GROUP 12 LUBRICATION

SPECIFICATIONS .............................................................................. 12-2

STRUCTURE AND OPERATION

1. Lubrication System ........................................................................... 12-3 12
2. Oil Pump ............................................................................................. 12-3
3. Oil Cooler ............................................................................................ 12-4
4. Oil Filter ....................................................................................... 12-5
5. Lubrication of Engine Components ................................................. 12-6

TROUBLESHOOTING ....................................................................... 12-9

GENERAL INSPECTION AND ADJUSTMENT

1. Oil Filter Replacement ..................................................................... 12-10
2. Engine Oil Replacement .................................................................. 12-12
3. Oil Pressure Measurement ............................................................. 12-13

OIL PAN, OIL JETS AND OIL LEVEL SENSOR .............................. 12-14

OIL PUMP, OIL STRAINER ............................................................. 12-16

OIL FILTER ...................................................................................... 12-18

OIL COOLER ................................................................................... 12-20

REGULATOR VALVE ....................................................................... 12-21

12-1
SPECIFICATIONS
Item Specifications
Method of lubrication Oil pump type
Oil filter Spin-on paper-filter type
Oil cooler Shell and plate type (multiple-plate type)
Grade API classification CD, CD/SF, CE, CE/SF, CF-4
Engine oil Oil pan Approx. 11 {11}, 12 {12}, 16 {16}, 28 {28},
Quantity dm3 {L}
Oil filter Approx. 2.3 {2.3}

12-2
STRUCTURE AND OPERATION 12
1. Lubrication System

1 Engine oil pressure switch 9 Oil pump 19 Camshaft bushing

2 Main oil gallery 10 Oil strainer 20 Rocker bushing
3 Bypass valve 11 Regulator valve 21 Roller
4 Oil cooler 12 Crankshaft main bearing 22 Valve bridge
5 Engine oil bypass alarm 13 Connecting rod bearing 23 No.1 Idler shaft
switch 14 Connecting rod bushing 24 No.2 Idler shaft
6 Full-flow filter element 15 Check valve for oil jet 25 No.3 Idler shaft
7 Bypass filter element 16 Piston 26 Turbocharger
8 Relief valve (built into oil 17 Air compressor 27 Oil pan
pump) 18 Timing gear

2. Oil Pump
• This engine uses a gear-type oil pump
driven by the rotation of the crankshaft
transmitted through the engagement
of the crankshaft gear and the oil
pump gear.
• The oil pump has a relief valve, which
prevents excessive pressure from
building up inside the lubricating sys-
tem by allowing part of the engine oil
to escape to the oil pan when the oil
pressure exceeds a specified level.

12-3
STRUCTURE AND OPERATION
3. Oil Cooler

3.1 Bypass valve

• When the engine oil is cool and its vis-
cosity is high, or when the oil cooler el-
ement becomes clogged and restricts
the flow of the engine oil, the bypass
valve opens to let the engine oil by-
pass the oil cooler and flow directly to
the oil filter.

3.2 Engine oil pressure switch and

regulator valve
• When the pressure of the engine oil to
the main oil gallery drops below the
specified level, an electrical contact in-
side the engine oil pressure switch
closes. This causes a warning lamp on
the meter cluster to illuminate and no-
tify the operator of the excessive pres-
sure drop.
• When the oil pressure in the main oil
gallery exceeds the specified level, the
regulator valve opens to adjust the oil
pressure by allowing part of the en-
gine oil to escape to the oil pan.

12-4
 12
4. Oil filter
• This oil filter is a spin-on paper-filter
type that incorporates both a full-flow
filter and a bypass filter.

4.1 Engine oil bypass alarm switch

• If the oil filter elements clog up, this
will restrict the flow of engine oil, caus-
ing the engine to seize. To prevent
this, the oil filter is provided with the
engine oil bypass alarm switch.
• If the oil filter clogs up, the engine oil
bypass alarm switch trips in such a
way as to direct the engine oil straight
on to the oil cooler, bypassing the full-
flow and bypass filter elements. When
the switch trips, the relevant warning
lamp illuminates to alert the operator
to the clogged oil filter.

12-5
STRUCTURE AND OPERATION
5. Lubrication of Engine Components

• The engine oil in the main oil gallery lubricates the engine components in the following ways.

5.1 Main bearing and connecting rod bearing

• Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of
each connecting rod. Simultaneously, engine oil supplied through an oil passage in the connecting rod lubricates
the connecting rod’s small end (connecting rod bushing).

5.2 Timing gears

• Engine oil in the main oil gallery is directed through the oil passages in the crankcase and cylinder head and is
used to lubricate the various gear shafts. After lubricating the gear shafts, the oil is used to lubricate the gears be-
fore returning the oil pan.

12-6
 12
5.3 Valve mechanism

• Engine oil in the main oil gallery is directed through the oil passages in the cylinder head, rocker case and front
rocker bracket. The oil is then supplied through the camshaft and rocker shaft. The oil flowing through the cam-
shaft also lubricates the camshaft journals. The oil flowing through the rocker shaft also lubricates the rockers.
The oil flowing to the adjusting screws on the rockers also lubricates the valve bridges. After lubricating the vari-
ous parts, the oil returns to the oil pan.

5.4 Check valves and oil jets

• An oil jet is fitted in the lower part of
the main oil gallery for each cylinder.
• Engine oil is sprayed out of the oil jet
into the piston to cool the piston.
• Each oil jet is fitted with a check valve
that opens and closes at predeter-
mined oil pressure levels. At low en-
gine speeds, the check valve closes to
maintain the required volume of oil in
the lubrication system and prevent re-
ductions in oil pressure.

12-7
STRUCTURE AND OPERATION
5.5 Turbocharger
• Engine oil in the main oil gallery is di-
rected through a pipe to the bearing
housing to lubricate the inner compo-
nents.
• A piston ring is provided on each end
of the turbine wheel shaft. The rings
function as oil sealing.

5.6 Air compressor

• Engine oil in the main oil gallery is di-
rected through a passage in the crank-
shaft to the supply pump coupling and
also to the big ends of the connecting
rods to lubricate these parts.
At the same time, the pistons and the
small ends of the connecting rods are
splash-lubricated with engine oil by
the rotating crankshaft.

12-8
TROUBLESHOOTING 12
Symptoms

Excessive oil consumption (oil leakage)

Engine is difficult to start
Reference Gr

Low oil pressure

Overheating
Possible causes
Incorrectly mounted element O O O
Defective gasket O O O
Defective O-ring O O O
Oil cooler
Clogged element O O
Damaged element O O O
Weakened bypass valve spring O
Malfunctioning oil pump O O
Interference between oil pump gear and oil pump case
O O
and/or cover
Oil pump
Incorrectly connected oil pipe O O
Clogged oil strainer O O
Weakened relief valve spring O
Incorrect installation O
Oil filter Clogged element O O
Defective O-ring O
Front cover timing gear Defective front oil seal O
case Incorrectly mounted front cover O
Gr11
Defective rear oil seal O
Flywheel housing
Incorrectly mounted gasket O
Weakened regulator valve spring O
Defective piston cooling oil jet(s) O
Oil working its way up into combustion chamber(s) through piston rings O
Gr11
Oil working its way down into combustion chamber(s) through valves O
Too high oil viscosity O
Poor oil quality O
Deterioration of oil O
Excess of oil O
Fuel mixed with oil O

12-9
GENERAL INSPECTION AND ADJUSTMENT
1. Oil Filter Replacement
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
– Drain plug (oil filter) 7.8 ± 2.0 {0.8 ± 0.2} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Engine oil
Approx. 2.3 dm3
– Oil filter API classification CD, CD/SF, CE,
{2.3L}
CE/SF, CF-4

Special tools
Mark Tool name and shape Part No. Application

Oil filter wrench MH061537 Removal of oil filter

WARNING
• Wipe up any spilled engine oil, as it can cause fires.

CAUTION
• Make sure not to put any engine oil on the V-belt when working on the oil filter. V-belts soiled with oil or
grease may easily slip, resulting in deteriorated performance of the cooling system.

[Removal]
• Remove the drain plug and drain the oil out of the oil filter.

• Remove the oil filter using .

12-10
 12
[Installation]
• Clean the surface of the oil filter head where the oil filter is to be
mounted.
• Apply a thin coat of engine oil onto the oil filter gasket.
• Screw in the oil filter by hand until the gasket contacts the oil fil-
ter head. Tighten further by 1 1/8 to 1 3/8 of a turn.
• Install the drain plug.
• With the oil filter installed, start the engine and ensure that there
is no oil leakage through the gasket.
• If oil is leaking, remove and reinstall the oil filter.
• Stop the engine and check the engine oil level.
• Add engine oil if the engine oil level is low.

12-11
GENERAL INSPECTION AND ADJUSTMENT
2. Engine Oil Replacement
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
– Drain plug (oil filter) 7.8 ± 2.0 {0.8 ± 0.2} –
– Drain plug (oil pan) 69 {7} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Approx. 2.3 dm3
– Oil filter
{2.3L}
Engine oil Approx. 11 dm3
API classification CD, CD/SF, CE, {11L}, 12 dm3
– Oil pan CE/SF, CF-4 {12L}, 16 dm3
{16L}, 28 dm3
{28L}

WARNING
• Wipe up any spilled engine oil, as it can cause fires.

CAUTION
• Make sure not to put any engine oil on the V-belt when working on the oil filter. V-belts soiled with oil or
grease may easily slip, resulting in deteriorated performance of the cooling system.

[Draining]
• Remove the filler cap.
• Remove the drain plugs of the oil filter or oil pan to drain out the
engine oil.

[Refilling]
• Tighten the drain plug to the specified torque, then pour a speci-
fied amount of new engine oil into the engine.
• Stop the engine and check the engine oil level.
• Add engine oil if the engine oil level is low.

CAUTION
• Do not add engine oil too much. An excessive oil level can
only lead to increased oil consumption or make the positive
crankcase ventilation system less efficient.

12-12
 12
3. Oil Pressure Measurement
Service standards
Location Maintenance item Standard value Limit Remedy
49 kPa
145 to 295 kPa
No-load minimum speed {0.5 kgf/
Oil pressure (oil tempera- {1.5 to 3 kgf/cm2}
– cm2} Inspect
ture at 70 to 90°C)
295 to 490 kPa 195 kPa
No-load maximum speed
{3 to 5 kgf/cm2} {2 kgf/cm2}

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Sealant
– Engine oil pressure switch 15 to 22 {1.5 to 2.2}
With cold engine

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
– Engine oil pressure switch threads Teflon tape 3 1/2 turns

• Remove the engine oil pressure switch.

• Using an adapter, connect an oil pressure gauge to the engine

oil pressure switch mounting hole.
• Warm up the engine until the oil temperature reaches 70 to
90°C.
• Measure the oil pressure while running the engine at a minimum
speed and then at maximum speed, both under no load.
• If the measurements are below the specified limits, overhaul the
lubrication system.
• After taking the measurements, wrap the threads of the engine
oil pressure switch with teflon tape and then tighten the switch to
the specified torque.

CAUTION
• Reinstall the oil pressure switch only when the engine is
cold.

12-13
OIL PAN, OIL JETS AND OIL LEVEL SENSOR
Disassembly sequence
1 Drain plug
2 Oil pan
3 Check valve
4 Oil jet

: Locating pin
: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.

CAUTION
• If overtightened, the check valve
will not operate properly, leading to
engine seizure. Be sure to tighten
the check valve to the specified
torque.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Drain plug 69 {7} –
Check valve 34 {3.5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Crankcase mounting surface of oil pan ThreeBond 1207C As required

12-14
 12
Installation procedure
Installation: Oil pan
• Clean the mating surfaces of each part.
• Apply a bead of sealant to the mating surface of the oil pan
evenly and without any breaks.
• Change the amount of application to A and B at four locations
shown in the illustration.
• Mount the oil pan within three minutes of applying the sealant.
Make sure that the sealant stays in place.
CAUTION
• Do not start the engine for one hour after installation. If the
oil pan mounting bolts were loosened or removed, be sure
to reapply sealant.

12-15
OIL PUMP, OIL STRAINER

Disassembly sequence
1 Oil strainer 8 Relief valve 15 Oil deflector
2 Gasket 9 Relief valve spring
3 Oil pipe 10 Washer a: Crankshaft gear
4 Gasket 11 Gear and case
*b: Oil pump gear
5 Cover 12 Shim
*
6 Driven gear 13 Shim : Locating pin
7 Ring 14 Gasket : Non-reusable parts

• The oil strainer, the oil pipe and the oil pump must all be removed together as an assembly.
• Do not disassemble the oil pump unless defects are evident.
• The gear and case assembly is not serviceable. If the gear and case assembly appears defective, replace it.

Assembly sequence
Follow the disassembly procedure in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
5, 11 Clearance between drive gear shaft and cover 0.04 to 0.07 0.15 Replace
Clearance between driven gear shaft and case, and
5, 6, 11 0.04 to 0.07 0.15 Replace
that between the shaft and cover
Clearance between case and tooth tips of each gear 0.10 to 0.19 0.2
6, 11 Replace
Difference between case depth and height of each gear 0.06 to 0.11 0.15
1.1 ± 0.1 MPa
8 Relief valve opening pressure – Replace
{11 ± 1 kgf/cm2}
9 Relief valve spring installed load (installed length: 30) 84N {8.6 kgf} – Replace
a, b Backlash between crankshaft gear and oil pump gear
* * 0.08 to 0.15 0.35 Adjust

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (oil pump cover mounting) 25 ± 4.9 {2.5 ± 0.5} –

12-16
 12
Inspection before removal
Inspection: Backlash between oil pump gear and crankshaft
gear
• If the measurement exceeds the limit, adjust by shimming.
Shim feeler Change in backlash
0.1 mm 0.073 mm
0.2 mm 0.146 mm

CAUTION
• Perform shimming such that the shim packs on both sides
will have the same feeler.

Inspection procedure
Inspection: Driven gear, Gear and case assembly
• Perform the following inspections. Replace the defective part(s)
as required.
(1) Difference between case depth and height of each gear

(2) Clearance between case and tooth tips of each gear

(3) Clearance between drive gear shaft and cover

(4) Clearance between driven gear shaft and case, and that
between the shaft and cover

12-17
OIL FILTER
Removal sequence
1 Drain plug
2 Oil filter
3 Engine oil bypass alarm switch
4 O-ring
5 Oil filter head
6 Gasket

: Non-reusable parts

Installation sequence
Follow the removal sequence in reverse.

WARNING
• Wipe up any spilled engine oil, as it can cause fires.
• To avoid any risk of burns, take care not to touch the engine oil when the engine is hot.

CAUTION
• When adding engine oil, be careful not to allow engine oil to smear the V-belt. A V-belt smeared with oil
will slip, resulting in reduced cooling efficiency.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Drain plug 7.8 ± 2 {0.8 ± 0.2} –
Engine oil bypass alarm switch 49 ± 4.9 {5.0 ± 0.5} –
Bolt (Oil filter head mounting) 37 to 53 {3.6 to 5.4} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Oil filter gasket
Engine oil As required
O-ring

12-18
 12
[Removal]
• Remove the drain plug and drain the oil out of the oil filter.

• Remove the oil filter using .

[Installation]
• Clean the surface of the oil filter head where the oil filter is to be
mounted.
• Apply a thin coat of engine oil onto the oil filter gasket.
• Screw in the oil filter by hand until the gasket contacts the oil fil-
ter head. Tighten further by 1 1/8 to 1 3/8 of a turn.
• Install the drain plug.
• With the oil filter installed, start the engine and ensure that there
is no oil leakage through the gasket.
• If oil is leaking, remove and reinstall the oil filter.
• Stop the engine and check the engine oil level.
• Add engine oil if the engine oil level is low.

12-19
OIL COOLER
Removal sequence
1 Bypass valve
2 O-ring
3 Plug
4 O-ring
5 Plug
6 O-ring
7 Engine oil pressure switch
8 Regulator valve
(See later pages.)
9 O-ring
10 Plug
11 O-ring
12 Plug
13 O-ring
14 Oil cooler element
15 Gasket
16 Oil cooler cover
17 Gasket
18 O-ring

: Non-reusable parts

Installation sequence
Follow the removal sequence in reverse.
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Air leakage from oil cooler element (air pressure: 1470
14 0 cm3 {0 mL} – Replace
kPa {15 kgf/cm2})

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bypass valve 15 to 20 {1.5 to 2.0} –
Nut (oil cooler element mounting) 24.5 to 32.3 {2.5 to 3.3} –
Engine oil pressure switch 15 to 22 {1.5 to 2.2} –
Regulator valve 98 to 118 {10 to 12} –
Plug 14.7 to 19.6 {1.5 to 2.0} –

Lubricant and/or sealant

Mark Points of application Lubricant and/or sealant Quantity
Engine oil pressure switch threads Teflon tape 3 1/2 turns
O-ring Engine oil As required

Inspection procedure
Inspection: Oil cooler element
• Plug the outlet of the oil cooler element and connect a hose to
the engine oil inlet port. Then, immerse the oil cooler element in
a tank of water.
• Apply a specified air pressure for 15 seconds through the hose,
and check for any air leaks.
• Replace the element if it leaks air.

12-20
REGULATOR VALVE 12
Disassembly sequence
1 Snap ring
2 Valve
3 Spring
4 Body

Assembly sequence
Follow the removal sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
392 ± 29 kPa
– Regulator valve opening pressure – Replace
{4.0 ± 0.3 kgf/cm2}
78.5 ± 1.96 N
3 Spring installed load (installed length 48.3) – Replace
{8.0 ± 0.2 kgf}

12-21