MAINTENANCE

L MAINTENANCE

SECTION

MAINTENANCE

MA

CONTENTS
PREPARATION ...................................................... ..... 3 Commercial Service Tool .................................... ..... 3 DESCRIPTION ....................................................... ..... 4 Pre-Delivery Inspection Items ............................. ..... 4 GENERAL MAINTENANCE .................................. ..... 6 General Maintenance .......................................... ..... 6 PERIODIC MAINTENANCE .................................. ..... 7 Periodic Maintenance .......................................... ..... 7 ENGINE AND EMISSION CONTROL MAINTENANCE (GASOLINE ENGINE) ........................ ..... 7 ENGINE AND EMISSION CONTROL MAINTENANCE (DIESEL ENGINE) .............................. ..... 8 CHASSIS AND BODY MAINTENANCE .......... ..... 9 MAINTENANCE UNDER SEVERE DRIVING CONDITIONS ................................................... ..... 9 RECOMMENDED FLUIDS AND LUBRICANTS ... ....11 Fluids and Lubricants .......................................... ....11 SAE Viscosity Number ........................................ ... 12 GASOLINE ENGINE OIL ................................. ... 12 DIESEL ENGINE OIL ....................................... ... 12 GEAR OIL ........................................................ ... 13 Engine Coolant Mixture Ratio ............................. ... 13 ENGINE MAINTENANCE (KA24DE) .................... ... 14 Checking Drive Belts ........................................... ... 14 Drive Belt Tension Adjustment ............................ ... 14 POWER STEERING PUMP BELT ................... ... 14 AIR CONDITIONER COMPRESSOR BELT .... ... 14 ALTERNATOR AND WATER PUMP BELT ...... ... 15 Changing Engine Coolant ................................... ... 15 DRAINING ENGINE COOLANT ...................... ... 15 REFILLING ENGINE COOLANT ..................... ... 15 FLUSHING COOLING SYSTEM ...................... ... 17 Checking Cooling System ................................... ... 18 CHECKING COOLING SYSTEM HOSES ....... ... 18 CHECKING RADIATOR ................................... ... 18 CHECKING RADIATOR CAP ........................... ... 18 CHECKING COOLING SYSTEM FOR LEAKS... 19 Checking Fuel Lines ............................................ ... 19 Changing Air Cleaner Filter ................................. ... 19 VISCOUS PAPER TYPE .................................. ... 19 DRY PAPER TYPE ........................................... ... 20 Changing Engine Oil ............................................ ... 20 Changing Oil Filter ............................................... ... 21 REMOVAL ........................................................ ... 21 INSTALLATION ................................................ ... 21 Changing Spark Plug ........................................... ... 21 REMOVAL ........................................................ ... 21 INSPECTION AFTER REMOVAL .................... ... 22 INSTALLATION ................................................ ... 22 Checking Ignition Wires ....................................... ... 22 Checking Positive Crankcase Ventilation (PCV) System ................................................................. ... 23 CHECKING PCV VALVE .................................. ... 23 CHECKING VENTILATION HOSES ................. ... 23 Checking Vacuum Hoses and Connections ........ ... 23 Checking EVAP Vapor Lines ............................... ... 23 Checking Heated Oxygen Sensor 1 .................... ... 23 CHECKING PROCEDURE .............................. ... 23 ENGINE MAINTENANCE (ZD30DD) ..................... ... 25 Checking Drive Belts ........................................... ... 25 Changing Engine Coolant .................................... ... 25 DRAINING ENGINE COOLANT ....................... ... 25 REFILLING ENGINE COOLANT ...................... ... 26 FLUSHING COOLING SYSTEM ...................... ... 27 Checking Cooling System ................................... ... 28 CHECKING HOSES ......................................... ... 28 CHECKING RADIATOR CAP ........................... ... 28 CHECKING COOLING SYSTEM FOR LEAKS ... 28 Checking Fuel Lines ............................................ ... 28 Changing Fuel Filter ............................................ ... 29 REMOVAL ........................................................ ... 29 INSTALLATION ................................................ ... 29 Changing Air Cleaner Filter ................................. ... 29 VISCOUS PAPER TYPE .................................. ... 29 DRY PAPER TYPE ........................................... ... 30 Changing Engine Oil ............................................ ... 30 Changing Oil Filter ............................................... ... 31 REMOVAL ........................................................ ... 31 INSTALLATION ................................................ ... 32

MA

MA-1

Draining Water ..................................................... ... 32 Checking Injection Nozzle ................................... ... 32 CHASSIS AND BODY MAINTENANCE ................ ... 34 Checking Exhaust System ................................... ... 34 Checking Clutch Fluid Level and Leaks .............. ... 34 Checking Clutch System ..................................... ... 34 Checking M/T Oil ................................................. ... 34 Changing M/T Oil ................................................. ... 34 Checking Propeller Shaft ..................................... ... 35 Checking Differential Gear Oil ............................. ... 35 Changing Differential Gear Oil ............................. ... 35 Balancing Wheels ................................................ ... 36 Rotation ............................................................... ... 36 Checking Brake Fluid Level and Leaks ............... ... 36 Checking Brake Lines and Cables ...................... ... 36 Changing Brake Fluid .......................................... ... 37 Checking Disc Brake ........................................... ... 37 ROTOR ............................................................. ... 37 CALIPER .......................................................... ... 37 PAD .................................................................. ... 37

Checking Drum Brake .......................................... ...37 WHEEL CYLINDER .......................................... ...37 DRUM ............................................................... ...38 LINING .............................................................. ...38 Checking Steering Gear and Linkage .................. ...38 STEERING GEAR ............................................ ...38 STEERING LINKAGE ....................................... ...38 Checking Power Steering Fluid and Lines ........... ...38 Axle and Suspension Parts .................................. ...39 Lubricating Locks, Hinges and Hood Latches ...... ...39 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters ....................................................... ...40 SERVICE DATA AND SPECIFICATIONS (SDS) ... ...41 Standard and Limit ............................................... ...41 BELT DEFLECTION AND TENSION (KA24DE)...41 BELT DEFLECTION AND TENSION (ZD30DD)...41 SPARK PLUG ................................................... ...41 IGNITION WIRE ................................................ ...41 WHEEL BALANCE ........................................... ...41

MA-2

PREPARATION PREPARATION Commercial Service Tool

Tool number Tool name Fuel filter wrench Description Removing fuel filter
PFP:00002

A
ELS0009K

D
PBIC0519E

MA

MA-3

DESCRIPTION DESCRIPTION Pre-Delivery Inspection Items

PFP:00000
ELS0006P

Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that necessary items other than those listed here be added, paying due regard to the conditions in each country. Perform applicable items on each model. Consult text of this section for specifications. UNDER HOOD engine off Radiator coolant level and coolant hose connections for leaks Battery fluid level, specific gravity and conditions of battery terminals Drive belts tension Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks Engine oil level and oil leaks Clutch and brake reservoir fluid level and fluid lines for leaks Windshield and rear window washer and headlamp cleaner reservoir fluid level Power steering reservoir fluid level and hose connections for leaks ON INSIDE AND OUTSIDE Remove front spring/strut spacer (If applicable) Operation of all instruments, gauges, lights and accessories Operation of horn(s), wiper and washer Steering lock for operation Check air conditioner for gas leaks Front and rear seats, and seat belts for operation All moldings, trims and fittings for fit and alignment All windows for operation and alignment Hood, trunk lid, door panels for fit and alignment Latches, keys and locks for operation Weatherstrips for adhesion and fit Headlamp aiming Tighten wheel nuts (Inc. inner nuts if applicable) Tire pressure (Inc. spare tire) Check front wheels for toe-in Install clock/voltmeter/room lamp fuse (If applicable) Install deodorizing filter to air conditioner (If applicable) Remove wiper blade protectors (If applicable) UNDER BODY Manual transmission/transaxle, transfer and differential gear oil level Brake and fuel lines and oil/fluid reservoirs for leaks Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts Tighten rear body bolts and nuts (Models with wooden bed only) ROAD TEST Clutch operation Parking brake operation Service brake operation Automatic transmission/transaxle shift timing and kickdown Steering control and returnability Engine performance

MA-4

DESCRIPTION
Squeaks and rattles ENGINE OPERATING AND HOT Adjust idle speed Automatic transmission/transaxle fluid level Engine idling and stop knob operation (Diesel only) FINAL INSPECTION Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps) Inspect for interior and exterior metal and paint damage Check for spare tire, jack, tools (wheel chock), and literature Wash, clean interior and exterior : Not applicable to this model
D C A

MA

MA-5

GENERAL MAINTENANCE GENERAL MAINTENANCE General Maintenance

PFP:00000
ELS0006Q

General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the checks and inspections themselves or they can have their NISSAN dealers do them for a nominal charge. OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise specified. Item Tires Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear. Check for cracks or wear if not functioning correctly. Check that all doors and back door operate properly. Also ensure that all latches lock securely. Lubricate if necessary. When driving in areas using road salt or other corrosive materials, check for lubrication frequently. Tires should be rotated every 10,000 km (6,000 miles). Reference page

Windshield/ rear wiper blades Doors

BL-17, BL-28

Tire rotation

MA-36

INSIDE THE VEHICLE

The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Item Reference page Lamps Make sure that the headlamps, stop lamps, tail lamps, turn signal lamps, and other lamps are all operating properly and installed securely. Also check headlamp aim. Make sure that all warning lamps and buzzers/chimes are operating properly. Check that it has the specified play. Check for changes in the steering conditions, such as excessive free play, hard steering or strange noises. Free play: Less than 35 mm (1.38 in) Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage.

Warning lamps and chimes Steering wheel

Seat belts

MA-40

UNDER THE HOOD AND VEHICLE

The maintenance items listed here should be checked periodically e.g. each time you check the engine oil or refuel. Item Reference page Windshield washer fluid Engine coolant level Engine oil level Brake and clutch fluid level Battery Check that there is adequate fluid in the tank. Check the coolant level when the engine is cold. Check the level after parking the vehicle (on level ground) and turning off the engine. Make sure that the brake fluid level is between the MAX and MIN lines on the reservoir. Check the fluid level in each cell. It should be between the MAX and MIN lines. MA-15,MA-25 MA-20,MA-30 MA-36,MA-34

MA-6

PERIODIC MAINTENANCE PERIODIC MAINTENANCE Periodic Maintenance

PFP:00026

A
ELS0006R

The following tables show the normal maintenance schedule. Depending upon weather and atmospheric conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent maintenance may be required. Periodic maintenance beyond the last period shown on the tables requires similar maintenance.

ENGINE AND EMISSION CONTROL MAINTENANCE (GASOLINE ENGINE)

Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, MAINTENANCE OPERATION km x 1,000 (Miles x 1,000) Months 1 (0.6) 10 (6) 6 A = Adjust, C = Clean, E = Check and correct the engine coolant mixture ratio. MAINTENANCE INTERVAL 20 (12) 12 30 (18) 18 40 (24) 24 50 (30) 30 60 (36) 36 70 (42) 42 80 (48) 48 Reference page

Perform either at number of kilometers (miles) or months, whichever comes first.

Underhood and under vehicle Torque of manifolds & exhaust tube nuts See NOTE (1) I*1 R I*1 EM22EM24 A*1 I*1 R R A*1 I R R A*1 I*1 R R A*1 I R EM-37 MA-14 MA-20

Intake & exhaust valve clearance Drive belts Engine oil (Use API SE, SF, SG, SH or SJ oil.) Engine oil filter (Use Part No. 15208 31U00 or 15208 65F00 or equivalent) Engine coolant (Use Nissan genuine engine coolant or equivalent in its quality.) Cooling system Fuel lines Air cleaner filter (Dry paper type) Air cleaner filter (Viscous paper type)

R See NOTE (2)

MA-21

E I I I C C C R R C C C I

R I I R R

MA-15 MA-18 MA-19 MA-19 MA-19

See NOTE (3) See NOTE (4) I*1 I*1 R*1 I*1 I*1 I*1

MA

Fuel filter Spark plugs (For leaded fuel) Spark plugs (For unleaded fuel) Ignition wires Positive crankcase ventilation (PCV) system Vacuum hoses & connections EVAP vapor lines (With carbon canister) Heated oxygen sensor 1 (Exhaust gas sensor) NOTE:
G

FL-7 R*1 R I I*1 I*1 I*1 I*1 I I I*1 I*1 I*1 I*1 R*1 I*1 I*1 I*1 R*1 R I I*1 I*1 I I MA-21 MA-21 MA-22 MA-23 MA-23 MA-23 MA-23

Maintenance items with Conditions.

should be performed more frequently according to Maintenance Under Severe Driving

(1) For three way catalyst models, periodic maintenance is not required. However, if valve noise increases, check valve clearance.

MA-7

PERIODIC MAINTENANCE
G

(2) Use Nissan genuine engine coolant, or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling system caused by the use of non-genuine engine coolant. After first replacement, replace every 40,000 km (24,000 miles) or 24 months (3) For optional specifications. (4) Maintenance-free item. For service procedures, refer to FL section. *1: Only on models without three way catalyst

G G G

ENGINE AND EMISSION CONTROL MAINTENANCE (DIESEL ENGINE)

Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION km x 1,000 (Miles x 1,000) Months 1 (0.6) 10 (6) 6 R = Replace, D = Check filter and drain water, E = Check and correct the engine coolant mixture ratio. MAINTENANCE INTERVAL 20 (12) 12 30 (18) 18 40 (24) 24 50 (30) 30 60 (36) 36 70 (42) 42 80 (48) 48 Reference page

Perform either at number of kilometers (miles) or months, whichever comes first.

Underhood and under vehicle Torque of manifolds & exhaust tube nuts See NOTE (1) I See NOTE (2) See NOTE (3) See NOTE (4) I I I I I I EM-114 EM-117 EM-142 MA-25 MA-30

Intake & exhaust valve clearance Drive belts Engine oil (Use API CE, CF, IF-4 oil.) Engine oil filter (Use Echo filter or equivalent) Engine coolant (Use Nissan genuine engine coolant or equivalent in its quality.) Cooling system Fuel lines Air cleaner filter (Dry paper type) Air cleaner filter (Viscous paper type) Fuel filter Injection nozzles NOTE:
G

Replace every 15,000 km (9,000 miles) or 12 months

Replace every 15,000 km (9,000 miles) or 12 months

MA-31

E I I C C C R R D D D R D D D C C C I

R I I R R R

MA-25 MA-28 MA-28 MA-30 MA-29 MA-29 MA-32

See NOTE (5)

Maintenance items with Conditions.

should be performed more frequently according to Maintenance Under Severe Driving

G G G G

(1) If valve noise increases, check valve clearance. (2) Never use API CG-4 grade oil. (3) Oil filter element assembly (part No. 15209 2W200) and O-ring seal (part No. 15226 2W200) are replacement parts. (4) Use Nissan genuine engine coolant, or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling system caused by the use of non-genuine engine coolant. After first replacement, replace every 40,000 km (24,000 miles) or 24 months. (5) If engine power decreases, black exhaust smoke emits, or engine noise increases, check the injection nozzles and, if necessary replace injection nozzle assembly.

MA-8

PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, MAINTENANCE OPERATION Perform either at number of kilometers (miles) or months, whichever comes first. km x 1,000 (Miles x 1,000) Months 1 (0.6) 10 (6) 6 MAINTENANCE INTERVAL 20 (12) 12 30 (18) 18 40 (24) 24 50 (30) 30 60 (36) 36 70 (42) 42 80 (48) 48 Reference page L = Lubricate.

Underhood and under vehicle Brake & clutch fluid (For level & leaks) Brake fluid Brake booster vacuum hoses, connections & check valve Power steering fluid & lines (For level & leaks) Brake, clutch & exhaust systems Manual transmission gear oil (For level & leaks) Manual transmission gear oil Differential gear oil (For level & leaks) Limited-slip differential (LSD) gear oil (If so equipped, For level & leaks) Steering gear & linkage, axle & suspension parts & propeller shafts I Outside and inside Wheel alignment (If necessary, rotate & balance wheels) Brake pads, rotors & other brake components Brake linings, drums & other brake components Locks, hinges & slide door rollers and links Seat belts, buckles, retractors, anchors & adjuster Foot brake, parking brake & clutch (For free play, stroke & operation) NOTE:
G

C
I R I I I I I R I I I I I MA-36, MA-34 MA-37 BR-22

E
I I I I MA-38 MA-37, MA-34, MA-34 MA-34 MA-34 R MA-35

Replace every 100,000 Km (60,000 miles) I I I R I I I

MA-35

I
I I I MA-38, MA-39 MA-35

I I I I

I I I

I I I

I I

MA-36, MA-36 MA-37

MA
I I I I MA-37 BL-17, BL-22, BL-28 MA-40 BR-6, PB-2 , CL-5

I I I I

I I I

I I I

I I

Maintenance items with Conditions.

should be performed more frequently according to Maintenance Under Severe Driving

MAINTENANCE UNDER SEVERE DRIVING CONDITIONS

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table. Severe driving conditions A Driving in dusty conditions

MA-9

PERIODIC MAINTENANCE
B Repeatedly driving short distances C Towing a trailer or caravan D Extensive idling E Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high F Driving in high humidity or mountainous areas G Driving in areas using salt or other corrosive materials H Driving on rough and/or muddy roads or in the desert I Driving with frequent use of braking or in mountainous areas
Maintenance operation: Check = Check and correct or replace as necessary. Driving condition Maintenance item Maintenance operation Clean & Replace Replace Replace Replace Replace Replace Replace Replace Replace Check Every 20,000 km (12,000 miles) or 12 months Every 5,000 km (3,000 miles) or 3 months More frequently Every 5,000 km (3,000 miles) or 3 months Every 7,500 km (4,500 miles) or 6 months Maintenance interval Reference page MA-19 MA-30 MA-19 MA-29 MA-20 MA-30 MA-21 MA-31 MA-29 MA-37 MA-35 MA-38, MA-39 MA-35 MA-37 Every 10,000 km (6,000 miles) or 6 months Every 5,000 km (3,000 miles) or 3 months MA-37 BL-17, BL-22, BL-28

Dry paper type A . . . . . . . . Air cleaner filter Viscous paper type Gasoline engine A B C D . . . . . Engine oil Diesel engine Gasoline engine A A . . . B . . . . C . . C . D . . . . . E . . . . . F . . . . . . G . . . H H . . . . . Engine oil filter Diesel engine

More frequently

Fuel filter (Diesel engine only) Brake fluid Limited slip differential (LSD) gear oil Steering gear & linkage, axle & suspension parts & propeller shafts Brake pads, rotors & other brake components Brake linings, drums & other brake components Locks, hinges & slide door rollers and links

Every 5,000 km (3,000 miles) or 3 months

A A

. .

C C

. .

. .

. .

G G

H H

I I

Check Check

Lubricate

MA-10

RECOMMENDED FLUIDS AND LUBRICANTS RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants
Capacity (Approximate) Liter With oil filter change Without oil filter change KA24DE ZD30DD KA24DE ZD30DD KA24DE Dry engine (engine overhaul) With front and rear heater Cooling system (with reservoir) With front heater ZD30DD KA24DE ZD30DD KA24DE ZD30DD KA24DE Without heater Reservoir Manual transmission gear oil Brake and clutch fluid Power steering fluid C200 Differential gear oil Limited-slip differential(LSD) gear oil Multi-purpose grease H233B ZD30DD 3.6 6.9 3.3 6.4 4.4 7.6 9.1 12.6 8.1 11.4 6.7 10.0 0.8 2.0 1.3 2.8 2.8 Imp measure 3-1/8 qt 6-1/8 qt 2-7/8 qt 5-5/8 qt 3-7/8 qt 6-3/4 qt 8 qt 11-1/8 qt 7-1/8 qt 10 qt 5-7/8 qt 8-3/4 qt 3/4 qt 3-1/2 pt 2-1/4 pt 4-7/8 pt 4-7/8 pt API GL-5*1 Gear oil hypoid LSD (Part No.:KLD31-1400203) or equivalent*4 NLGI No. 2 (Lithium soap base) API GL-4, Viscosity SAE 75W-85 DOT 3 (US FMVSS No. 116) DEXRON
TM
G G G

PFP:00000

A
ELS0006S

Recommended Fluids/Lubricants

Engine oil Drain and refill

Gasoline engine: API SE, SF, SG, SH or SJ*1 ILSAC grade GF-I or GF-II*1 Diesel engine: API CE, CF or CF-4*1, *2

Nissan Genuine Engine Coolant or equivalent in its quality *3

III or equivalent

*1: For further details, see SAE Viscosity Number. *2: Never use CG-4 grade oil. *3: Use Nissan Genuine Engine Coolant, or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling system caused by the use of non-genuine engine coolant. Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be covered by the warranty even if such incidents occurred during the warranty period. *4: API GL-5, SAE 140 and 10% volume of LSD Friction Modifier (Part No.: 38469-C6000) is an equivalent.

MA

MA-11

RECOMMENDED FLUIDS AND LUBRICANTS SAE Viscosity Number

GASOLINE ENGINE OIL
G
ELS0006T

For warm and cold areas: 10W-30 is preferable for ambient temperatures above -20C(-4F). For hot areas: 20W-40 and 20W-50 are suitable.

SMA084D

DIESEL ENGINE OIL

G G

For cold areas: 10W-30 is preferable. For hot and warm areas: 20W-40 and 20W-50 are suitable.

SMA090D

MA-12

RECOMMENDED FLUIDS AND LUBRICANTS

GEAR OIL
G

For warm and cold areas: 80W-90 for the differential gear and 75W-85 for transmission gear are preferable. For hot areas: 90 is suitable for ambient temperatures below 40C(104F).

G
SLIA0015E

Engine Coolant Mixture Ratio

ELS00083

The engine cooling system is filled at the factory with a high-quality, year-round and extended life engine coolant. The high quality engine I coolant contains the specific solutions effective for the anti-corrosion and the anti-freeze function. Therefore, additional cooling system additives are not necessary.The engine cooling system is filled at the factory with a high-quality, year-round and extended life engine coolJ ant. The high quality engine coolant contains the specific solutions effective for the anti-corrosion and the anti-freeze function. Therefore, additional cooling system additives are not necessary. K CAUTION: G When adding or replacing coolant, be sure to use only a SMA089D Nissan Genuine Engine Coolant or equivalent in its quality MA with the proper mixture ratio. See the examples shown in the figure. The use of other types of engine coolant may damage your cooling system. G When checking the engine coolant mixture ratio by the coolant hydrometer, use the chart below to correct M your hydrometer reading (specific gravity) according to coolant temperature. Mixed coolant specific gravity
Unit: specific gravity Engine coolant mixture ratio 30% 50% Coolant temperature C (F) 15 (59) 1.046 - 1.050 1.076 - 1.080 25 (77) 1.042 - 1.046 1.070 - 1.076 35 (95) 1.038 - 1.042 1.065 - 1.071 45 (113) 1.033 - 1.038 1.059 - 1.065

WARNING: Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator. Wait until the engine and radiator cool down.

MA-13

ENGINE MAINTENANCE (KA24DE) ENGINE MAINTENANCE (KA24DE) Checking Drive Belts

WARNING: Be sure to perform when the engine is stopped. G Inspection should be done only when engine is cold, or over 30 minutes after engine is stopped. G Measure belt tension with tension meter (special service tool) at points marked shown in the figure.
G

PFP:00100
ELS0009N

Measure belt deflection by applying load of 98.1 N {10 kg} to

PBIC0422E

Unit: mm (in) Deflection adjustment Used belt Limit Alternator Air conditioner compressor Power steering oil pump Applied pushing force 11 (0.43) 13 (0.51) 13 (0.51) After adjustment 7 - 8 (0.28 - 0.31) 8 - 10 (0.31 - 0.39) 8 - 10 (0.31 - 0.39) 98 N (10 kg, 72 lb)
ELS0009O

New belt 6 - 7 (0.24 - 0.28) 7 - 8 (0.28 - 0.31) 7 - 8 (0.28 - 0.31)

Drive Belt Tension Adjustment

CAUTION: G When belt is replaced with a new one, tighten it a little stronger than current one to accommodate for insufficient adaptability with pulley grooves. G When tension of belt being used exceeds Retightening limit, adjust it to value for Used belt. G When installing belt, make sure that it is correctly engaged with pulley groove. G Keep oil and water away from belt. G Do not twist or bend belt excessively.

POWER STEERING PUMP BELT

1. 2. Open and fix engine compartment LH cover. Loosen idler pulley lock nut (A) and adjust tension by turning adjusting bolt (B). G For specified belt tension, refer to MA-14, "Checking Drive Belts" . Tighten nut (A). : 25.5 - 32.4 Nm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)

3.

EMK0571D

AIR CONDITIONER COMPRESSOR BELT

1. 2. 3. Open and fix engine compartment LH cover (passenger side for RHD models or driver-side for LHD models). Loosen idler pulley lock nut (C) and adjust tension by turning adjusting bolt (D). G For specified belt tension, refer to MA-14, "Checking Drive Belts" . Tighten nut (C).

MA-14

ENGINE MAINTENANCE (KA24DE)

: 25.5 - 32.4 Nm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
A

ALTERNATOR AND WATER PUMP BELT

1. 2. 3. 4. Remove front-side under cover. Remove RH seat. Refer to SE-4, "FRONT SEAT" . Remove engine compartment RH cover. Refer to EM-12, "ENGINE ROOM COVER" . Loosen alternator mounting bolt (E) and adjuster lock bolt (F), and adjust tension by turning adjusting nut (G). G For specified belt tension, refer to MA-14, "Checking Drive Belts" . Tighten bolts (E), (F) and (G). : 45.1 - 59.8 Nm (4.6 - 6.1 kg-m, 34 - 44 ft-lb) for E bolt : 15.7 - 20.6 Nm (1.6 - 2.1 kg-m, 12 - 15 ft-lb) for F bolt : 6.5 - 7.6 Nm (0.67 - 0.77 kg-m, 58 - 67 in-lb) for G bolt
E B

5.

Changing Engine Coolant

ELS0009P

WARNING: G To avoid being scalded, never change the coolant when the engine is hot. G Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn to release built-up pressure. Then turn the cap all the way.

DRAINING ENGINE COOLANT

H

1. 2. 3. 4. 5.

Set temperature of front heater control to FULL HOT. Open and secure engine room LH cover. Remove radiator cap. Remove plate under radiator. Connect hose to drain cock to drain coolant. G Use commercially available hose. [Inside diameter: approx. 9 mm (0.35 in), length: approx. 300 mm (11.81 in)].

MA

KBIA0839E

6. 7.

Remove drain plug from cylinder block to drain coolant. Drain coolant from reservoir tank. G Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated flush engine cooling system, refer to MA-27, "FLUSHING COOLING SYSTEM" .

KBIA0840E

REFILLING ENGINE COOLANT

1. Install reservoir tank, radiator drain plug and cylinder block drain plugs. Apply sealant to the thread of cylinder block drain plugs.

MA-15

ENGINE MAINTENANCE (KA24DE)

G

Use Genuine Liquid Gasket or equivalent. : 34.3 - 44.1 Nm (3.5 - 4.5 kg-m , 26 - 32 ft-lb)

2.
G

Fill radiator and reservoir tank to specified level. Use Nissan genuine coolant or equivalent mixed with water (distilled or demineralized). Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . Engine coolant capacity (With reservoir tank): With front and rear heater: Approximately 9.1 With front heater: (8 Imp qt)
SMA182B

Approximately 8.1 (7-1/8 Imp qt) Without heater: Approximately 6.7 Reservoir tank capacity: 0.8 3. 4. 5. (3/4 lmp qt) Make certain each hose clamp and drain plug are securely tightened. Set temperature of front heater control to FULL HOT. Remove air relief plug on engine. (5-7/8 Imp qt)

KBIA0841E

6.

Remove front grille, and remove front heater air relief plug. G For removal of front grille, refer to EI-12, "FRONT GRILLE" .

KBIA0842E

MA-16

ENGINE MAINTENANCE (KA24DE)

7. Remove rear heater air relief plug from right-side of fuel tank under vehicle (models with rear heater).
A

C
KBIA0843E

D Pour coolant through coolant filler neck slowly of less than 2 (1-3/4 Imp qt) a minute to allow air in system to escape. G When coolant overflows air relief hole on heater hose, install air relief plug. E 9. Fill reservoir tank with coolant up to the MAX level. 10. Warm up engine to normal operating temperature without radiator cap installed. F G If coolant overflows radiator filler hole, install filler cap. 11. Run engine at 3,000 rpm for 10 seconds and return to idle speed with radiator cap installed. G G Repeat two or three times. Watch coolant temperature gauge so as not to overheat the H engine. SMA412B 12. Stop engine. CAUTION: I Steps 10 and 11 (shown above) must be finished within one minute to prevent coolant temperature from rising. 13. Cool down to less than approximately 50C (122F). J G Cool down using a fan to shorten the time. G If necessary, refill radiator up to filler neck with coolant. 14. Refill reservoir tank to MAX level line with coolant. K 15. Repeat steps 10 through 13 two or more times with radiator cap installed until coolant level no longer drops. 16. Check cooling system for leaks with engine running. MA 17. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature controller set at several position between COOL and WARM. CAUTION: M Be careful not to overheat. G To check thermostat valve condition, touch lower radiator hose by hand. If water flow is hot, valve is open. 18. Stop engine. 19. After cooling engine [approx. 50C (122F) or lower], remove radiator cap and check coolant level. If level is low, fill up to radiator neck again and repeat from step 15. 20. When coolant level stabilizes, fill reservoir tank up to MAX line.

8.

FLUSHING COOLING SYSTEM

1. 2. 3. 4. 5. 6. 7. Open air relief plug. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Replace steps 1 through 6 until clear water begins to drain from radiator.

MA-17

ENGINE MAINTENANCE (KA24DE) Checking Cooling System

ELS00091

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.

CHECKING COOLING SYSTEM HOSES

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows. G Be careful not to bend or damage the radiator fins. G When radiator is cleaned without removal, remove all surrounding 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 vertically downward. 2. Apply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downward.
G

5. 1.
G

Use compressed air lower than 490 kPa (5 kg/cm2 , 71 psi) and keep distance more than 30 cm (11.8 in). Blow air again into all the radiator core surfaces once per minute until no water sprays out.

CHECKING RADIATOR CAP

Pull the negative pressure valve to open it and check that it close completely when released. Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. Check that there are no abnormalities in the opening and closing conditions of the negative-pressure valve.

SMA967B

2.

Check radiator cap relief pressure. Standard: 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2 , 11- 14 psi) Limit: 59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi)

When connecting the radiator cap to the tester, apply engine coolant to the cap seal part. Replace the radiator cap if there is an abnormality in the negative-pressure valve, or if the open-valve pressure is outside of the standard values.

SLC755AC

MA-18

ENGINE MAINTENANCE (KA24DE)

CHECKING COOLING SYSTEM FOR LEAKS
G

To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm , 23 psi)
2

WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage.

SLC756AA

Checking Fuel Lines

Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace faulty parts.

ELS00092

H
SMA803A

CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Tightening torque specifications are the same for all rubber hose clamps. Ensure that screw does not contact adjacent parts.

MMA104A

MA

Changing Air Cleaner Filter

Air cleaner is located behind front RH wheel.

ELS0009Q

KBIA0749E

VISCOUS PAPER TYPE

The viscous paper type air cleaner filter does not require any cleaning operation between renewal.

MA-19

ENGINE MAINTENANCE (KA24DE)

DRY PAPER TYPE
It is necessary to clean the element or replace it at the recommended intervals, more often under dusty driving conditions.

SMA485B

Changing Engine Oil

ELS0009R

WARNING: G Be careful not to burn yourself, as the engine oil is hot. G Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine. 2. Stop engine and wait for 10 minutes. 3. Remove engine room LH cove and secure it. Refer to EM-12, "ENGINE ROOM COVER" . 4. Remove drain plug and oil filler cap. 5. Drain oil. 6. Install drain plug and refill with new engine oil. Oil specification and viscosity: G API Certification Mark G API grade SE, SF, SG, SH or SJ G ILSAC grade GF-I or GF-II G Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . Oil capacity (Approximate):
Unit: liter (lmp qt) With oil filter change Drain and refill Dry engine (engine overhaul) Without oil filter change Approximately 3.6 (3-1/8) Approximately 3.3 (2-7/8) Approximately 4.4 (3-7/8)

CAUTION: G Be sure to clean drain plug and install with new washer. Oil pan drain plug: : 29 - 39 Nm (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
G

7. 8.

The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only. Always use the dipstick to determine when the proper amount of oil is in the engine. Warm up engine and check area around drain plug and oil filter for oil leakage. Stop engine and wait for 10 minutes.

MA-20

ENGINE MAINTENANCE (KA24DE)

9. Check oil level.
A

C
PBIC0497E

Changing Oil Filter

REMOVAL
1. Remove front-side under cover. 2. Using an oil filter wrench, remove the oil filter. CAUTION: G Be careful not to get burned when the engine and engine oil are hot. G When removing, prepare a shop cloth to absorb any oil leakage or spillage. G Do not allow engine oil to adhere to the drive belts. G Completely wipe off any oil that adhere to the engine and the vehicle.

D
ELS0009S

H
KBIA0833E

INSTALLATION
1. Remove foreign materials adhering to the oil filter installation surface. 2. Apply engine oil to the oil seal circumference of the new oil filter. CAUTION: G The oil filter is provided with a relief valve. Use genuine NISSAN oil filter or equivalent.
I

MA
SMA010

3.

Screw the oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. Oil filter: : 14.7 - 20.5 Nm (1.5 - 2.1 kg-m, 11 - 15 ft-lb)

SMA229B

4. 5.

After warming up the engine, check for engine oil leakage. Check oil level and add engine oil. Refer to LU-5, "ENGINE OIL" .
ELS0009T

Changing Spark Plug

REMOVAL
1. Open and fix engine compartment LH cover.

MA-21

ENGINE MAINTENANCE (KA24DE)

2. 3. Disconnect high-tension cables from rocker cover. Remove spark plugs with a spark plug wrench (commercial service tool). G Remove and install No. 4 cylinder by connecting extension bar of 75 mm and universal socket to spark plug wrench.

SMA581C

INSPECTION AFTER REMOVAL

Check spark plug gap. Adjust or replace if necessary. Standard
Spark plug:

: 1.0 - 1.1 mm (0.039 - 0.043 in) NGK BKR5E-11 BKR6E-11 BKR7E-11

SMA476

Make Standard type Cold type

G

Use a wire brush for cleaning, if necessary.

INSTALLATION
Install in the reverse order of removal, paying attention to the following. Spark plug: : 20 - 29 Nm (2.0 - 3.0 Kg-m, 14 - 22 ft-lb)
G

Refer to EM-30, "ROCKER COVER" for installation of spark plug cap and high-tension cables.
ELS0009A

Checking Ignition Wires

1. 2. Check the high tension wires for cracks, damage, burned terminals and for proper fit. Measure the resistance of the high tension wires, by shaking them and checking for intermittent breaks. Resistance: 13.6 - 18.4 km (4.15 - 5.61 k/ft) [at 25C (77F)]
Cylinder No. 1 2 3 4 Resistance k [at 25C (77F)] Approximately 5.7 Approximately 7.5 Approximately 9.7 Approximately 11.5

SMA015A

If it exceeds the limit, replace the ignition wire with a new one.

MA-22

ENGINE MAINTENANCE (KA24DE) Checking Positive Crankcase Ventilation (PCV) System

CHECKING PCV VALVE
With engine running at idle, remove ventilation hose with PCV valve from breather separator; if valve is working properly, a hissing noise will be heard as air passes through it and a strong vacuum should be felt immediately when a finger is placed over valve inlet.
ELS0009B

D
SMA048

CHECKING VENTILATION HOSES

1. 2. Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.
ELS0009D

Checking Vacuum Hoses and Connections

Check vacuum hoses for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. Refer to EC-18, "Vacuum Hose Drawing" .

Checking EVAP Vapor Lines

1. Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration. 2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to EC-23, "Evaporative Emission System" .

ELS00097

PBIB0206E

Checking Heated Oxygen Sensor 1

CHECKING PROCEDURE

ELS00098

MA

1. INSPECTION START
Do you have a CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 3.
M

MA-23

ENGINE MAINTENANCE (KA24DE)

2. CHECKING HEATED OXYGEN SENSOR 1 CIRCUIT

With CONSULT-II Start engine and warm it up to normal operating temperature. Make sure that "M/R F/C MNT" in "DATA MONITOR" mode indicates "RICH" and "LEAN" periodically more than 5 times during 10 seconds at 2,000 rpm. OK or NG OK >> INSPECTION END NG >> Check and adjustment should be made. Refer to EC-45, "TROUBLE DIAGNOSIS - BASIC INSPECTION" . 1. 2.

PBIB0265E

3. CHECKING HEATED OXYGEN SENSOR 1 CIRCUIT

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Stop engine and set ECM Diagnostic Test Mode II (Heated oxygen sensor 1 monitor). 3. Restart engine and run it at about 2,000 rpm for about 2 minutes under no-load. 4. Keep engine speed at 2,000 rpm and make sure that the malfunction indicator lamp on the instrument panel comes on more than 5 times during each 10 seconds. OK or NG OK >> INSPECTION END NG >> Check and adjustment should be made. Refer to EC-45, "TROUBLE DIAGNOSIS - BASIC INSPECTION" .

SAT652J

MA-24

ENGINE MAINTENANCE (ZD30DD) ENGINE MAINTENANCE (ZD30DD) Checking Drive Belts

WARNING: Be sure to perform after engine has stopped. G Accessory belt is automatically adjusted by auto tensioner, so tension check for accessory belt is unnecessary. G Belt tensioning is not necessary, as it is automatically adjusted by auto belt tensioner.
PFP:00100

A
ELS0008L

H
KBIA0744E

Changing Engine Coolant

ELS0009L

WARNING: G To avoid being scalded, never change the coolant when the engine is hot. G Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn to release built-up pressure. Then turn the cap all the way.

DRAINING ENGINE COOLANT

1. 2. 3. 4. 5. Set temperature of front heater control to FULL HOT. Open and secure engine room LH cover. Remove radiator cap. Remove plate from under radiator. Connect hose to drain cock to drain coolant. G Use commercially available hose. [Inside diameter: approx. 9 mm (0.35 in), length: approx. 300 mm (11.81 in)].

MA

KBIA0839E

MA-25

ENGINE MAINTENANCE (ZD30DD)

6. 7. Remove drain plug from cylinder block to drain coolant. Drain coolant from reservoir tank. G Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated flush engine cooling system, refer to MA-27, "FLUSHING COOLING SYSTEM" .

PBIC0415E

REFILLING ENGINE COOLANT

1. Install reservoir tank, radiator drain plug and cylinder block drain plugs. Apply sealant to the thread of cylinder block drain plugs. G Use Genuine Liquid Gasket or equivalent. : 23.5 - 26.5 Nm (2.4 - 2.7 kg-m , 18 - 19 ft-lb) 2.
G

Fill radiator and reservoir tank to specified level. Use Nissan genuine coolant or equivalent mixed with water (distilled or demineralized). Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS". Engine coolant capacity (With reservoir tank): With front and rear heater: Approximately 12.6 With front heater: (11-1/8 Imp qt)
SMA182B

Approximately 11.4 (10 Imp qt) Without heater: Approximately 10.0 Reservoir tank capacity: 0.8 3. 4. 5. (3/4 lmp qt) Make certain each hose clamp and drain plug are securely tightened. Set temperature of front heater control to FULL HOT. Remove front grille, and remove front heater air relief plug. G For removal of front grille, refer to EI-12, "FRONT GRILLE" . (8-3/4 Imp qt)

KBIA0842E

MA-26

ENGINE MAINTENANCE (ZD30DD)

6. Remove rear heater air relief plug from right-side of fuel tank under vehicle (models with rear heater).
A

C
KBIA0843E

7.

Pour coolant through coolant filler neck slowly of less than 2 (1-3/4 Imp qt) a minute to allow air in system to escape. E G When coolant overflows air relief hole on heater hose, install air relief plug. 8. Fill reservoir tank with coolant up to the MAX level. 9. Warm up engine to normal operating temperature without radiaF tor cap installed. G If coolant overflows radiator filler hole, install filler cap. 10. Run engine at 3,000 rpm for 10 seconds and return to idle speed G with radiator cap installed. G Repeat two or three times. Watch coolant temperature gauge so as not to overheat the H engine. SMA412B 11. Stop engine. CAUTION: I Steps 10 and 11 (shown above) must be finished within one minute to prevent coolant temperature from rising. 12. Cool down to less than approximately 50C (122F). J G Cool down using a fan to shorten the time. G If necessary, refill radiator up to filler neck with coolant. 13. Refill reservoir tank to MAX level line with coolant. K 14. Repeat steps 10 through 13 two or more times with radiator cap installed until coolant level no longer drops. 15. Check cooling system for leaks with engine running. MA 16. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature controller set at several position between COOL and WARM. CAUTION: M Be careful not to overheat. G To check thermostat valve condition, touch lower radiator hose by hand. If water flow is hot, valve is open. 17. Stop engine. 18. After cooling engine [approx. 50C (122F) or lower], remove radiator cap and check coolant level. If level is low, fill up to radiator neck again and repeat from step 16. 19. When coolant level stabilizes, fill reservoir tank up to MAX line.

FLUSHING COOLING SYSTEM

1. 2. 3. 4. 5. 6. 7. Open air relief plug. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Replace steps 1 through 6 until clear water begins to drain from radiator.

MA-27

ENGINE MAINTENANCE (ZD30DD) Checking Cooling System

CHECKING HOSES
Check hoses for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.
ELS0009G

CHECKING RADIATOR CAP

1.
G

Pull the negative pressure valve to open it and check that it close completely when released. Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. Check that there are no unusualness in the opening and closing conditions of the negative-pressure valve.

SMA967B

2.

Check radiator cap relief pressure. Standard Limit : 108 - 127 kPa (1.08 - 1.27 bar, 1.1 - 1.3 kg/cm2 , 16 - 18psi) : 88 kPa (0.88 bar, 0.9 kg/cm2 , 13 psi)

When connecting the radiator cap to the tester, apply coolant to the cap seal part. Replace the radiator cap if there is an unusual condition in the negative-pressure valve, or if the open-valve pressure is outside of the standard values.

SLC755AC

CHECKING COOLING SYSTEM FOR LEAKS

G

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)

WARNING: Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure coolant escaping from the radiator. CAUTION: Higher pressure than specified above may cause radiator damage.

SLC756AA

Checking Fuel Lines

Inspect fuel lines, filler cap and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace faulty parts.

ELS0008Y

SMA803A

MA-28

ENGINE MAINTENANCE (ZD30DD) Changing Fuel Filter

REMOVAL
1. 2. 3. Remove floor cover from rear of RH seat. Disconnect harness connector from fuel filter switch. Remove fuel hose from fuel filter bracket. CAUTION: Plug the pipe to prevent fuel from draining. Remove fuel filter with bracket. CAUTION: Do not splash fuel during removal. If fuel is splashed, immediately wipe it off.
ELS0009J

4.

E
PBIC0401E

5. 6.

Using band-type filter wrench (commercial service tool), remove fuel filter. Turn fuel filter upside down to drain fuel.

PBIC0402E

INSTALLATION
Install in reverse order of removal, paying attention to following: G Screw the fuel filter by hand until packing contacts sealing surface of bracket. Then tighten it by turning approximately 2/3 turn. G After installation, bleed air from fuel path. Refer to FL-5, "Air Bleeding" . G Run engine and check for fuel leakage at connections.
J

Changing Air Cleaner Filter

Air cleaner is located behind front RH wheel.

ELS0008U

MA

KBIA0749E

VISCOUS PAPER TYPE

The viscous paper type air cleaner filter does not require any cleaning operation between renewal.

MA-29

ENGINE MAINTENANCE (ZD30DD)

DRY PAPER TYPE
It is necessary to clean the element or replace it at the recommended intervals, more often under dusty driving conditions.

SMA485B

Changing Engine Oil

ELS0008N

WARNING: G Be careful not to burn yourself, as the engine oil is hot. G Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, and check for oil leakage from engine components. 2. Stop engine and wait for 10 minutes. 3. Open engine room LH cover and secure it. 4. Remove drain plug and oil filler cap. 5. Drain engine oil. 6. Install drain plug and refill with new engine oil. CAUTION: G Be sure to clean drain plug and install with new washer. Oil pan drain plug: : 53.9 - 58.8 Nm (5.5 - 6.0 kg-m, 40 - 43 ft-lb) The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only. G Always use the dipstick to determine when the proper amount of oil is in the engine. Oil specification and viscosity G API grade CE, CF or CF-4 G Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
G

Oil capacity (Approximate):

Unit: liter (lmp qt) Drain and refill Dry engine (engine overhaul) With oil filter change Without oil filter change Approximately 6.9 (6-1/8) Approximately 6.4 (5-5/8) Approximately 7.6 (6-3/4)

7. 8.

Warm up engine and check area around drain plug and oil filter for oil leakage. Stop engine and wait for 10 minutes.

MA-30

ENGINE MAINTENANCE (ZD30DD)

9. Check oil level.
A

C
KBIA0834E

Changing Oil Filter

REMOVAL

D
ELS0009M

G
KBIA0836E

1. 2.

Open access hole on undercover. Insert 12.7 mm (1/2 inch) square extension bar into square hole on filter body. Loosen it by approximately 4 turns.

KBIA0837E

3.

4. 5.

Align protrusions on front of oil cooler housing and on filter body (indicated by mark) to drain oil. G Catch the oil with a pan or cloth. NOTE: G It takes approx. 3 minutes to completely drain oil. G The drained oil flows over the right surface of the filter body. CAUTION: G Completely wipe clean any engine oil remaining on the filter body or vehicle. Remove the filter body, then remove the oil filter element. Remove the O-ring from the filter body. Push the O-ring in one direction, lift the slack part using fingers, and remove the O-ring from the filter body. CAUTION: Do not use wires or flat-bladed screwdrivers etc. As they may cause damage to the filter body.
G

MA

KBIA0838E

JLC292B

MA-31

ENGINE MAINTENANCE (ZD30DD)

INSTALLATION
1. 2. 3. 4. 5. Completely remove all foreign objects adhering to the inside of the filter body or O-ring mounting area (body side and bracket side). Install the oil filter element and O-ring to the filter body. G Push the oil filter element into the filter body completely. Apply engine oil to the oil seal circumference of the oil filter body. Install the filter body to the oil filter bracket. Screw the oil filter body manually until it touches the installation surface. : 20 - 24 Nm (2.0 - 2.5 kg-m, 15 - 18 ft-lb) 6. 7. After warming up the engine, check for engine oil leakage. Check oil level and add engine oil. Refer to LU-16, "ENGINE OIL" .
ELS0008S

Draining Water

If malfunction indicator lamp lights up (not flashes) during engine operation, drain coolant from fuel filter as follows. 1. Remove floor cover from rear of driver seat. 2. Connect drain hose [vinyl hose of inside diameter 6 mm (0.24 in), which reaches floor] to engine coolant drain cock at the bottom of fuel filter switch. 3. Prepare a tray at the drain hose end. (Refer to step 4 for tray capacity.) 4. Loosen engine coolant drain cock, and operate priming pump to drain coolant from fuel filter. KBIA0889E NOTE: Remaining engine coolant amount when warning lamp lights up: approximately 90 - 150 ml (3.2 - 5.3 Imp fl oz). CAUTION: G Coolant in filter is drained with fuel. Prepare larger capacity pan than value shown above. G Drained coolant is mixed with fuel. Prevent fuel from adhering to rubber parts such as engine mount insulator. 5. After draining, disconnect drain hose, then close engine coolant drain cock by hand. CAUTION: If drain cock is tightened excessively, it may be damaged and fuel will leak. Do not use tools to tighten drain cock. 6. Bleed air in fuel piping. Refer to FL-5, "Air Bleeding" . 7. Start engine, then confirm that malfunction indicator lamp goes off.

Checking Injection Nozzle

G G

ELS0008V

Remove and install injection nozzle. Refer to EM-124, "INJECTION TUBE AND INJECTION NOZZLE" . Connect a nozzle tester to high-pressure injection nozzle assembly. Move nozzle tester lever fully by speed of 1 stroke/second. At the same time, check valve opening pressure and injection performance during injection. Standard Limit : 20,399 to 22,458 kPa (204 to 225 bar,208 to 229 kg/cm2 , 2,958 to 3,256 psi) : 17,751 kPa (178 bar,181 kg/cm2 , 2,574 psi)
EMR0055D

MA-32

ENGINE MAINTENANCE (ZD30DD)

NOTE: G High-pressure injection nozzle assembly injects in 2-stage pressure. Judge its performance (OK/NG) by checking valve opening pressure at 1st stage. Injection performance NG: Does not inject straight and strong (B in the figure). Fluid drops (C in the figure). Does not inject evenly (D in the figure).
G

If valve opening pressure exceeds limit value, or injection performance is NG, replace high-pressure injection nozzle assembly. CAUTION: Do not disassemble high-pressure injection nozzle assembly.

F
JEF349Y

MA

MA-33

CHASSIS AND BODY MAINTENANCE CHASSIS AND BODY MAINTENANCE Checking Exhaust System
Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage, chafing or deterioration.
PFP:00100
ELS0009Y

SMA211A

Checking Clutch Fluid Level and Leaks

If fluid level is extremely low, check clutch system for leaks.

ELS000AF

SMA642C

Checking Clutch System

Check fluid lines and operating cylinder for improper attachment, cracks, damage, loose connections, chafing and deterioration.

ELS000AG

SMA859

Checking M/T Oil

Check for oil leakage and oil level. CAUTION: Never start engine while checking oil level. Filler plug: : 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)

ELS0009Z

SMA103

Changing M/T Oil

1. 2. Drain oil from drain plug and refill with new gear oil. Check oil level.

ELS000A0

MA-34

CHASSIS AND BODY MAINTENANCE

Oil grade: API GL-4 Viscosity: Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" Oil capacity: RS5W71C Approx. 2.0 Drain plug: (3-1/2 lmp pt)
A

: 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)

Checking Propeller Shaft

Check propeller shaft for damage, looseness or grease leakage. Tightening torque: Refer toPR-3, "REAR PROPELLER SHAFT"

D
ELS000AH

G
SMA118A

Checking Differential Gear Oil

1. Check for oil leakage and oil level. Filler plug: : 59 - 98 Nm (6 - 10 kg-m, 43 - 72 ft-lb)

H
ELS000A1

Changing Differential Gear Oil

1. 2. Drain oil from drain plug and refill with new gear oil. Check oil level. Oil grad and Viscosity Capacity Refer toMA-11, "Fluids and Lubricants" : C200 1.3 (2-1/4 lmp pt) H233B 2.8 (4-7/8 lmp pt) :59 98 Nm (6 10 kg-m),43 72 ft-lb)

J
ELS000A2

MA

Drain plug

SMA440B

SMA257A

MA-35

CHASSIS AND BODY MAINTENANCE Balancing Wheels

Adjust wheel balance using the road wheel center. Wheel balance (Maximum allowable unbalance) :Refer to MA-41, "WHEEL BALANCE" .
ELS000AI ELS000A3

Rotation
G G

After rotating the tires, adjust the tire pressure. Retighten the wheel nuts when the vehicle has been driven for 1,000 km (600 miles) (also in cases of a flat tire, etc.). CAUTION: When installing wheels, tighten them diagonally by dividing the work two to three times in order to prevent the wheels from developing any distortion. Tightening torque of wheel nut: 98 - 118Nm (10 - 12 kg-m, 72 - 87 ft-lb)

SEIA0107E

Checking Brake Fluid Level and Leaks

G

ELS000A5

If fluid level is extremely low, check brake system for leaks.

SFIA0178J

Checking Brake Lines and Cables

G

ELS000A6

Check brake fluid lines and parking brake cables for improper attachment, leaks, chafing, abrasions, deterioration, etc.

SBR389C

MA-36

CHASSIS AND BODY MAINTENANCE Changing Brake Fluid

1. 2. Drain brake fluid from each air bleeder valve. Refill until new brake fluid comes out from each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to BR-8, "Changing Brake Fluid" . G Refill with recommended Genuine Brake Fluid or equivalent DOT 3 or DO4. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . G Never reuse drained brake fluid. G Be careful not to splash brake fluid on painted areas.
ELS000A7

D
SBR419C

Checking Disc Brake

ROTOR
Check condition, wear, and damage.
Front Brake model Standard thickness Maximum runout Minimum thickness (Wear limit) AD35VA 30.0 mm (1.181 in) 0.1 mm (0.004 in) 28.0 mm (1.102 in)

ELS000A8

CALIPER
G

Check for leakage.

I

K
SMA922A

PAD
G

MA

Check for wear or damage.

Brake model Standard thickness Minimum thickness (Wear Limit) AD35VA 11.0 mm (0.433 in) 2.0 mm (0.079 in)

BRA0010D

Checking Drum Brake

WHEEL CYLINDER
Check for leakage.

ELS000AJ

MA-37

CHASSIS AND BODY MAINTENANCE

DRUM
Check condition and inner surface.
Standard inner diameter Drum repair limit (Inner diameter) 260.0 mm (10.24 in) 261.5 mm (10.30 in)

SMA848B

LINING
Check wear or damage.
Standard thickness Lining Wear Limit (Minimum thickness) 5.5 mm (0.217 in) 1.5 mm (0.059 in)

SMA849B

Checking Steering Gear and Linkage

STEERING GEAR
G

ELS000A9

Check gear housing and boots for looseness, damage and grease leakage. Check connection with steering column for looseness.

SLIA0014E

STEERING LINKAGE
Check ball joint, dust cover and other component parts for looseness, wear, damage and grease leakage.

Checking Power Steering Fluid and Lines

Check fluid level in reservoir tank with engine off. Use HOT range at fluid temperatures of 50 to 80C (122 to 176F) or COLD range at fluid temperatures of 0 to 30C (32 to 86F). CAUTION: G Do not overfill.
G

ELS000AA

Recommended fluid is DEXRONTM III or equivalent. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS"
SST850C

MA-38

CHASSIS AND BODY MAINTENANCE

G

Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. Check rack boots for accumulation of power steering fluid.

C
SST851C

Axle and Suspension Parts

Check front and rear axle and suspension parts for excessive play, cracks, wear or other damage. G Shake each wheel to check for excessive play. G Check wheel bearings for smooth operation. G Check axle and suspension nuts and bolts for looseness. G Check strut (shock absorber) for oil leakage or other damage. G Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage.

D
ELS000AB

G
SMA525A

K
SFA392B

Lubricating Locks, Hinges and Hood Latches

Front door Slide door Back door Refer to BL-17, "Fitting Adjustment for Front Door" . Refer to BL-22, "Fitting Adjustment for Sliding Door" . Refer to BL-28, "Fitting Adjustment for Back Door" .

ELS000AD

MA

MA-39

CHASSIS AND BODY MAINTENANCE Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters
ELS000AE

SHIA0246E

MA-40

SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit
BELT DEFLECTION AND TENSION (KA24DE)
Deflection adjustment Used belt Limit Alternator Air conditioner compressor Power steering oil pump Applied pushing force 11 (0.43) 15 (0.59) 16 (0.63) After adjustment 7 - 8 (0.28 - 0.31) 10 - 12 (0.39 - 0.47) 11 - 13 (0.43 - 0.51) 98N (10kg, 22lb) 6 - 7 (0.24 - 0.28) 8 - 10 (0.31 - 0.39) 9 - 10 (0.35 - 0.39) New belt
PFP:00030

A
ELS0007M

BELT DEFLECTION AND TENSION (ZD30DD)

Tensions of drive belts Auto-adjustment by auto tensioner

SPARK PLUG
Make Standard Type Cold Plug gap mm (in) NGK BKR5E-11 BKR6E-11, BKR7E-11 1.0 - 1.1 (0.039 - 0.043)

IGNITION WIRE
Cylinder No. 1 2 3 4 Resistance k [at 25C (77F)] Approximately 5.7 Approximately 7.5 Approximately 9.7 Approximately 11.5

WHEEL BALANCE
Dynamic (At rim flange) Maximum allowable unbalance Static 10 g (0.35 oz) (one side) 20 g (0.71 oz)

MA

MA-41

SERVICE DATA AND SPECIFICATIONS (SDS)

MA-42