DAIHATSU

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LUBRICATION SYSTEM

DESCRIPTION LU-2 TROUBLE SHOOTING LU-3 OIL PRESSURE CHECK LU-3 ENGINE OIL CHANGE & OIL FILTER

REPLACEMENT LU-5 OIL COOLER LU-7

WRUQO-LUO01

LUBRICATION SYSTEM

DESCRIPTION

The lubrication system employs a fully-forced feed, filtering method. The oil stored in the oil pan is sucked by an oil pump which is directly driven by the crankshaft. Then, the thus-sucked oil flovvs through an oil pump strainer and is filtered at an oil filter. After having passed through the passages of the cylinder block, it will be divided into two streams so as to lubricate various sections. One stream of the lubrication oil performs lubrication of various sections of the crankshaft and connecting rod- and piston-related parts, The other stream of the lubrication oil rises to the cylinder head section. Then, it performs lubrication of the camshaft and valve rocker shaft-related parts

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va1ve rocker shafts

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LUBRICATION SYSTEM

TROUBLE SHOOTING

Problem Possible causes Remedies

Page

Oil leakage Cylinder head, cylinder block, oil

cooler or oil pump body damaged or

cracked _

Oil Seal faulty Gasket faulty

Repair, if necessary.

Replace oi! seal. Replace gasket,

Low oil pressure Oil leakage

Relief valve faulty OH pump faulty Poor quaiity engine oi! Crankshaft bearing faulty Connecting rod bearing faulty Oil filter clogged Low oil level

Repair, as necessary. Replace relief valve. Repair oil pump. Change engine oil Replace bearing. Replace bearing. Replace oil filter. Check oil Ievei

High oil pressure Relief valve faulty Replace relief vaive.

1. Oil quality check

Check the oil for deterioration, water entry, discoloring or dilution. If oi! quaiity is poor, change the oil. Use API grade SG or SF rnuitigrade viscosity, fuel-efficient oii. (See page LU-5.)

2. Oil level check l

The oil level should be between the L and F levels on the dlpstick. If the level is low, check to see if any oil leakage is present. Acld oil tothe F level.

NOTE: - The amount of oil between the [L] level and the [F] equals to one liter (1.1 US qt). V

Low Ievel Full

level

3. Oil pressure check

(1) Disconnect the battery ground cable from the negative

(-) terminal of the battery. (2) Remove the air cleaner and hose assembiy. (3) Temporarily detach the air conditioner compressor

sembiy. (See EM-86.)

(4) Disconnect the oil pressure switch connector.

LUBRICATION SYSTEM

(5) Remove the oil pressure switch. NOTE: Use a hexagonal iong box wrench for the removal.

(6) Install the oil pressure gauge. NOTE: The pressure gauge is available as a SST.

SST: 09268-87701-000

(7) Start the engine and warm it to the normal operating

temperature. Check the oiI pressure. At Idle Speed: More Than 0.2 kg/cmz (2.8 psi) At 3000 rpm: 2.5 - 5.0 kg/cmz (35.6 - 71.0 psi)

ll the measured value fails to conform to the specified value, check and repair the oil pump. (See page El\/l-121.) (8) Stop the engine. (9) Remove the oil pressure gauge. (10) Clean the threaded portion of the oii pressure switch. Wind sea! tape around the threaded portion. Install the oil pressure switch in the oil pump. Tightening Torque:

1.2 - 2.0 kg-m (8.7 - 14.5 ft-Ib, 11.8 - 19.6 N-m)

NOTE: ~ Use a hexagonal long box wrench for the installation. o The new oil pressure switch is coated with sealing

materials.

(11) Connect the connector of the oil pressure switch. (12) install the air conditioner compressor assembly onto

bracket. (See page EM-146.) (13) install the air cleaner and hose assembly into position.

(See page (14) Connect the battery ground cable to the negative (~)

terminal of the battery. (15) Start the engine and check it for oll leakage.

Repair the leaky point lf oil leakage exists.

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LUBRICATION SYSTEM

ENGINE OIL CHANGE & OIL FILTER REPLACEMENT

1. Drain the engine oii as follows:

(1) Disconnect the battery ground cable from the negative

(-) terminal of the battery. (2) Piace a euitabie container under the oii drain plug. (3) Remove the engine under cover. (4) Drain the oil by removing the oil drain plug.

2. Oil filter replacement

(1) Remove the air cleaner and hose assembiy. (2) Remove the oil filter element, using the oil fiiter remover. NOTE: Place a suitable container under the oil filter because the engine oil flows out.

(3) inspect and clean the oil filter instaliation surface.

(4) Thiniy apply engine oi! to the “O” ring of a new ci! filter.

(5) Screw in the oil filter by hand, until the “O” ring of the

oil filter contacts the oil filter installing surface.

LUBRICATION SYSTEM

(6) Tighten the oil filter three fourths to one complete turn,

using the oil filter remover. (7) install the air cleaner and hose assembly into position.

(See page El\/l-35.)

3. Filling engine oil

(1) Clean the oll drain plug. Install it with a new gasket

interposed. NOTE: Remove any remaining gasket material from the oil pan, using a gasket scraper.

Tightening Torque:

2.0 - 3.0 (14.5 - 21.7 ft-Ib, 19.6 29.4 N- m)

(2) Fill the engine with engine oil.

The oil should be API grade SG or SF multigrade vis- cosity, fuei-efficient oil. Oil capacity

When only engine oil is changed:

3.3 liter (3.5 US qt.) When engine oil is changed and oil filter is replaced:

3.5 liter (3.7 US qt.) After engine has been overhauled or when engine oil has been drained completely from engine:

3.8 liter (4.0 US qt.)

(3) Connect the battery ground cable to the negative (~)

terminal of the battery.

(4) Start the engine and check it for leakage.

Repair the leaky point if oi! leakage exists. (5) Stop the engine. After a Iapse of two or three minutes,

check the oil level. lf oll level is less than the full level, replenish the oil to the lull level.

Classification

("F) 0 10 20 30 40 50 6G 70 80 90 100 (°C) I-18) (-12) (-1) (4) (10) (16) (21) (27) (32) (38)

Atmosphere temperature range anticipated before next oil change

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Low level Full ieve!

LUBRICATION SYSTEM

OIL COOLER

coMP0NENTs

REMOVAL OF OIL COOLER

Disconnect the battery ground cable from the negative (-) terminal of the battery. Drain the coolant. (See page CO-4.) Remove the air cleaner and nose assembly. Temporariiy remove the air conditioner compressor assembly. (See EM~86.) Remove the oii filter. (See page LU~5.) Disconnect the oil cooler nose at the radiator side.

8. Remove the oi! cooler pipe from the hose by sliding the H

hose bands. U

hose bands

LUBRICATION SYSTEM

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9. Remove the oil cooler, using the following SST.

SST: 09268-87704-OOO

NOTE: Place a suitable container below the oil cooler attaching section so as to receive any oil and water flowing from the oil cooler.

10. Disconnect the Water hose from the oii cooler.

INSPECTION OF OIL COOLER

1. Check the oil cooler for damage.

Replace the oil cooler if the oil cooler exhibits damage.

2. Blow air from one end ofthe oi! cooler pipe. Ensure that air

continuity exists.

3. With one end of the oil cooler pipe plugged with your finger, apply a negative pressure of 100 mml-lg ($3.937 inchl-lg) to the other end, using a or a vacuum pump. Ensure that the applied negative pressure is retained. lf the negative pressure is not kept, replace the oil cooler.

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LUBBICATION SYSTEM

4. Check the oil cooler set bolt for damage.

Replace the oil cooler set bolt if it exhibits damage.

2. Install the new “O” ring on the cooler.

3. Connect the water hoSe to the oil cooler. Attach the hose

bands.

4. Using the set bolts, install the oii cooler by making the locating rib of the oii cooler Contact with the cylinder block.

NOTE: Care must be exercised to ensure that the “O” ring may not be displaced during the installation.

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LUBRICATION SYSTEM

6. Connect the oil cooler inlet pipe to the oil cooler hose that K

has been installed on the oil cooler. NOTE: _ it i Y i install the oil cooler pipe, by taking into consideration an i V angie at which it is mounted on the cylinder block. /5. “_

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7. Connect the oi! cooler hose to the radiator lower tank.

NOTE: Ensure that the clamp is securely installed.

8. Install the oil cooler pipe on the cylinder block with a new V

_ gasket interposed. igfv

Tightening Torque (Union bolt):

9. installation of oil filter

(1) Clean the oil filter instailation surface of the oil cooler. (2) Install the oil fifter. (See page LU~6.) - 10. lnstall the air conditioner compressor assembly. (See EM-146.) 11. Install the air cleaner and hose assembly onto position. (See EM-35.) 12. Fill coolant. (See page CO-4.) 13. Connect the battery ground cable to the negative (-) terminal of the battery. 14. Start the engine. Check to see if any oil leakage oil fuel leakage is present.

lf the engine exhibits any defect, repair it or replace the defective part, as required. 15. Stop the engine. After two or three minutes, check the engine oil level, using the oil level gauge. Replenish

engine oil to the FULL level, as required. (See page LU-6.)

WRUQO-LUO38

LU-10