MA-1

MAINTENANCE
L MAINTENANCE
CONTENTS
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SECTION
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B
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MAINTENANCE
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 MAINTE-
NANCE (GASOLINE ENGINE) ............................. 7
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (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 .............................................. 22
REMOVAL ........................................................ ... 22
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-2
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
CheckingSeat 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
PREPARATION
MA-3
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PREPARATION PFP:00002
Commercial Service Tool ELS0009K
Tool number
Tool name Description
Fuel filter wrench Removing fuel filter
PBIC0519E
MA-4
DESCRIPTION
DESCRIPTION PFP:00000
Pre-delivery Inspection Items 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
DESCRIPTION
MA-5
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Engine performance
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
MA-6
GENERAL MAINTENANCE
GENERAL MAINTENANCE PFP:00000
General Maintenance 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.
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.
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
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

blades
Check for cracks or wear if not functioning correctly.
Doors 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.
BL-17, BL-28
Tire rotation Tires should be rotated every 10,000 km (6,000 miles). MA-36
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 head-
lamp aim.

Warning lamps and

chimes
Make sure that all warning lamps and buzzers/chimes are operating properly.
Steering wheel 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)

Seat belts 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.
MA-40
Item Reference page
Windshield washer
fluid
Check that there is adequate fluid in the tank.
Engine coolant level Check the coolant level when the engine is cold. CO-9,CO-32
Engine oil level Check the level after parking the vehicle (on level ground) and turning off the
engine.
MA-20,MA-30
Brake and clutch fluid
level
Make sure that the brake fluid level is between the MAX and MIN lines on the
reservoir.
MA-36,MA-34
Battery Check the fluid level in each cell. It should be between the MAX and MIN
lines.

PERIODIC MAINTENANCE
MA-7
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PERIODIC MAINTENANCE PFP:00026
Periodic Maintenance ELS0006R
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-
nance 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, A = Adjust, C = Clean, E = Check and correct the
engine coolant mixture ratio.
NOTE:
G Maintenance items with should be performed more frequently according to Maintenance Under Severe Driving
Conditions.
G (1) For three way catalyst models, periodic maintenance is not required. However, if valve noise increases, check valve clearance.
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Refer-
ence
page
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
20
(12)
12
30
(18)
18
40
(24)
24
50
(30)
30
60
(36)
36
70
(42)
42
80
(48)
48
Underhood and under vehicle
Torque of manifolds & exhaust tube nuts I*1
EM-
22EM-
24
Intake & exhaust valve clearance
See
NOTE
(1)
A*1 A*1 A*1 A*1 EM-38
Drive belts I*1 I*1 I I*1 I MA-14
Engine oil (Use API SE, SF, SG, SH or SJ
oil.)
R R R R R R R R MA-20
Engine oil filter (Use Part No. 15208 31U00
or 15208 65F00 or equivalent)
R R R R R R R R MA-21
Engine coolant (Use Nissan genuine engine
coolant or equivalent in its quality.)
See
NOTE
(2)
E R MA-15
Cooling system I I I I MA-18
Fuel lines I I MA-19
Air cleaner filter (Dry paper type)
C C C R C C C R MA-19
Air cleaner filter (Viscous paper type)
See
NOTE
(3)
R R MA-19
Fuel filter
See
NOTE
(4)
FL-7
Spark plugs (For leaded fuel) I*1 R*1 I*1 R*1 I*1 R*1 I*1 R*1 MA-22
Spark plugs (For unleaded fuel) I*1 I*1 I*1 R I*1 I*1 I*1 R MA-22
Ignition wires I I MA-22
Positive crankcase ventilation (PCV) system I*1 I*1 I*1 I*1 MA-23
Vacuum hoses & connections I*1 I*1 I*1 I*1 MA-23
EVAP vapor lines (With carbon canister) I I MA-23
Heated oxygen sensor 1 (Exhaust gas sen-
sor)
I I MA-23
MA-8
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
G (3) For optional specifications.
G (4) Maintenance-free item. For service procedures, refer to FL section.
G *1: Only on models without three way catalyst
ENGINE AND EMISSION CONTROL MAINTENANCE (DIESEL ENGINE)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, D = Check filter and drain water, E = Check and cor-
rect the engine coolant mixture ratio.
NOTE:
G Maintenance items with should be performed more frequently according to Maintenance Under Severe Driving
Conditions.
G (1) If valve noise increases, check valve clearance.
G (2) Never use API CG-4 grade oil.
G (3) Oil filter element assembly (part No. 15209 2W200) and O-ring seal (part No. 15226 2W200) are replacement parts.
G (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.
G (5) If engine power decreases, black exhaust smoke emits, or engine noise increases, check the injection nozzles and, if
necessary replace injection nozzle assembly.
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Refer-
ence
page
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
20
(12)
12
30
(18)
18
40
(24)
24
50
(30)
30
60
(36)
36
70
(42)
42
80
(48)
48
Underhood and under vehicle
Torque of manifolds & exhaust tube nuts I
EM-115
EM-118
Intake & exhaust valve clearance
See
NOTE
(1)
EM-142
Drive belts I I I I I MA-25
Engine oil (Use API CE, CF, IF-4 oil.)
See
NOTE
(2)
Replace every 15,000 km (9,000 miles) or 12 months MA-30
Engine oil filter (Use Echo filter or equiva-
lent)
See
NOTE
(3)
Replace every 15,000 km (9,000 miles) or 12 months MA-31
Engine coolant (Use Nissan genuine
engine coolant or equivalent in its quality.)
See
NOTE
(4)
E R MA-25
Cooling system I I I I MA-28
Fuel lines I I MA-28
Air cleaner filter (Dry paper type)
C C C R C C C R MA-30
Air cleaner filter (Viscous paper type)
R R MA-29
Fuel filter
D D D R D D D R MA-29
Injection nozzles
See
NOTE
(5)
MA-32
PERIODIC MAINTENANCE
MA-9
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B
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CHASSIS AND BODY MAINTENANCE
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate.
NOTE:
G Maintenance items with should be performed more frequently according to Maintenance Under Severe Driving
Conditions.
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 per-
formed on the following items as shown in the table.
Severe driving conditions
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Reference
page
Perform either at number of kilome-
ters (miles) or months, whichever
comes first.
km x 1,000
(Miles x
1,000)
Months
1
(0.6)

10
(6)
6
20
(12)
12
30
(18)
18
40
(24)
24
50
(30)
30
60
(36)
36
70
(42)
42
80
(48)
48
Underhood and under vehicle
Brake & clutch fluid (For level &
leaks)
I I I I I I I I
MA-36,
MA-34
Brake fluid
R R MA-37
Brake booster vacuum hoses, con-
nections & check valve
I I BR-22
Power steering fluid & lines (For
level & leaks)
I I I I I I I I MA-38
Brake, clutch & exhaust systems I I I I I I I I
MA-37,
MA-34,
MA-34
Manual transmission gear oil (For
level & leaks)
I I I I I I I I MA-34
Manual transmission gear oil Replace every 100,000 Km (60,000 miles) MA-34
Differential gear oil (For level &
leaks)
I I I R I I I R MA-35
Limited-slip differential (LSD) gear
oil (If so equipped, For level &
leaks)
I R I R MA-35
Steering gear & linkage, axle & sus-
pension parts & propeller shafts
I I I I
MA-38,
MA-39
MA-35
Outside and inside
Wheel alignment (If necessary,
rotate & balance wheels)
I I I I
MA-36,
MA-36
Brake pads, rotors & other brake
components
I I I I I I I I MA-37
Brake linings, drums & other brake
components
I I I I MA-37
Locks, hinges & slide door rollers
and links
L L L L L L L L
BL-17,
BL-22,
BL-28
Seat belts, buckles, retractors,
anchors & adjuster
I I I I MA-40
Foot brake, parking brake & clutch
(For free play, stroke & operation)
I I I I I I I I
BR-6, PB-3
, CL-5
MA-10
PERIODIC MAINTENANCE
A Driving in dusty conditions
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
Mainte-
nance
operation
Maintenance interval
Refer-
ence page
A . . . . . . . . Air cleaner filter
Dry paper type
Clean &
Replace
More frequently
MA-19
MA-30
Viscous paper
type
Replace
MA-19
MA-29
A B C D . . . . . Engine oil
Gasoline engine Replace
Every 5,000 km (3,000
miles) or 3 months
MA-20
Diesel engine Replace More frequently MA-30
A B C D . . . . . Engine oil filter
Gasoline engine Replace
Every 5,000 km (3,000
miles) or 3 months
MA-21
Diesel engine Replace
Every 7,500 km (4,500
miles) or 6 months
MA-31
A . . . E . . . . Fuel filter (Diesel engine only) Replace
Every 20,000 km (12,000
miles) or 12 months
MA-29
. . . . . F . . . Brake fluid Replace MA-37
. . C . . . . H . Limited slip differential (LSD) gear oil Replace MA-35
. . . . . . G H .
Steering gear & linkage, axle & suspen-
sion parts & propeller shafts
Check
Every 5,000 km (3,000
miles) or 3 months
MA-38,
MA-39
MA-35
A . C . . . G H I
Brake pads, rotors & other brake com-
ponents
Check MA-37
A . C . . . G H I
Brake linings, drums & other brake
components
Check
Every 10,000 km (6,000
miles) or 6 months
MA-37
. . . . . . G . .
Locks, hinges & slide door rollers and
links
Lubricate
Every 5,000 km (3,000
miles) or 3 months
BL-17,
BL-22,
BL-28
RECOMMENDED FLUIDS AND LUBRICANTS
MA-11
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RECOMMENDED FLUIDS AND LUBRICANTS PFP:00000
Fluids and Lubricants ELS0006S
*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.
Capacity (Approximate)
Recommended Fluids/Lubricants
Liter Imp measure
Engine oil
Drain and refill
With oil filter
change
KA24DE 3.6 3-1/8 qt
G Gasoline engine: API SE, SF, SG, SH or SJ*1
G ILSAC grade GF-I or GF-II*1
G Diesel engine: API CE, CF or CF-4*1, *2
ZD30DD 6.9 6-1/8 qt
Without oil filter
change
KA24DE 3.3 2-7/8 qt
ZD30DD 6.4 5-5/8 qt
Dry engine (engine overhaul)
KA24DE 4.4 3-7/8 qt
ZD30DD 7.6 6-3/4 qt
Cooling system
(with reservoir)
With front and
rear heater
KA24DE 9.1 8 qt
Nissan Genuine Engine Coolant or equivalent in
its quality *3
ZD30DD 12.6 11-1/8 qt
With front heater
KA24DE 8.1 7-1/8 qt
ZD30DD 11.4 10 qt
Without heater
KA24DE 6.7 5-7/8 qt
ZD30DD 10.0 8-3/4 qt
Reservoir 0.8 3/4 qt
Manual transmission gear oil 2.0 3-1/2 pt API GL-4, Viscosity SAE 75W-85
Brake and clutch fluid DOT 3 (US FMVSS No. 116)
Power steering fluid DEXRON
TM
III or equivalent
Differential gear oil
C200 1.3 2-1/4 pt
API GL-5*1
H233B 2.8 4-7/8 pt
Limited-slip differential(LSD) gear oil 2.8 4-7/8 pt
Gear oil hypoid LSD (Part No.:KLD31-14002) or
equivalent*4
Multi-purpose grease NLGI No. 2 (Lithium soap base)
MA-12
RECOMMENDED FLUIDS AND LUBRICANTS
SAE Viscosity Number ELS0006T
GASOLINE ENGINE OIL
G For warm and cold areas: 10W-30 is preferable for ambient
temperatures above -20C(-4F).
G For hot areas: 20W-40 and 20W-50 are suitable.
DIESEL ENGINE OIL
G For cold areas: 10W-30 is preferable.
G For hot and warm areas: 20W-40 and 20W-50 are suitable.
SMA084D
SMA090D
RECOMMENDED FLUIDS AND LUBRICANTS
MA-13
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GEAR OIL
G For warm and cold areas: 80W-90 for the differential gear
and 75W-85 for transmission gear are preferable.
G For hot areas: 90 is suitable for ambient temperatures
below 40C(104F).
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
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 cool-
ant. The high quality engine coolant contains the specific solutions
effective for the anti-corrosion and the anti-freeze function. There-
fore, additional cooling system additives are not necessary.
CAUTION:
G When adding or replacing coolant, be sure to use only a
Nissan Genuine Engine Coolant or equivalent in its quality
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
your hydrometer reading (specific gravity) according to coolant temperature.
Mixed coolant specific gravity
Unit: specific gravity
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.
SLIA0015E
SMA089D
Engine coolant mixture
ratio
Coolant temperature C (F)
15 (59) 25 (77) 35 (95) 45 (113)
30% 1.046 - 1.050 1.042 - 1.046 1.038 - 1.042 1.033 - 1.038
50% 1.076 - 1.080 1.070 - 1.076 1.065 - 1.071 1.059 - 1.065
MA-14
ENGINE MAINTENANCE (KA24DE)
ENGINE MAINTENANCE (KA24DE) PFP:00100
Checking Drive Belts ELS0009N
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 Measure belt deflection by applying load of 98.1 N {10 kg} to .
Unit: mm (in)
Drive Belt Tension Adjustment ELS0009O
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. Open and fix engine compartment LH cover.
2. Loosen idler pulley lock nut (A) and adjust tension by turning
adjusting bolt (B).
G For specified belt tension, refer to EM-14, "Checking Drive
Belts" .
3. Tighten nut (A).
AIR CONDITIONER COMPRESSOR BELT
1. Open and fix engine compartment LH cover (passenger side for RHD models or driver-side for LHD mod-
els).
2. Loosen idler pulley lock nut (C) and adjust tension by turning adjusting bolt (D).
G For specified belt tension, refer to EM-14, "Checking Drive Belts" .
3. Tighten nut (C).
PBIC0422E
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)
: 25.5 - 32.4 Nm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
EMK0571D
ENGINE MAINTENANCE (KA24DE)
MA-15
C
D
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ALTERNATOR AND WATER PUMP BELT
1. Remove front-side under cover.
2. Remove RH seat. Refer to SE-3, "FRONT SEAT" .
3. Remove engine compartment RH cover. Refer to EM-12, "ENGINE ROOM COVER" .
4. 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 EM-14, "Checking Drive Belts" .
5. Tighten bolts (E), (F) and (G).
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
1. Set temperature of front heater control to FULL HOT.
2. Open and secure engine room LH cover.
3. Remove radiator cap.
4. Remove plate under radiator.
5. 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)].
6. Remove drain plug from cylinder block to drain coolant.
7. Drain coolant from reservoir tank.
G 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" .
REFILLING ENGINE COOLANT
1. Install reservoir tank, radiator drain plug and cylinder block drain plugs.
: 25.5 - 32.4 Nm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
: 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
KBIA0839E
KBIA0840E
MA-16
ENGINE MAINTENANCE (KA24DE)
Apply sealant to the thread of cylinder block drain plugs.
G Use Genuine Liquid Gasket or equivalent.
2. Fill radiator and reservoir tank to specified level.
G Use Nissan genuine coolant or equivalent mixed with water
(distilled or demineralized).
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
3. Make certain each hose clamp and drain plug are securely tightened.
4. Set temperature of front heater control to FULL HOT.
5. Remove air relief plug on engine.
6. Remove front grille, and remove front heater air relief plug.
G For removal of front grille, refer to EI-12, "FRONT GRILLE" .
: 34.3 - 44.1 Nm (3.5 - 4.5 kg-m , 26 - 32 ft-lb)
Engine coolant capacity (With reservoir tank):
With front and rear heater:
Approximately 9.1 (8 Imp qt)
With front heater:
Approximately 8.1 (7-1/8 Imp qt)
Without heater:
Approximately 6.7 (5-7/8 Imp qt)
SMA182B
Reservoir tank capacity:
0.8 (3/4 lmp qt)
KBIA0841E
KBIA0842E
ENGINE MAINTENANCE (KA24DE)
MA-17
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7. Remove rear heater air relief plug from right-side of fuel tank
under vehicle (models with rear heater).
8. 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.
G When coolant overflows air relief hole on heater hose, install air relief plug.
9. Fill reservoir tank with coolant up to the MAX level.
10. Warm up engine to normal operating temperature without radia-
tor cap installed.
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 Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
12. Stop engine.
CAUTION:
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).
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.
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.
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:
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.
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.
KBIA0843E
SMA412B
MA-18
ENGINE MAINTENANCE (KA24DE)
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.
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 Use compressed air lower than 490 kPa (5 kg/cm
2
, 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.
G Check that there is no dirt or damage on the valve seat of the
radiator cap negative-pressure valve.
G Check that there are no abnormalities in the opening and closing
conditions of the negative-pressure valve.
2. Check radiator cap relief pressure.
G When connecting the radiator cap to the tester, apply engine
coolant to the cap seal part.
G Replace the radiator cap if there is an abnormality in the nega-
tive-pressure valve, or if the open-valve pressure is outside of
the standard values.
SMA967B
Standard:
78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2
, 11- 14 psi)
Limit:
59 kPa (0.59 bar, 0.6 kg/cm
2
, 9 psi)
SLC755AC
ENGINE MAINTENANCE (KA24DE)
MA-19
C
D
E
F
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CHECKING COOLING SYSTEM FOR LEAKS
G To check for leakage, apply pressure to the cooling system with
a tester.
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.
Checking Fuel Lines ELS00092
Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, loose connections, chafing or deterioration. If necessary,
repair or replace faulty parts.
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.
Changing Air Cleaner Filter ELS0009Q
Air cleaner is located behind front RH wheel.
VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any cleaning operation between renewal.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2
, 23 psi)
SLC756AA
SMA803A
MMA104A
KBIA0749E
MA-20
ENGINE MAINTENANCE (KA24DE)
DRY PAPER TYPE
It is necessary to clean the element or replace it at the recom-
mended intervals, more often under dusty driving conditions.
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)
CAUTION:
G Be sure to clean drain plug and install with new washer.
G The refill capacity depends on the oil temperature and drain time. Use these specifications for ref-
erence only.
G 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.
SMA485B
Drain and refill
With oil filter change Approximately 3.6 (3-1/8)
Without oil filter change Approximately 3.3 (2-7/8)
Dry engine (engine overhaul) Approximately 4.4 (3-7/8)
Oil pan drain plug:
: 29 - 39 Nm (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
ENGINE MAINTENANCE (KA24DE)
MA-21
C
D
E
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9. Check oil level.
Changing Oil Filter ELS0009S
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.
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.
3. Screw the oil filter manually until it touches the installation sur-
face, then tighten it by 2/3 turn.
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" .
PBIC0497E
KBIA0833E
SMA010
Oil filter:
: 14.7 - 20.5 Nm (1.5 - 2.1 kg-m, 11 - 15 ft-lb)
SMA229B
MA-22
ENGINE MAINTENANCE (KA24DE)
Changing Spark Plug ELS0009T
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).
G Remove and install No. 4 cylinder by connecting extension
bar of 75 mm and universal socket to spark plug wrench.
INSPECTION AFTER REMOVAL
Check spark plug gap. Adjust or replace if necessary.
Spark plug:
G Use a wire brush for cleaning, if necessary.
INSTALLATION
Install in the reverse order of removal, paying attention to the following.
G 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.
If it exceeds the limit, replace the ignition wire with a new one.
SMA581C
Standard : 1.0 - 1.1 mm (0.039 - 0.043 in)
Make NGK
Standard type BKR5E-11
Cold type
BKR6E-11
BKR7E-11
SMA476
Spark plug:
: 20 - 29 Nm (2.0 - 3.0 Kg-m, 14 - 22 ft-lb)
Resistance:
13.6 - 18.4 km (4.15 - 5.61 k/ft) [at 25C
(77F)]
Cylinder No. Resistance k [at 25C (77F)]
1 Approximately 5.7
2 Approximately 7.5
3 Approximately 9.7
4 Approximately 11.5
SMA015A
ENGINE MAINTENANCE (KA24DE)
MA-23
C
D
E
F
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Checking Positive Crankcase Ventilation (PCV) System ELS0009B
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.
CHECKING VENTILATION HOSES
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.
Checking Vacuum Hoses and Connections ELS0009D
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 ELS00097
1. Visually inspect EVAP vapor lines for improper attachment and
for cracks, damage, loose connections, chafing and deteriora-
tion.
2. Inspect vacuum relief valve of fuel tank filler cap for clogging,
sticking, etc.
Refer to EC-23, "Evaporative Emission System" .
Checking Heated Oxygen Sensor 1 ELS00098
CHECKING PROCEDURE
1. INSPECTION START
Do you have a CONSULT-II?
Yes or No
Yes >> GO TO 2.
No >> GO TO 3.
SMA048
PBIB0206E
MA-24
ENGINE MAINTENANCE (KA24DE)
2. CHECKING HEATED OXYGEN SENSOR 1 CIRCUIT
With CONSULT-II
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
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" .
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 mal-
function 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" .
PBIB0265E
SAT652J
ENGINE MAINTENANCE (ZD30DD)
MA-25
C
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ENGINE MAINTENANCE (ZD30DD) PFP:00100
Checking Drive Belts ELS0008L
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.
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. Set temperature of front heater control to FULL HOT.
2. Open and secure engine room LH cover.
3. Remove radiator cap.
4. Remove plate from under radiator.
5. 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)].
KBIA0744E
KBIA0839E
MA-26
ENGINE MAINTENANCE (ZD30DD)
6. Remove drain plug from cylinder block to drain coolant.
7. Drain coolant from reservoir tank.
G Check drained coolant for contaminants such as rust, corro-
sion or discoloration. If contaminated flush engine cooling
system, refer to MA-27, "FLUSHING COOLING SYSTEM" .
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.
2. Fill radiator and reservoir tank to specified level.
G Use Nissan genuine coolant or equivalent mixed with water
(distilled or demineralized).
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
CANTS".
3. Make certain each hose clamp and drain plug are securely tightened.
4. Set temperature of front heater control to FULL HOT.
5. Remove front grille, and remove front heater air relief plug.
G For removal of front grille, refer to EI-12, "FRONT GRILLE" .
PBIC0415E
: 23.5 - 26.5 Nm (2.4 - 2.7 kg-m , 18 - 19 ft-lb)
Engine coolant capacity (With reservoir tank):
With front and rear heater:
Approximately 12.6 (11-1/8 Imp qt)
With front heater:
Approximately 11.4 (10 Imp qt)
Without heater:
Approximately 10.0 (8-3/4 Imp qt)
SMA182B
Reservoir tank capacity:
0.8 (3/4 lmp qt)
KBIA0842E
ENGINE MAINTENANCE (ZD30DD)
MA-27
C
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MA
6. Remove rear heater air relief plug from right-side of fuel tank
under vehicle (models with rear heater).
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.
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 radia-
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
with radiator cap installed.
G Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
11. Stop engine.
CAUTION:
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).
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.
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.
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:
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. 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.
KBIA0843E
SMA412B
MA-28
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.
G Check that there is no dirt or damage on the valve seat of the
radiator cap negative-pressure valve.
G Check that there are no unusualness in the opening and closing
conditions of the negative-pressure valve.
2. Check radiator cap relief pressure.
G When connecting the radiator cap to the tester, apply coolant to
the cap seal part.
G 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.
CHECKING COOLING SYSTEM FOR LEAKS
G To check for leakage, apply pressure to the cooling system with
a tester.
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 dam-
age.
Checking Fuel Lines ELS0008Y
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.
SMA967B
Standard : 108 - 127 kPa (1.08 - 1.27 bar, 1.1 - 1.3
kg/cm
2
, 16 - 18psi)
Limit
: 88 kPa (0.88 bar, 0.9 kg/cm
2
, 13 psi)
SLC755AC
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2
, 23 psi)
SLC756AA
SMA803A
ENGINE MAINTENANCE (ZD30DD)
MA-29
C
D
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Changing Fuel Filter ELS0009J
REMOVAL
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.
CAUTION:
Plug the pipe to prevent fuel from draining.
4. Remove fuel filter with bracket.
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
5. Using band-type filter wrench (commercial service tool), remove
fuel filter.
6. Turn fuel filter upside down to drain fuel.
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.
Changing Air Cleaner Filter ELS0008U
Air cleaner is located behind front RH wheel.
VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any cleaning operation between renewal.
PBIC0401E
PBIC0402E
KBIA0749E
MA-30
ENGINE MAINTENANCE (ZD30DD)
DRY PAPER TYPE
It is necessary to clean the element or replace it at the recom-
mended intervals, more often under dusty driving conditions.
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.
G The refill capacity depends on the oil temperature and drain time. Use these specifications for ref-
erence 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" .
Oil capacity (Approximate):
Unit: liter (lmp qt)
7. Warm up engine and check area around drain plug and oil filter for oil leakage.
8. Stop engine and wait for 10 minutes.
SMA485B
Oil pan drain plug:
: 53.9 - 58.8 Nm (5.5 - 6.0 kg-m, 40 - 43 ft-lb)
Drain and refill
With oil filter change Approximately 6.9 (6-1/8)
Without oil filter change Approximately 6.4 (5-5/8)
Dry engine (engine overhaul) Approximately 7.6 (6-3/4)
ENGINE MAINTENANCE (ZD30DD)
MA-31
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9. Check oil level.
Changing Oil Filter ELS0009M
REMOVAL
1. Open access hole on undercover.
2. Insert 12.7 mm (1/2 inch) square extension bar into square hole
on filter body. Loosen it by approximately 4 turns.
3. 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.
4. Remove the filter body, then remove the oil filter element.
5. Remove the O-ring from the filter body.
G Push the O-ring in one direction, lift the slack part using fin-
gers, 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.
KBIA0834E
KBIA0836E
KBIA0837E
KBIA0838E
JLC292B
MA-32
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.
G 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.
6. After warming up the engine, check for engine oil leakage.
7. Check oil level and add engine oil. Refer to LU-16, "ENGINE OIL" .
Draining Water ELS0008S
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 bot-
tom 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.
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 ELS0008V
G Remove and install injection nozzle. Refer to EM-125, "INJECTION TUBE AND INJECTION NOZZLE" .
G Connect a nozzle tester to high-pressure injection nozzle
assembly.
G 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.
: 20 - 24 Nm (2.0 - 2.5 kg-m, 15 - 18 ft-lb)
KBIA0889E
Standard : 20,399 to 22,458 kPa (204 to 225 bar,208 to
229 kg/cm
2
, 2,958 to 3,256 psi)
Limit
: 17,751 kPa (178 bar,181 kg/cm
2
, 2,574 psi)
EMR0055D
ENGINE MAINTENANCE (ZD30DD)
MA-33
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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.
G If valve opening pressure exceeds limit value, or injection perfor-
mance is NG, replace high-pressure injection nozzle assembly.
CAUTION:
Do not disassemble high-pressure injection nozzle assembly.
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).
JEF349Y
MA-34
CHASSIS AND BODY MAINTENANCE
CHASSIS AND BODY MAINTENANCE PFP:00100
Checking Exhaust System ELS0009Y
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage, chafing or deterioration.
Checking Clutch Fluid Level and Leaks ELS000AF
If fluid level is extremely low, check clutch system for leaks.
Checking Clutch System ELS000AG
Check fluid lines and operating cylinder for improper attachment,
cracks, damage, loose connections, chafing and deterioration.
Checking M/T Oil ELS0009Z
Check for oil leakage and oil level.
CAUTION:
Never start engine while checking oil level.
Changing M/T Oil ELS000A0
1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
SMA211A
SMA642C
SMA859
Filler plug:
: 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
SMA103
CHASSIS AND BODY MAINTENANCE
MA-35
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Checking Propeller Shaft ELS000AH
Check propeller shaft for damage, looseness or grease leakage.
Checking Differential Gear Oil ELS000A1
1. Check for oil leakage and oil level.
Changing Differential Gear Oil ELS000A2
1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS"
Oil capacity:
RS5W71C Approx. 2.0 (3-1/2 lmp pt)
Drain plug:
: 25 - 34 Nm (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
Tightening torque:
Refer toPR-3, "REAR PROPELLER SHAFT"
SMA118A
Filler plug:
: 59 - 98 Nm (6 - 10 kg-m, 43 - 72 ft-lb)
Oil grad and
Viscosity
Refer toMA-11, "Fluids and Lubricants"
Capacity : C200
1.3 (2-1/4 lmp pt)
H233B
2.8 (4-7/8 lmp pt)
Drain plug
:59 98 Nm (6 10 kg-m),43 72 ft-lb)
SMA440B
SMA257A
MA-36
CHASSIS AND BODY MAINTENANCE
Balancing Wheels ELS000A3
Adjust wheel balance using the road wheel center.
Rotation ELS000AI
G After rotating the tires, adjust the tire pressure.
G 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.
Checking Brake Fluid Level and Leaks ELS000A5
G If fluid level is extremely low, check brake system for leaks.
Checking Brake Lines and Cables ELS000A6
G Check brake fluid lines and parking brake cables for improper
attachment, leaks, chafing, abrasions, deterioration, etc.
Wheel balance (Maximum allowable unbalance) :Refer to MA-41, "WHEEL BALANCE"
.
Tightening torque of wheel nut:
98 - 118Nm (10 - 12 kg-m, 72 - 87 ft-lb)
SEIA0107E
SFIA0178J
SBR389C
CHASSIS AND BODY MAINTENANCE
MA-37
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Changing Brake Fluid ELS000A7
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
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 LUBRI-
CANTS" .
G Never reuse drained brake fluid.
G Be careful not to splash brake fluid on painted areas.
Checking Disc Brake ELS000A8
ROTOR
Check condition, wear, and damage.
CALIPER
G Check for leakage.
PAD
G Check for wear or damage.
Checking Drum Brake ELS000AJ
WHEEL CYLINDER
Check for leakage.
SBR419C
Front
Brake model AD35VA
Standard thickness 30.0 mm (1.181 in)
Maximum runout 0.1 mm (0.004 in)
Minimum thickness (Wear limit) 28.0 mm (1.102 in)
SMA922A
Brake model AD35VA
Standard thickness 11.0 mm (0.433 in)
Minimum thickness (Wear Limit) 2.0 mm (0.079 in)
BRA0010D
MA-38
CHASSIS AND BODY MAINTENANCE
DRUM
Check condition and inner surface.
LINING
Check wear or damage.
Checking Steering Gear and Linkage ELS000A9
STEERING GEAR
G Check gear housing and boots for looseness, damage and
grease leakage.
G Check connection with steering column for looseness.
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
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 Recommended fluid is DEXRON
TM
III or equivalent.
Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
CANTS"
Standard inner diameter 260.0 mm (10.24 in)
Drum repair limit (Inner diameter) 261.5 mm (10.30 in)
SMA848B
Standard thickness 5.5 mm (0.217 in)
Lining Wear Limit (Minimum thickness) 1.5 mm (0.059 in)
SMA849B
SLIA0014E
SST850C
CHASSIS AND BODY MAINTENANCE
MA-39
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G Check lines for improper attachment, leaks, cracks, dam-
age, loose connections, chafing and deterioration.
G Check rack boots for accumulation of power steering fluid.
Axle and Suspension Parts ELS000AB
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.
Lubricating Locks, Hinges and Hood Latches ELS000AD
SST851C
SMA525A
SFA392B
Front door Refer to BL-17, "Fitting Adjustment for Front Door" .
Slide door Refer to BL-22, "Fitting Adjustment for Sliding Door" .
Back door Refer to BL-28, "Fitting Adjustment for Back Door" .
MA-40
CHASSIS AND BODY MAINTENANCE
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters ELS000AE
SHIA0246E
SERVICE DATA AND SPECIFICATIONS (SDS)
MA-41
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SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
Standard and Limit ELS0007M
BELT DEFLECTION AND TENSION (KA24DE)
BELT DEFLECTION AND TENSION (ZD30DD)
SPARK PLUG
IGNITION WIRE
WHEEL BALANCE
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 15 (0.59) 10 - 12 (0.39 - 0.47) 8 - 10 (0.31 - 0.39)
Power steering oil pump 16 (0.63) 11 - 13 (0.43 - 0.51) 9 - 10 (0.35 - 0.39)
Applied pushing force 98N (10kg, 22lb)
Tensions of drive belts Auto-adjustment by auto tensioner
Make NGK
Type
Standard BKR5E-11
Cold BKR6E-11, BKR7E-11
Plug gap mm (in) 1.0 - 1.1 (0.039 - 0.043)
Cylinder No. Resistance k [at 25C (77F)]
1 Approximately 5.7
2 Approximately 7.5
3 Approximately 9.7
4 Approximately 11.5
Maximum allowable unbalance
Dynamic (At rim flange) 10 g (0.35 oz) (one side)
Static 20 g (0.71 oz)
MA-42
SERVICE DATA AND SPECIFICATIONS (SDS)