Professional Documents
Culture Documents
L MAINTENANCE
B
SECTION
MAINTENANCE C
E
CONTENTS
PREPARATION ........................................................... 3 DRY PAPER TYPE .............................................. 19 F
Commercial Service Tool ......................................... 3 Changing Engine Oil ............................................... 19
DESCRIPTION ............................................................ 4 Changing Oil Filter .................................................. 20
Pre-delivery Inspection Items ................................... 4 REMOVAL ........................................................... 20 G
GENERAL MAINTENANCE ....................................... 6 INSTALLATION ................................................... 21
General Maintenance ............................................... 6 Changing Spark Plug .............................................. 21
PERIODIC MAINTENANCE ....................................... 7 REMOVAL ........................................................... 21
H
Periodic Maintenance ............................................... 7 INSPECTION AFTER REMOVAL ....................... 22
ENGINE AND EMISSION CONTROL MAINTE- INSTALLATION ................................................... 22
NANCE (GASOLINE ENGINE) ............................. 7 Checking Ignition Wires .......................................... 22
ENGINE AND EMISSION CONTROL MAINTE- Checking Positive Crankcase Ventilation (PCV) I
NANCE (DIESEL ENGINE) ................................... 8 System .................................................................... 22
CHASSIS AND BODY MAINTENANCE ............... 9 CHECKING PCV VALVE ..................................... 22
MAINTENANCE UNDER SEVERE DRIVING CHECKING VENTILATION HOSES .................... 22 J
CONDITIONS ........................................................ 9 Checking Vacuum Hoses and Connections ........... 23
RECOMMENDED FLUIDS AND LUBRICANTS .......11 Checking EVAP Vapor Lines .................................. 23
Fluids and Lubricants ..............................................11 Checking Heated Oxygen Sensor 1 ....................... 23
K
SAE Viscosity Number ........................................... 12 CHECKING PROCEDURE ................................. 23
GASOLINE ENGINE OIL .................................... 12 ENGINE MAINTENANCE (ZD30DD) ........................ 25
DIESEL ENGINE OIL .......................................... 12 Checking Drive Belts .............................................. 25
GEAR OIL ........................................................... 13 Changing Engine Coolant ....................................... 25 MA
Engine Coolant Mixture Ratio ................................ 13 DRAINING ENGINE COOLANT .......................... 25
ENGINE MAINTENANCE (KA24DE) ....................... 14 REFILLING ENGINE COOLANT ......................... 26
Checking Drive Belts .............................................. 14 FLUSHING COOLING SYSTEM ......................... 27 M
Drive Belt Tension Adjustment ............................... 14 Checking Cooling System ...................................... 28
POWER STEERING PUMP BELT ...................... 14 CHECKING HOSES ............................................ 28
AIR CONDITIONER COMPRESSOR BELT ....... 14 CHECKING RADIATOR CAP .............................. 28
ALTERNATOR AND WATER PUMP BELT ......... 15 CHECKING COOLING SYSTEM FOR LEAKS ... 28
Changing Engine Coolant ...................................... 15 Checking Fuel Lines ............................................... 28
DRAINING ENGINE COOLANT ......................... 15 Changing Fuel Filter ............................................... 29
REFILLING ENGINE COOLANT ........................ 15 REMOVAL ........................................................... 29
FLUSHING COOLING SYSTEM ......................... 17 INSTALLATION ................................................... 29
Checking Cooling System ...................................... 17 Changing Air Cleaner Filter .................................... 29
CHECKING COOLING SYSTEM HOSES .......... 17 VISCOUS PAPER TYPE ..................................... 29
CHECKING RADIATOR ...................................... 18 DRY PAPER TYPE .............................................. 30
CHECKING RADIATOR CAP .............................. 18 Changing Engine Oil ............................................... 30
CHECKING COOLING SYSTEM FOR LEAKS... 18 Changing Oil Filter .................................................. 31
Checking Fuel Lines ............................................... 19 REMOVAL ........................................................... 31
Changing Air Cleaner Filter .................................... 19 INSTALLATION ................................................... 32
VISCOUS PAPER TYPE ..................................... 19
MA-1
Draining Water ........................................................ 32 Checking Drum Brake .............................................37
Checking Injection Nozzle ...................................... 32 WHEEL CYLINDER .............................................37
CHASSIS AND BODY MAINTENANCE ................... 34 DRUM ..................................................................38
Checking Exhaust System ...................................... 34 LINING .................................................................38
Checking Clutch Fluid Level and Leaks ................. 34 Checking Steering Gear and Linkage .....................38
Checking Clutch System ........................................ 34 STEERING GEAR ...............................................38
Checking M/T Oil .................................................... 34 STEERING LINKAGE ..........................................38
Changing M/T Oil .................................................... 34 Checking Power Steering Fluid and Lines ..............38
Checking Propeller Shaft ........................................ 35 Axle and Suspension Parts .....................................39
Checking Differential Gear Oil ................................ 35 Lubricating Locks, Hinges and Hood Latches .........39
Changing Differential Gear Oil ................................ 35 Checking Seat Belts, Buckles, Retractors, Anchors
Balancing Wheels ................................................... 36 and Adjusters ..........................................................40
Rotation .................................................................. 36 SERVICE DATA AND SPECIFICATIONS (SDS) ......41
Checking Brake Fluid Level and Leaks .................. 36 Standard and Limit ..................................................41
Checking Brake Lines and Cables ......................... 36 BELT DEFLECTION AND TENSION (KA24DE)...41
Changing Brake Fluid ............................................. 37 BELT DEFLECTION AND TENSION (ZD30DD)...41
Checking Disc Brake .............................................. 37 SPRK PLUG ........................................................41
ROTOR ................................................................ 37 IGNITION WIRE ...................................................41
CALIPER ............................................................. 37 WHEEL BALANCE ..............................................41
PAD ..................................................................... 37
MA-2
PREPARATION
PREPARATION PFP:00002
A
Commercial Service Tool ELS0009K
Tool number
Tool name Description B
Fuel filter wrench Removing fuel filter
D
PBIC0519E
MA
MA-3
DESCRIPTION
DESCRIPTION PFP:00000
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.
MA-4
DESCRIPTION
MA
MA-5
GENERAL MAINTENANCE
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 Reference page
Tires Check the pressure with a gauge periodically when at a service station, includ-
ing the spare, and adjust to the specified pressure if necessary. Check carefully
for damage, cuts or excessive wear.
Windshield/ rear wiper
Check for cracks or wear if not functioning correctly.
blades
Doors Check that all doors and back door operate properly. Also ensure that all latches
lock securely. Lubricate if necessary.
BL-17, BL-28
When driving in areas using road salt or other corrosive materials, check for
lubrication frequently.
Tire rotation Tires should be rotated every 10,000 km (6,000 miles). MA-36
MA-6
PERIODIC MAINTENANCE
The following tables show the normal maintenance schedule. Depending upon weather and atmospheric con-
ditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent mainte- B
nance may be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.
ENGINE AND EMISSION CONTROL MAINTENANCE (GASOLINE ENGINE) C
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust, C = Clean, E = Check and correct the
engine coolant mixture ratio.
MAINTENANCE OPERATION MAINTENANCE INTERVAL
D
km x Refer-
1,000 1 10 20 30 40 50 60 70 80 ence
Perform either at number of kilometers (miles)
(Miles x (0.6) (6) (12) (18) (24) (30) (36) (42) (48) page
or months, whichever comes first. E
1,000) 6 12 18 24 30 36 42 48
Months
Underhood and under vehicle
EM- F
Torque of manifolds & exhaust tube nuts I*1 22EM-
24
See G
Intake & exhaust valve clearance NOTE A*1 A*1 A*1 A*1 EM-38
(1)
Drive belts I*1 I*1 I I*1 I MA-14 H
Engine oil (Use API SE, SF, SG, SH or SJ
R R R R R R R R MA-19
oil.)
Engine oil filter (Use Part No. 15208 31U00 I
R R R R R R R R MA-20
or 15208 65F00 or equivalent)
See
Engine coolant (Use Nissan genuine engine J
NOTE E R MA-15
coolant or equivalent in its quality.)
(2)
Cooling system I I I I MA-17
Fuel lines I I MA-19 K
NOTE:
Maintenance items with should be performed more frequently according to Maintenance Under Severe Driving
Conditions.
(1) For three way catalyst models, periodic maintenance is not required. However, if valve noise increases, check valve clearance.
MA-7
PERIODIC MAINTENANCE
(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
See
Injection nozzles NOTE MA-32
(5)
NOTE:
Maintenance items with should be performed more frequently according to Maintenance Under Severe Driving
Conditions.
(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
NOTE:
Maintenance items with should be performed more frequently according to Maintenance Under Severe Driving
Conditions.
MA-9
PERIODIC MAINTENANCE
MA-10
RECOMMENDED FLUIDS AND LUBRICANTS
Capacity (Approximate)
Recommended Fluids/Lubricants B
Liter Imp measure
MA-11
RECOMMENDED FLUIDS AND LUBRICANTS
SMA084D
SMA090D
MA-12
RECOMMENDED FLUIDS AND LUBRICANTS
GEAR OIL
For warm and cold areas: 80W-90 for the differential gear A
and 75W-85 for transmission gear are preferable.
For hot areas: 90 is suitable for ambient temperatures
below 40C(104F). B
SLIA0015E
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pres-
sure fluid escaping from the radiator. Wait until the engine and radiator cool down.
MA-13
ENGINE MAINTENANCE (KA24DE)
WARNING:
Be sure to perform when the engine is stopped.
Inspection should be done only when engine is cold, or over 30
minutes after engine is stopped.
Measure belt tension with tension meter (special service tool) at
points marked shown in the figure.
Measure belt deflection by applying load of 98.1 N {10 kg} to .
PBIC0422E
Unit: mm (in)
Deflection adjustment
Used belt
New belt
Limit After adjustment
Alternator 11 (0.43) 7 - 8 (0.28 - 0.31) 6 - 7 (0.24 - 0.28)
Air conditioner compressor 13 (0.51) 8 - 10 (0.31 - 0.39) 7 - 8 (0.28 - 0.31)
Power steering oil pump 13 (0.51) 8 - 10 (0.31 - 0.39) 7 - 8 (0.28 - 0.31)
Applied pushing force 98 N (10 kg, 72 lb)
CAUTION:
When belt is replaced with a new one, tighten it a little stronger than current one to accommodate
for insufficient adaptability with pulley grooves.
When tension of belt being used exceeds Retightening limit, adjust it to value for Used belt.
When installing belt, make sure that it is correctly engaged with pulley groove.
Keep oil and water away from belt.
Do not twist or bend belt excessively.
POWER STEERING PUMP BELT
1. Open and fix engine compartment LH cover.
2. Loosen idler pulley lock nut (A) and adjust tension by turning
adjusting bolt (B).
For specified belt tension, refer to EM-14, "Checking Drive
Belts" .
3. Tighten nut (A).
EMK0571D
MA-14
ENGINE MAINTENANCE (KA24DE)
MA
KBIA0839E
M
6. Remove drain plug from cylinder block to drain coolant.
7. Drain coolant from reservoir tank.
Check drained coolant for contaminants such as rust, corro-
sion or discoloration. If contaminated flush engine cooling
system, refer to CO-34, "FLUSHING COOLING SYSTEM" .
KBIA0840E
MA-15
ENGINE MAINTENANCE (KA24DE)
KBIA0841E
6. Remove front grille, and remove front heater air relief plug.
For removal of front grille, refer to EI-12, "FRONT GRILLE" .
KBIA0842E
7. Remove rear heater air relief plug from right-side of fuel tank
under vehicle (models with rear heater).
KBIA0843E
MA-16
ENGINE MAINTENANCE (KA24DE)
8. Pour coolant through coolant filler neck slowly of less than 2 (1-3/4 Imp qt) a minute to allow air in sys- A
tem to escape.
When coolant overflows air relief hole on heater hose, install air relief plug.
9. Fill reservoir tank with coolant up to the MAX level. B
10. Warm up engine to normal operating temperature without radia-
tor cap installed.
If coolant overflows radiator filler hole, install filler cap. C
11. Run engine at 3,000 rpm for 10 seconds and return to idle speed
with radiator cap installed.
Repeat two or three times. D
Watch coolant temperature gauge so as not to overheat the
engine.
12. Stop engine. SMA412B E
CAUTION:
Steps 10 and 11 (shown above) must be finished within one minute to prevent coolant temperature
from rising. F
13. Cool down to less than approximately 50C (122F).
Cool down using a fan to shorten the time.
If necessary, refill radiator up to filler neck with coolant. G
14. Refill reservoir tank to MAX level line with coolant.
15. Repeat steps 10 through 13 two or more times with radiator cap installed until coolant level no longer
drops. H
16. Check cooling system for leaks with engine running.
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. I
CAUTION:
Be careful not to overheat.
To check thermostat valve condition, touch lower radiator hose by hand. If water flow is hot, valve is open. J
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. K
20. When coolant level stabilizes, fill reservoir tank up to MAX line.
FLUSHING COOLING SYSTEM MA
1. Open air relief plug.
2. 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. M
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water.
7. Replace steps 1 through 6 until clear water begins to drain from radiator.
Checking Cooling System ELS00091
WARNING:
Never remove the radiator cap when the engine is hot; serious burns could be caused by high pres-
sure 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.
MA-17
ENGINE MAINTENANCE (KA24DE)
CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows.
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all 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.
Use compressed air lower than 490 kPa (5 kg/cm2 , 71 psi) and keep distance more than 30 cm (11.8
in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CHECKING RADIATOR CAP
1. 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
MA-18
ENGINE MAINTENANCE (KA24DE)
A
Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, loose connections, chafing or deterioration. If necessary,
repair or replace faulty parts.
B
D
SMA803A
E
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 F
hose clamps.
Ensure that screw does not contact adjacent parts.
G
MMA104A
H
Changing Air Cleaner Filter ELS0009Q
KBIA0749E
MA
VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any cleaning operation between renewal.
M
DRY PAPER TYPE
It is necessary to clean the element or replace it at the recom-
mended intervals, more often under dusty driving conditions.
SMA485B
WARNING:
Be careful not to burn yourself, as the engine oil is hot.
MA-19
ENGINE MAINTENANCE (KA24DE)
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:
API Certification Mark
API grade SE, SF, SG, SH or SJ
ILSAC grade GF-I or GF-II
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
Oil capacity (Approximate):
Unit: liter (lmp qt)
With oil filter change Approximately 3.6 (3-1/8)
Drain and refill
Without oil filter change Approximately 3.3 (2-7/8)
Dry engine (engine overhaul) Approximately 4.4 (3-7/8)
CAUTION:
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)
The refill capacity depends on the oil temperature and drain time. Use these specifications for ref-
erence only.
Always use the dipstick to determine when the proper amount of oil is in the engine.
7. Warm up engine and check area around drain plug and oil filter for oil leakage.
8. Stop engine and wait for 10 minutes.
9. Check oil level.
PBIC0497E
REMOVAL
1. Remove front-side under cover.
MA-20
ENGINE MAINTENANCE (KA24DE)
SMA010
H
3. Screw the oil filter manually until it touches the installation sur-
face, then tighten it by 2/3 turn.
I
Oil filter:
: 14.7 - 20.5 Nm (1.5 - 2.1 kg-m, 11 - 15 ft-lb) J
SMA229B
MA
4. After warming up the engine, check for engine oil leakage.
5. Check oil level and add engine oil. Refer to LU-5, "ENGINE OIL" .
Changing Spark Plug ELS0009T
M
REMOVAL
1. Open and fix engine compartment LH cover.
2. Disconnect high-tension cables from rocker cover.
3. Remove spark plugs with a spark plug wrench (commercial ser-
vice tool).
Remove and install No. 4 cylinder by connecting extension
bar of 75 mm and universal socket to spark plug wrench.
SMA581C
MA-21
ENGINE MAINTENANCE (KA24DE)
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)
Refer to EM-30, "ROCKER COVER" for installation of spark plug cap and high-tension cables.
Checking Ignition Wires ELS0009A
1. Check the high tension wires for cracks, damage, burned termi-
nals and for proper fit.
2. 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)]
If it exceeds the limit, replace the ignition wire with a new one.
Checking Positive Crankcase Ventilation (PCV) System ELS0009B
SMA048
MA-22
ENGINE MAINTENANCE (KA24DE)
A
Check vacuum hoses for improper attachment and for leaks, cracks, damage, loose connections, chafing and
deterioration.
Refer to EC-18, "Vacuum Hose Drawing" .
B
Checking EVAP Vapor Lines ELS00097
PBIB0206E
F
Checking Heated Oxygen Sensor 1 ELS00098
CHECKING PROCEDURE
G
1. INSPECTION START
Do you have a CONSULT-II?
H
Yes or No
Yes >> GO TO 2.
No >> GO TO 3.
I
2. CHECKING HEATED OXYGEN SENSOR 1 CIRCUIT
With CONSULT-II J
1. Start engine and warm it up to normal operating temperature.
2. Make sure that "M/R F/C MNT" in "DATA MONITOR" mode indi-
cates "RICH" and "LEAN" periodically more than 5 times during K
10 seconds at 2,000 rpm.
OK or NG
OK >> INSPECTION END MA
NG >> Check and adjustment should be made. Refer to EC-45,
"TROUBLE DIAGNOSIS - BASIC INSPECTION" .
M
PBIB0265E
MA-23
ENGINE MAINTENANCE (KA24DE)
SAT652J
MA-24
ENGINE MAINTENANCE (ZD30DD)
WARNING:
Be sure to perform after engine has stopped. B
Accessory belt is automatically adjusted by auto tensioner, so
tension check for accessory belt is unnecessary.
Belt tensioning is not necessary, as it is automatically adjusted C
by auto belt tensioner.
H
KBIA0744E
KBIA0839E
MA-25
ENGINE MAINTENANCE (ZD30DD)
PBIC0415E
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
KBIA0843E
D
7. Pour coolant through coolant filler neck slowly of less than 2 (1-3/4 Imp qt) a minute to allow air in sys-
tem to escape.
When coolant overflows air relief hole on heater hose, install air relief plug. E
8. Fill reservoir tank with coolant up to the MAX level.
9. Warm up engine to normal operating temperature without radia-
tor cap installed. F
If coolant overflows radiator filler hole, install filler cap.
10. Run engine at 3,000 rpm for 10 seconds and return to idle speed
with radiator cap installed. G
Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the
H
engine.
11. Stop engine. SMA412B
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
Cool down using a fan to shorten the time.
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.
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. Open air relief plug.
2. 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.
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water.
MA-27
ENGINE MAINTENANCE (ZD30DD)
7. Replace steps 1 through 6 until clear water begins to drain from radiator.
Checking Cooling System ELS0009G
CHECKING HOSES
Check hoses for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterio-
ration.
CHECKING RADIATOR CAP
1. 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
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.
SMA803A
MA-28
ENGINE MAINTENANCE (ZD30DD)
REMOVAL A
1. Remove floor cover from rear of RH seat.
2. Disconnect harness connector from fuel filter switch.
3. Remove fuel hose from fuel filter bracket. B
CAUTION:
Plug the pipe to prevent fuel from draining.
4. Remove fuel filter with bracket. C
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off. D
PBIC0401E
E
PBIC0402E
I
INSTALLATION
Install in reverse order of removal, paying attention to following:
Screw the fuel filter by hand until packing contacts sealing surface of bracket. Then tighten it by turning J
approximately 2/3 turn.
After installation, bleed air from fuel path. Refer to FL-5, "Air Bleeding" .
Run engine and check for fuel leakage at connections. K
KBIA0749E
MA-29
ENGINE MAINTENANCE (ZD30DD)
SMA485B
WARNING:
Be careful not to burn yourself, as the engine oil is hot.
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:
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 ref-
erence only.
Always use the dipstick to determine when the proper amount of oil is in the engine.
Oil specification and viscosity
API grade CE, CF or CF-4
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
Oil capacity (Approximate):
Unit: liter (lmp qt)
With oil filter change Approximately 6.9 (6-1/8)
Drain and refill
Without oil filter change Approximately 6.4 (5-5/8)
Dry engine (engine overhaul) Approximately 7.6 (6-3/4)
7. Warm up engine and check area around drain plug and oil filter for oil leakage.
8. Stop engine and wait for 10 minutes.
MA-30
ENGINE MAINTENANCE (ZD30DD)
KBIA0834E
D
Changing Oil Filter ELS0009M
REMOVAL
E
G
KBIA0836E
1. Open access hole on undercover.
2. Insert 12.7 mm (1/2 inch) square extension bar into square hole H
on filter body. Loosen it by approximately 4 turns.
KBIA0837E
K
3. Align protrusions on front of oil cooler housing and on filter body
(indicated by mark) to drain oil.
Catch the oil with a pan or cloth. MA
NOTE:
It takes approx. 3 minutes to completely drain oil.
The drained oil flows over the right surface of the filter body. M
CAUTION:
Completely wipe clean any engine oil remaining on the
filter body or vehicle.
4. Remove the filter body, then remove the oil filter element. KBIA0838E
JLC292B
MA-31
ENGINE MAINTENANCE (ZD30DD)
INSTALLATION
1. Completely remove all foreign objects adhering to the inside of the filter body or O-ring mounting area
(body side and bracket side).
2. Install the oil filter element and O-ring to the filter body.
Push the oil filter element into the filter body completely.
3. Apply engine oil to the oil seal circumference of the oil filter body.
4. Install the filter body to the oil filter bracket.
5. Screw the oil filter body manually until it touches the installation surface.
Remove and install injection nozzle. Refer to EM-125, "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 per-
formance during injection.
Standard : 20,399 to 22,458 kPa (204 to 225 bar, 208 to
229 kg/cm2 , 2,958 to 3,256 psi)
Limit : 17,751 kPa (178 bar, 181 kg/cm2 , 2,574 psi)
NOTE: EMR0055D
High-pressure injection nozzle assembly injects in 2-stage pres-
sure. Judge its performance (OK/NG) by checking valve opening pressure at 1st stage.
MA-32
ENGINE MAINTENANCE (ZD30DD)
E
JEF349Y
MA
MA-33
CHASSIS AND BODY MAINTENANCE
SMA211A
SMA642C
SMA859
SMA103
1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
MA-34
CHASSIS AND BODY MAINTENANCE
Oil grade: A
API GL-4
Viscosity:
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" B
Oil capacity:
RS5W71C Approx. 2.0 (3-1/2 lmp pt)
C
Drain plug:
: 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
D
Checking Propeller Shaft ELS000AH
SMA118A
H
Checking Differential Gear Oil ELS000A1
: 59 - 98 Nm (6 - 10 kg-m, 43 - 72 ft-lb)
J
Changing Differential Gear Oil ELS000A2
1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level. K
Oil grad and Refer toMA-11, "Fluids and Lubricants"
Viscosity
Capacity : C200 MA
1.3 (2-1/4 lmp pt)
H233B
2.8 (4-7/8 lmp pt) M
Drain plug :59 98 Nm (6 10 kg-m),43 72 ft-lb)
SMA440B
SMA257A
MA-35
CHASSIS AND BODY MAINTENANCE
Rotation ELS000AI
SEIA0107E
SFIA0178J
Check brake fluid lines and parking brake cables for improper
attachment, leaks, chafing, abrasions, deterioration, etc.
SBR389C
MA-36
CHASSIS AND BODY MAINTENANCE
A
1. Drain brake fluid from each air bleeder valve.
2. Refill until new brake fluid comes out from each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill B
brake fluid.
Refer to BR-8, "Changing Brake Fluid" .
Refill with recommended Genuine Brake Fluid or equivalent C
DOT 3 or DO4.
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" . D
SBR419C
Never reuse drained brake fluid.
CALIPER
Check for leakage. I
SMA922A
MA
PAD
Check for wear or damage.
Unit: mm (in) M
Brake model AD35VA
Standard thickness 11.0 (0.433)
Minimum thickness (Wear Limit) 2.0 (0.079)
BRA0010D
WHEEL CYLINDER
Check for leakage.
MA-37
CHASSIS AND BODY MAINTENANCE
DRUM
Check condition and inner surface.
Unit: mm (in)
Standard inner diameter 260.0 (10.24)
Drum repair limit (Inner diameter) 261.5 (10.30)
SMA848B
LINING
Check wear or damage.
Unit: mm (in)
Standard thickness 5.5 mm (0.217 in)
Lining Wear Limit (Minimum thickness) 1.5 mm (0.059 in)
SMA849B
STEERING GEAR
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 ELS000AA
SST850C
MA-38
CHASSIS AND BODY MAINTENANCE
SST851C
D
Axle and Suspension Parts ELS000AB
Check front and rear axle and suspension parts for excessive play,
cracks, wear or other damage. E
Shake each wheel to check for excessive play.
Check wheel bearings for smooth operation.
Check axle and suspension nuts and bolts for looseness. F
Check strut (shock absorber) for oil leakage or other damage.
Check suspension ball joint for grease leakage and ball joint
dust cover for cracks or other damage. G
SMA525A
K
SFA392B
MA-39
CHASSIS AND BODY MAINTENANCE
SHIA0246E
MA-40
SERVICE DATA AND SPECIFICATIONS (SDS)
SPRK PLUG
Make NGK F
Standard BKR5E-11
Type Cold BKR6E-11, BKR7E-11
G
Plug gap mm(in) 1.0 - 1.1 (0.039 - 0.043)
IGNITION WIRE
H
Cylinder No. Resistance k [at 25C (77F)]
1 Approximately 5.7
2 Approximately 7.5 I
3 Approximately 9.7
4 Approximately 11.5
J
WHEEL BALANCE
Dynamic (At rim flange) 10 g (0.35 oz) (one side)
Maximum allowable unbalance
Static 20 g (0.71 oz) K
MA
MA-41
SERVICE DATA AND SPECIFICATIONS (SDS)
MA-42