COOLING SYSTEMS
SECTION LC
CONTENTS
ZD TD27Ti
PRECAUTIONS AND PREPARATION............................2 PREPARATION..............................................................18
Liquid Gasket Application Procedure ..........................2 PRECAUTION................................................................19
Special Service Tools ..................................................2 ENGINE LUBRICATION SYSTEM ................................20
ENGINE LUBRICATION SYSTEM ..................................3 Lubrication Circuit ......................................................20
Lubricating Circuit ........................................................3 Oil Pressure Check....................................................21
Oil Pressure Check......................................................4 Oil Pump ....................................................................22
Oil Pump ......................................................................5 Oil Filter Bracket ........................................................24
Oil Jet...........................................................................7 Oil Cooler...................................................................25
Oil Cooler.....................................................................8 Oil Jet.........................................................................26
ENGINE COOLING SYSTEM..........................................9 ENGINE COOLING SYSTEM........................................27
Cooling Circuit .............................................................9 Cooling Circuit ...........................................................27
System Check............................................................10 System Inspection .....................................................28
Water Pump ...............................................................11 Water Pump ...............................................................29
Thermostat.................................................................12 Thermostat.................................................................31
Water Outlet...............................................................13 Radiator .....................................................................32
Radiator .....................................................................14 Cooling Fan ...............................................................33
Cooling Fan (Crankshaft driven) ...............................15 SERVICE DATA AND SPECIFICATIONS (SDS) ..........34
EGR Cooler ...............................................................16 Engine Lubrication System........................................34
SERVICE DATA AND SPECIFICATIONS (SDS) ..........17 Engine Cooling System .............................................34
Engine Lubrication System........................................17
Engine Cooling System .............................................17
PRECAUTIONS AND PREPARATION ZD
AEM080
NT558
NT559
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
NT564 Unit: mm (in)
LC-2
ENGINE LUBRICATION SYSTEM ZD
Lubricating Circuit
SLC361B
LC-3
ENGINE LUBRICATION SYSTEM ZD
SLC694A
JLC362B
LC-4
ENGINE LUBRICATION SYSTEM ZD
Oil Pump
REMOVAL AND INSTALLATION
Refer to TIMING GEAR in EM section.
DISASSEMBLY AND ASSEMBLY
JLC363B
I When installing the inner and outer gear, face mating mark
toward the oil pump cover as shown (left).
JLC364B
LC-5
ENGINE LUBRICATION SYSTEM ZD
Oil Pump (Contd)
OIL PUMP INSPECTION
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
0.114 - 0.200
Body to outer gear radial clearance q
1
(0.0045 - 0.0079)
Inner gear to outer gear tip clearance q
2 Less than 0.180 (0.0071)
0.05 - 0.09
Body to inner gear axial clearance q
3
(0.0020 - 0.0035)
JLC365B
0.050 - 0.105
Body to outer gear axial clearance q
4
(0.0020 - 0.0041)
Inner gear to brazed portion of housing 0.045 - 0.091
clearance q5 (0.0018 - 0.0036)
Regulator valve to oil pump cover 0.040 - 0.097
clearance q6 (0.0016 - 0.0038)
JLC366B
JLC367B
SLC369B
LC-6
ENGINE LUBRICATION SYSTEM ZD
Oil Pump (Contd)
OIL PRESSURE RELIEF VALVE AND BYPASS VALVE
INSPECTION (For oil cooler)
1. Inspect oil pressure relief valve for movement, cracks and
breaks by pushing the ball. If replacement is necessary, remove
valve by prying it out with suitable tool.
Install a new valve in place by tapping it.
SLC371B
Oil Jet
INSPECTION (For timing chain)
Make sure that the holes are not clogged. Clean them with a wire
if necessary.
Drive oil jet into place after positioning alignment mark on.
SLC385B
FEM124
When installing oil jet, align oil jets boss with hole on cylin-
der block.
Oil jet:
: 30 - 39 Nm (3.0 - 4.0 kg-m, 22 - 28 ft-lb)
FEM125
LC-7
ENGINE LUBRICATION SYSTEM ZD
Oil Jet (Contd)
OIL FILTER
The oil filter is an element type. Refer to Changing Oil Filter in MA
section.
Oil Cooler
YLC030
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-8
ENGINE COOLING SYSTEM ZD
Cooling Circuit
YLC031
LC-9
ENGINE COOLING SYSTEM ZD
System Check
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant 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.
SLC134B
SLC135B
SMA967B
LC-10
ENGINE COOLING SYSTEM ZD
Water Pump
CAUTION:
I When removing water pump assembly, be careful not to
get coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
I Always replace with new gasket.
I After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
Refer to MA section.
JLC373B
LC-11
ENGINE COOLING SYSTEM ZD
Water Pump (Contd)
INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
2. Check for rough operation due to excessive end play.
CAUTION:
Do not disassemble water pump coupling assembly.
SLC374B
Thermostat
YLC032
LC-12
ENGINE COOLING SYSTEM ZD
Thermostat (Contd)
REMOVAL AND INSTALLATION
1. Drain engine coolant. Refer to MA section, Changing Engine
Coolant.
2. Remove left side battery. (If so equipped)
3. Remove radiator upper hose.
4. Remove radiator shroud.
5. Remove intake air duct, inlet pipe.
6. Remove harness and connectors.
7. Install in reverse order of removal.
I After installation, run engine for a few minutes and check
JLC384B for leaks.
I Be careful not to spill coolant in 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 maximum valve lift.
Valve opening temperature C (F) 82 (180)
Maximum valve lift mm/C (in/F) 10/95 (0.39/203)
Water Outlet
INSPECTION
Visual inspection for water leaks. If there is leakage, replace gas-
ket.
YLC033
LC-13
ENGINE COOLING SYSTEM ZD
Radiator
YLC034
LC-14
ENGINE COOLING SYSTEM ZD
Radiator (Contd)
REMOVAL AND INSTALLATION
1. Remove under cover.
2. Drain engine coolant. Refer to MA section, Changing Engine
Coolant.
3. Remove air cleaner case, air duct and resonator.
4. Remove battery (right side).
5. Remove radiator shroud (lower).
6. Remove radiator shroud (front).
7. Disconnect radiator hose (upper and lower).
8. Disconnect reservoir tank hose.
9. Disconnect A/T oil cooler hose (Only A/T models).
10. Remove radiator.
11. After repairing or replacing radiator, install all removed parts in
reverse order of removal.
JLC379B
LC-15
ENGINE COOLING SYSTEM ZD
EGR Cooler
YLC042
q
1 EGR tube assembly q
6 Water hose q
10 EGR tube
q
2 Gasket q
7 Clamp q
11 Gasket
q
3 EGR cooler bracket q
8 Water hose q
12 EGR cooler bracket
q
4 Water hose q
9 Clamp q
13 EGR cooler
q
5 Clamp
LC-16
SERVICE DATA AND SPECIFICATIONS (SDS) ZD
0.050 - 0.105
Body to outer gear axial clearance q
4
(0.0020 - 0.0041)
LC-17
PREPARATION TD27Ti
Tool number
Description
Tool name
ST25051001 Measuring oil pressure
Oil pressure gauge Maximum measuring range:
2,452 kPa (24.5 bar, 25 kg/cm2, 356 psi)
NT558
NT559
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
NT564 Unit: mm (in)
WS39930000 Pressing the tube of liquid gasket
Tube presser
NT052
LC-18
PRECAUTION TD27Ti
LC-19
ENGINE LUBRICATION SYSTEM TD27Ti
Lubrication Circuit
ELC037
LC-20
ENGINE LUBRICATION SYSTEM TD27Ti
SLC964
If difference is extreme, check oil passage and oil pump for oil
leaks.
SLC003A
6. Install oil pressure switch.
Use proper liquid sealant.
Oil pressure switch:
: 10 - 13 Nm (1.0 - 1.3 kg-m, 87 - 113 in-lb)
LC-21
ENGINE LUBRICATION SYSTEM TD27Ti
Oil Pump
MLC128A
SLC966
Gear backlash:
Less than 0.43 mm (0.0169 in)
SLC967
SLC968
LC-22
ENGINE LUBRICATION SYSTEM TD27Ti
Oil Pump (Contd)
4. Measure outside diameter B of drive gear shaft.
B: 12.974 - 12.992 mm (0.5108 - 0.5115 in)
5. Calculate oil pump bushing clearance.
Oil pump bushing clearance (A B):
Less than 0.15 mm (0.0059 in)
SLC969
NLC057
LC-23
ENGINE LUBRICATION SYSTEM TD27Ti
NLC056
q
1 O-ring q
3 Oil filter q
5 Oil filter relief valve
q
2 Oil pump relief valve q
4 Oil filter bracket q
6 Protection shield
LC-24
ENGINE LUBRICATION SYSTEM TD27Ti
Oil Cooler
NLC055
q
1 Oil pressure switch q
3 Oil cooler element q
5 O-ring
q
2 Regulator valve q
4 Oil filter relief valve
LC-25
ENGINE LUBRICATION SYSTEM TD27Ti
Oil Jet
INSPECTION (For gear train)
Make sure that the holes are not clogged. Clean them with a wire
if necessary.
Oil jet has to be installed with oil hole facing crank gear and
idler gear.
SLC974
SLC015
When installing oil jet, align oil jets boss with hole on cylin-
der block.
Oil jet bolt:
: 29 - 39 Nm
(3.0 - 4.0 kg-m, 22 - 29 ft-lb)
SLC975
Dimension D:
22 mm (0.87 in)
SLC325A
LC-26
ENGINE COOLING SYSTEM TD27Ti
Cooling Circuit
NLC011
LC-27
ENGINE COOLING SYSTEM TD27Ti
System Inspection
CHECKING HOSES
Check hoses for proper attachment, leaks, cracks, damage, loose
connections, chafing and deterioration.
SLC613
SMA990A
LC-28
ENGINE COOLING SYSTEM TD27Ti
Water Pump
REMOVAL AND INSTALLATION
Drain coolant from drain plugs on cylinder block and radiator.
Cylinder block drain plug:
(Use proper sealant)
: 20 - 29 Nm (2.0 - 3.0 kg-m, 14 - 22 ft-lb)
NLC012
NLC058
CAUTION:
I When removing water pump assembly, be careful not to
spill coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
I Always replace with new gasket.
I After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
LC-29
ENGINE COOLING SYSTEM TD27Ti
Water Pump (Contd)
INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
SLC979
2. Check the water pump bushing for excessive end play and
irregular movement.
SLC244
SLC245
LC-30
ENGINE COOLING SYSTEM TD27Ti
Thermostat
NLC059
q
1 Water outlet q
4 Water connector q
6 Engine coolant temperature sen-
q
2 Thermostat with jiggle valve q
5 Thermostat housing sor
q
3 Rubber seal q
7 Thermal transmitter
CAUTION:
I After installation, run engine for a few minutes, and check
for leaks.
I Be careful not to spill coolant over engine compartment.
Place a rag to absorb coolant.
INSPECTION
1. Check for valve seating condition at ordinary temperatures. It
should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Standard type Optional type
Valve opening temperature C (F) 82 (180) 88 (190)
Max. valve lift 8/95 8/100
mm/C (in/F) (0.315/203) (0.315/212)
LC-31
ENGINE COOLING SYSTEM TD27Ti
Radiator
NLC082
CAUTION:
When filling radiator with coolant, refer to MA section.
LC-32
ENGINE COOLING SYSTEM TD27Ti
Cooling Fan
DISASSEMBLY AND ASSEMBLY
YLC041
INSPECTION
Check fan coupling for irregular operation, oil leakage or bent
bimetal.
SLC072
LC-33
SERVICE DATA AND SPECIFICATIONS (SDS) TD27Ti
12.974 - 12.992
Drive gear shaft outside diameter
(0.5108 - 0.5115)
LC-34