlet
16 - 21 (1.6 - 2.1, 12 - 15)
2.5Ä…0.5
2.5 (0.098)
3.5 (0.138)
(0.098Ä…0.020)
dia.
Bolt hole
Bolt hole 2.5Ä…0.5 (0.098Ä…0.020) dia.
2.5Ä…0.5 (0.098Ä…0.020) dia.
2.5Ä…0.5
2.5Ä…0.5
(0.098Ä…0.020) dia.
(0.098Ä…0.020) dia.
Unit: mm (in)
: N·m (kg-m, ft-lb)
SLC564AA
1. Drain engine coolant.
2. Remove lower radiator hose.
3. Remove water inlet, then take out thermostat.
4. Before installing thermostat, remove all traces of liquid gasket
from mating surface of each part using a scraper.
5. Apply liquid gasket to water outlet, thermostat housing and
water inlet.
6. Install thermostat with jiggle valve uppermost.
After installation, run engine for a few minutes, and check
Upper
for leaks.
Jiggle valve
Air bleeder
SLC097
LC-34
CD20T
ENGINE COOLING SYSTEM
Thermostat (Cont d)
INSPECTION
1. Check valve seating condition at ordinary temperatures. 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 10/95 (0.39/203)
3. Then check if valve closes at 5°C (41°F) below valve opening
SLC343
temperature.
LC-35
CD20T
ENGINE COOLING SYSTEM
Radiator
Radiator
4.0 - 4.5
(0.41 - 0.45,
36 - 39)
4.0 - 4.5
(0.41 - 0.45,
36 - 39)
3.8 - 4.5
(0.39 - 0.45,
34 - 39)
3.25 - 4.25
(0.33 - 0.43,
28.8 - 37.6)
: N·m (kg-m, in-lb)
NLC089
1 Reservoir tank 5 Upper radiator hose 9 Cooling fan

2 Reservoir tank hose 6 Mounting rubber 10 Cooling fan motor

3 Radiator cap 7 Radiator 11 Cooling fan motor shield

4 Mounting bracket 8 Lower radiator hose

Cooling fan control system
Cooling fans are controlled by the ECM. For details, refer to EC
section ( COOLING FAN ,  Diagnostic Procedure , EC-CD-
90).
Refilling engine coolant
For details on refilling engine coolant, refer to MA section
( ENGINE MAINTENANCE ,  Changing Engine Coolant ,
MA-52).
LC-36
ENGINE COOLING SYSTEM
Overheating Cause Analysis
Overheating Cause Analysis
NCLC0028
Symptom Check items
Water pump malfunction Worn or loose drive belt
Thermostat stuck closed 
Dust contamination or
Poor heat transfer paper clogging 
Damaged fins
Mechanical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate
Reduced air flow High resistance to fan rota-  
tion
Damaged fan blades
Damaged radiator shroud   
Improper coolant mixture
  
Cooling sys- ratio
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, deterio-
Insufficient coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leaks into
Overflowing reservoir tank
Cylinder head gasket dete-
cooling system
rioration
LC-37
ENGINE COOLING SYSTEM
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
Dragging brakes
parts mal-
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
LC-38
QG
SERVICE DATA AND SPECIFICATIONS (SDS)
Oil Pressure Check
Oil Pressure Check
NCL0011
Engine speed Approximate discharge pressure
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
NCLC0013
Unit: mm (in)
Body to outer gear radial clearance 0.250 - 0.325 (0.0098 - 0.0128)
Inner gear to outer gear tip clearance Below 0.18 (0.0071)
Body to inner gear clearance 0.030 - 0.085 (0.0012 - 0.0033)
Body to outer gear axial clearance 0.030 - 0.090 (0.0012 - 0.0035)
Inner gear to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036)
Regulator Valve Inspection
NCLC0012
Unit: mm (in)
Regulator valve to oil pump cover clearance 0.052 - 0.088 (0.0020 - 0.0035)
Thermostat
NCLC0029
Valve opening temperature °C(°F) 82 (180)
Valve lift mm/°C (in/°F) More than 9/95 (0.35/203)
Radiator
NCLC0030
Unit: kPa (bar, kg/cm2, psi)
Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Cap relief pressure
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure 157 (1.57, 1.6, 23)
LC-39
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS)
Oil Pressure Check
Oil Pressure Check
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)
Idle speed More than 78 (0.78, 0.8, 11)
3,200 314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 - 57)
Oil Pump Inspection
Unit: mm (in)
Body to outer gear clearance (radial) 0.114 - 0.200 (0.0045 - 0.0079)
Inner gear to outer gear tip clearance Below 0.18 (0.0020 - 0.0071)
Body to inner gear clearance 0.05 - 0.09 (0.0020 - 0.0035)
Body to outer gear clearance (axial) 0.05 - 0.11 (0.0020 - 0.0043)
Inner gear to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036)
Regulator Valve Inspection
Unit: mm (in)
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)
Thermostat
Valve opening temperature °C(°F) 82 (180)
Valve lift mm/°C (in/°F) More than 9/95 (0.35/203)
Radiator
Unit: kPa (bar, kg/cm2, psi)
Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Cap relief pressure
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure 157 (1.57, 1.6, 23)
LC-40
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS)
Oil Pressure Check
Oil Pressure Check
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)
Idle speed More than 59 (0.59, 0.6, 9)
2,000 294 (2.9, 3, 43)
Oil Pump Inspection
Unit: mm (in)
Body to outer gear clearance (radial) 0.114 - 0.200 (0.0045 - 0.0079)
Outer gear to inner gear clearance Less than 0.18 (0.0071)
Housing to inner gear clearance 0.05 - 0.09 (0.0020 - 0.0035)
Housing to outer gear clearance (axial) 0.05 - 0.11 (0.0020 - 0.0043)
Inner gear to housing clearance 0.045 - 0.091 (0.0018 - 0.0036)
Thermostat
Valve opening temperature °C(°F) 82 (180)
Valve lift mm/°C (in/°F) More than 10/95 (0.39/203)
Radiator
Unit: kPa (bar, kg/cm2, psi)
Standard 98 - 118 (0.98 - 1.18, 1.0 - 1.2, 14 - 17)
Cap relief pressure
Limit 59 - 118 (0.59 - 1.18, 0.6 - 1.2, 8.6 - 17.1)
Leakage test pressure 157 (1.57, 1.6, 23)
LC-41
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS)
NOTE
LC-42