CONTENTS PREPARATION PRE-DELIVERY INSPECTION ITEMS PERIODIC MAINTENANCE GENERAL MAINTENANCE RECOMMENDED FLUIDS AND LUBRICANTS ENGINE MAINTENANCE CHASSIS AND BODY MAINTENANCE SERVICE DATA AND SPECIFICATIONS (8.0.8) __ MAINTENANCE SECTION M A | MA- 2 MA 3 MA. 4 MA- 9 MAM MA-24 MA-34PREPARATION SPECIAL SERVICE TOOLS ‘Too! number Toot name Description 617650301 Radiator cap tester adapter kv11100300 Nozzle holder socket MA-2_—_— — — — — —— PRE-DELIVERY INSPECTION ITEMS ‘Shown below are Pre-delivery Inspection Items required for the new vehicl necessary items other than those listed here be added, paying due regard to the conditions in country. It Is recommended that ch Pertorm applicable items on each model. Consuit text of this section for specifications. UNDER HOOD — engine off [TRasiator coolant level and coolant hose connec- tions for leaks (Battery fluid level, specitic gravity and conditions of battery terminals (drive belts tension (Feel titer tor water or dusts, and fuel lines and connections for leaks [Engine oil level and cil leaks [ cuten and brake reservoir fluid level and fluid lines for leaks [J windshield and rear window washer and headlamp cleaner reservoir fiuid level [J Power steering reservoir fluid level and hose con- nections for leaks ON INSIDE AND OUTSIDE [J Remove tront spring/strut spacer (I applicable) [I Operation of ail instruments, gauges, ights and accessories [operation of horns), wiper and washer Steering lock tor operation TS check air consitioner tor gas leaks Front and rear seats, and seat belts for operation At moicings, trims and fittings for ft and align- ment At windows tor operation and alignment Hood, trunk lid, door panels for fit and alignment TH tutehes, keys and locks for operation TS Weatherstrips for adhesion and fit Headlamp aiming Tighten wheel nuts (Inc. inner nuts if applicable) Tice pressure tine. spare tire) TS Check tront wheels for toe-in instal clock/voltmeter/toom lamp fuse (If applica bie) 5 Instat! deodorizing fiter to air purer (if applicable) Remove wiper blade protectors (i applicable) UNDER BODY [Manual transmission/transaxle, transfer and ditter- ential gear oil level [OoBrake and fuel lines and oilfluid reservoirs tor 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 (J oiuten operation Parking brake operation isemice brake operation [automatic transmission/transaxte shift timing and kiokdown [Olsteering contro! and retunabiity [Engine pertormance squeaks and rates ENGINE OPERATING AND HOT [CJAdjust idle mixture and speed (and ignition timing"1) (Automatic transmission/transaxle tluid level Jengine idling and stop knob operation (Diesel only) FINAL INSPECTION [CJ install necessary parts (outside mirror, wheel cov- ‘ers, seat belts, mat, carpet or mud flaps) [Cinspect for interior and exterior metal and paint damage (check for spare tire, jack, tools (wheel chock), and iterature (wash, clean interior and exterior “1: Not required on models with a direct ignition sys~ tem MA-3PERIODIC MAINTENANCE, The following tables show the normal maintenance schedule, Depending upon weather and atmospheric conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent maintenance will be required. Periodic maintenance beyond the last period shown on the tables requires similar maintenance. STANDARD & THE FIRST FREE SERVICES TAINTENANGE OPERATION WAINTENANGE INTERVAL efor the standard sevice on aveary Months ee ce bans but on amieage bare hen ving km 1000 aS oe mote then 20,000 4m 112.00 miles ® YEO ages x 1,000) (os 82) 20 136) (ENGINE) Underhood and under vehicle ‘Check ove be Tor eke, raving, wear & enon eer aaT x x man ax x MAN (Shack eines x x wat Replace air cleaer fier (Vout x x MAIS Feploce fue fiers x MAI (heck nese, SenoTe nL Mats Cheek ina seed caeeeceaeeeMeeeK HA Replace timing bel Every 100/90 em 160,000 mie wan NOTE: (1) If engine power decreases, black exhaust smoke is emitted oF engine noise increases, check and, if necessary, adjust the fue injection nozzle’ starting pressure and the fuel spray pattern. (2) Maintenance items with “A” should be performed more frequently according to “Maintenance under severe Ariving conditions”. Check: Check. Correct or replace if necessary, MA-4—V———————— PERIODIC MAINTENANCE TWAINTENANGE OPERATION MAINTENANGE INTERVAL Perform th standardservice ona yearly Month ae tau but ona epe base when Gon kev 1 000 ee er ‘mer than 20000 km (12.00 mite 883". ites 1,000) (08) (12) (28) (9648) (CHASSIS AND BODY) Undertood ‘Check ake Bech, Tullow! 8 To Take re ee ‘hangers de x Se clea Check rake boorer a0 ROVE CORRECT B Gc wah x = Twa ‘Check ower wring Tul ine eae eee Under vehicle eal cain wraon’ aratitoionie aaa eee a MA24,28 Ganga ir ancl Wanerison, ander & Goa) = 1MA26, 25,26 Gress sain poof worng ikaw 8 ropa ah racer Aca Ei Cheat serng et Box Tnkage ere B sutpentn pre ler sat exhort sytem fr duraped, loos x x MA24, 25,31, taningberaruorentan ease x Fae. Check swing aver Ga es Fetigten body mount acces Mica ac a apa Outside and inside Check whe alent rwceary, rise & balone ahenls a anna ‘eck brake pas, dit other brake components or wea, ee seterioration& leak ‘Check front wheel bearing area & fee running hub greeie® x x MAR Fepark (vont wheel bearing & font exe int grease, & | ee trae-unning hut grease _ = - eae (Check seatbelts, buckles, retractors, onchors & acjurer x x MAS? ‘Cheek fot brake, parking brake & elvth fr free pa - stroke & operation felicia Cus, BRT Check body cvroson “Annually MASS ENGINE OIL SERVICE WAINTENANCE OPERATION WAINTENANGE INTERVAL Performat the sified time Months - 8 2 wm m0 we a oF mies whenever comes km 3,000 1 10 20 20 40 50 60 70 ao ‘"wlerenee pase bee (Wiles x1,000) 10.8) (6) (12) (18) (24)_(3O)_ (36) _142)_(40 : Underhood ‘Change engine of (Use recommended ole Every 6 months or 6000 kim (3,000 miles). MATS {Change engine ol iter® Siete eS SEE MEEERSE eAC NOTE: (1) Maintenance items with ” should be performed more frequently according to “Maintenance under severe Chect Check. Correct or replace if necessary. MA-5PERIODIC MAINTENANCE MAINTENANCE UNDER SEVERE DRIVING CONDITIONS The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table. Severe driving conditions ‘A. — Driving under dusty conditions B — Driving repeatedly short distances © — Towing a trailer 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 areas or in mountainous areas, @ — Driving in areas using salt or other corrosive materials HH — Driving on rough and/or muddy roads or in the desert 1 — Driving with frequent use of braking or in mountainous areas J — Frequent driving in water Driving condition wainares Mania Meineanes Reference pose Standard service x Tireleaner fiker Raplece Every 12monthe or MATS Fe td ace «29,000 kes (12,000 tes) ane x = Fuel fier Riplece Every 18 months or 0,000 km (18,000 mitee)__MA%9 © 4 Lited sip differential Replace aa (5.0. ero 28 on ‘Steering gear & linkage ‘Cheek Every 12 months or faxle& suspension parts, 20,000 ke (12,000 mies) MA24,26, 31, Propeller shat a FAS, RAG exaust system aoe GH 1. Brokepads,dise & other Check ee brake components Every 6 months or GH 1 J Greasing points of neering Lubricate 10,000 kr (6,000 mies} linkage & propeller shafts MA26,31 Front wheel besrng grease Check Every 3 months or fresunning hb grease 5.000 km (3,000 mies) anu Engine oll service zeco apie of Replace Mare frequentiy MATa ABCD Engine oi iter place Every Smohths or ae 5,000 km (3,000 rales) TMaintenanse operations Check = Ghack, Correct or replace W necorany, MA-6PERIODIC MAINTENANCE. Maintenance for off-road driving Whenever you drive off-road through sand, mud or water as deep as the wheel hub, more frequent maintenance will be required of the following items: Brake pads and discs Brake lines and hoses Wheel bearing grease and free-running hub grease Differential, transmission and transfer oil Steering linkage Propeller shafts Air cleaner filter Clutch housing and knuckle flange (Check water entry. Refer to MA-25 & 27.) > rrr rrr MA-7——————— 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. hem Reference pages OUTSIDE THE VEHICLE “The maintenance items listed here should be performed from time to time, unless otherwise speciied Tires Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or - Windshield wiper blades Check for eracks or wear if they do not wipe properly. = Doors and engine hood Check that all doors, the engine hood, the trunk lid and back door ‘operate properly. Also ensure that all latches lock securely. Lubricate if ncessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is released Mase When driving in areas using road salt or other corrosive materials, check for lubricstion frequently Tite rotation Tires should be rotated every 10,000 km (6,000 miles). Maso INSIDE THE VEHICLE ‘The maintenance items listed here should be checked on 2 regular basis, such as when per forming periodie msintenance, cleaning the vehicle ete. Lights Make sure that the headlights, stop lights til ights, turn signal lights, and other lights ae all opersting properly and installed securely. Also check headlight aim. ‘Warning lights and chimes Make sure that all warning lights and chimes are operating properly. - ‘Steering wheel Check for change in the steering conditions, such as excessive free play, hard steering or strange noises. - Free play: Less than 35 mm (1.38 in) 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 Windshield washer fluid Check that there is adequate fluid in the tank. 5 Engine coolant level Check the coolant level when the engine is col. MA12 Engine il level Check the level after parking the vehicle on level spot and turning off the gine cil level Check the level after parking the vehicle on @ level spot and turning maa engine. Brake and clutch flu Make sure that the brake and cluteh fluid level is between the 1 clutch fluid level tthe brake and clutch fluid level is between the 8 "MAX" and MIN" Tines on the reservoir, Battery Check the fluid level in each cell It should be between the "MAX" and “MIN” lines = MA-8SNe RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants Capacity (Approximate) Recommended lubricants Lite Imp measure Engine oil (Refil) With oil fier 64 55/8qt APLC"? Without ol iter 87 Sat Cooling systern (With reservoir tank) With rear heater 136 rat ‘Antifreeze coolant (Ethylene glycol bese) Without rear heater 124 107/8 at ‘Manual transmission gear oll ED 67/8 pt 7 APIGL.A"1 Transfer 19 1-5/8 at Differential car Front Standard differential: APIGL5*1 54 43/4qt __Limited-slip differentia: ———— Only L.S.D. gear oil: API GL-5 and SAE Rear BOW-90"2. Contact a Nissan dealer for 2338 et 17/eat, suitable oils. 30's 25/8 at"3 Power steering fluid 09-10 _9/4-7/8qt__Type DEXRON™ Brake and clutch fluid - S DOTS (US FMVSS No, 116) Multi-purpose grease - = NLGI No. 2 (Lithium soap base) 7 NLGI No. 2 (Molybdenum disulphide Front axle joint grease ian oan 2way lock free-running hub grease - = a eee (Part No.: KRC19.00025) or equivalent “it For further details, se “SAE Viscosity Number" 12: SAE 90 is acceptable for ambient temperatures above ~18°C (0°F). "3: With differential lock MA-9RECOMMENDED FLUIDS AND LUBRICANTS SAE Vis iscosity Number ide Temperature Range Before Next Oil Change DIESEL ENGINE OIL * Not recommended | for sustained high speed driving Outside Temperature Range Anticipated Before Next Oil Chany GEAR OIL, Bw abw 70-20 20". 90 For cold areas: 10W-30 is preferable. On turbo models, SW-20 is not recommended, and SW-30 should be used only below 0°C (32°F). For hot and warm areas: 20W-40 and 20W-50 are suitable. MA-1 For cold areas: 75W-90 for transmission of gasoline engine model and transfer, 80W-90 for differential carrier and for transmission of diesel engine model are preferable. For warm and hot areas: 90 is suitable for ambient temperatures below 40°C (104°F). oOENGINE MAINTENANCE lst putey Worer pump 7 Alternator l Checking Drive Belts 1. Inspect for cracks, fraying, wear or oil adhesion. Replace if necessary, The belts should not touch the bottom of the pulley groove. Cooling fan is driven by two belts. When replacement is needed, always replace both fan belts. 2. Check drive belt deflections by pushing midway between pulleys. Adjust if belt deflections exceed the limit. nits tnd Used belt deflection ‘Set cetlecton of Tin [Adjusted detection) new belt 12-14 on ‘Alternator Atcha (047-058) | 1038-049) ‘ir conditonge 79 6 compressor Ata (oz8-038) | (024-0311 Power steering i: 10-12 on ol pump nee! (039-047) | 1035-049) ‘Apalieg pushing for 96/0 (10 ka, 2218) Inspect drive belt deflections when engine is cold. it engine is hot, check deflections in 30 minutes or more. Changing Engine Coolant WARNING: To avoid the danger of being scalded, never attempt to change the coolant when the engine is hot. When changing engine coolant, set heater “TEMP” control lever at fully “HOT” position. 1. Drain coolant. (1) Open drain cock at the bottom of radiator, and remove radiator cap. (2) Remove cylinder block drain cock and drain water com- pletely. : 2. Refill radiator and engine with new coolant. (1) Install radiator drain cock and cylinder block drain cock securely. Cylinder block drain cock (Use proper liquid seal- ant] "6: 20-29 Nem 20-30 kgm, 14-22 Rb) MA-11ENGINE MAINTENANCE Changing Engine Coolant (Cont'd) (2) Open air relief plug. (3) Fill radiator and engine with new coolant up to filler opening. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity (With reservoir tank) (Approximate): With rear heater 1366 liters (12 Imp qt) Without rear heater 124 liters (10-7/8 Imp qt) Slowly pour coolant through coolant filler neck to allow air in system to escape. (4) Tighten air relief plug. (5) Fill reservoir tank up to “MAX” level. Then close radiator cap. (6) Warm up the engine sufficiently until thermostat opens (about 10 minutes). Keep a close watch on movement of water temperature gauge needle. (7) Stop the engine and after it cools down, refill the radiator and engine with coolant up to the filer opening. Fill the reservoir tank with coolant up to MAX" level. (8) Repeat steps (6) and (7) until coolant level does not go lower after running the engine. Checking Cooling System CHECKING HOSES Check hoses for proper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. CHECKING COOLING SYSTEM FOR LEAKS Apply pressure to the cooling system by means of a tester to check for leakage. Testing pressure: 98 kPa (0.98 bar, 1.0 kg/cm’, 14 psi) ‘CAUTION: Higher than the specified pressure may cause radiator dam- age. MA-12ENGINE MAINTENANCE Checking Cooling System (Cont'd) CHECKING RADIATOR CAP Apply pressure to radiator cap by means of a cap tester to see it it is satisfactory. Radiator cap relief pressure: 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/em’, 11 - 14 psi) Checking Fuel Lines Check fuel lines and tank for proper attachment, leaks, cracks, damage, loose connections, chafing and deterioration, Replacing Air Cleaner Filter The viscous paper type air cleaner filter does not require any cleaning operation between renewal. \ rain cock Checking Fuel Filter and Replacing Filter This filter includes priming pump and fuel filter sensor. Reuse the fuel filter sensor. REPLACING FUEL FILTER 1. Remove fuel filter sensor and drain fuel 2. Remove fuel filter, using suitable tool. 3. Install fuel filter sensor to new fuel filter. 4. Install fuel filter to priming pump. 5. Bleed air Refer to section EF & EC for fuel system bleeding instruc- tions. Start engine and check for leaks. MA-13ENGINE MAINTENANCE Checking Fuel Filter and Replacing Filter ] (Cont'd) DRAIN WATER 4. Set a container under fue! filter. 2. Loosen drain cock and drain water. Loosening drain cock 4 to 5 turns causes water to start draining Do not remove drain cock by loosening it exces- sively. 3. Bleed air Refer to section EF & EC for fuel system bleeding instruc- tions. Changing Engine Oil WARNING: Be careful not to burn yourself, as the engine oll may be hot. 1. Warm up engine, and check for oil leakage from engine ‘components. 2. Stop the engine. 3. Remove oil filer cap and drain plug. 4. Drain oil and refill with new engine oil. ‘il capacity (Approxim: With olf filter change 6.4 liters (5-5/8 Imp qt) Without oll filter change 57 liters (5 Imp at) Sy): CAUTION: ‘© Be sure to clean drain plug and install with new washer. Drain plug: 7:29 - 39 Nem (@.0 - 4.0 kg-m, 22 - 29 ft-1b) © Use recommended engine oll. Refill oll to “H” level @ Do not overfill. 5. Check oil level 6. Start engine. Check area around drain plug and oil filter for any sign of oil leakage. 7. Run engine for a few minutes, then tur it off. After several minutes check oil level. Changing Engine Oil Filter 4. Remove oil fter WARNING: Be careful not to burn yourself, as engine and engine oll are hot. MA-14ENGINE MAINTENANCE 7 | 219 of turn __ip Asting shim Changing Engine Oil Filter (Cont'd) 2. Before installing new oil fiter, wipe clean oil filter mounting surface on cylinder block, and smear a little engine oll on rubber seal of oil fiter. 3. Screw oil filter on until a slight resistance is felt, then tighten by at least an additional 2/3 turn further. 4. Add engine oi Refer to Changing Engine Oil. Checking Injection Nozzle WARNING: When using nozzle tester, be careful not to allow diesel fuel sprayed from nozzle to come into contact with your hand or body, and make sure that your eyes are properly protected, 4. Clean and check nozzles. 2. Install nozzle to injection nozzle tester and bleed air trom flare nut. 3. Check initial injection pressure by pumping tester handle one time per second, Initial injection pressure: 12,259 - 13,239 kPa (122.6 - 132.4 bar, 125 - 135 kg/cm’, 1,778 - 1,920 psi) New nozzle initial injection pressure: 13,239 - 14,024 kPa (132.4 - 140.2 bar, 135 - 143 kg/cm’, 41,920 - 2,033 psi) Initial injection pressure must always be checked when installing a new nozzl 4, To adjust injection pressure, change adjusting shims. a. Increasing the thickness of adjusting shims increases Initial injection pressure. Decreasing shim thickness re- duces initial injection pressure. b. A shim thickness of 0.04 mm (0.0016 in) corresponds approximately to a difference of 471 kPa (4.71 bar, 4.8 kg/cm’, 68 psi) in initial injection pressure. MA-15ENGINE MAINTENANCE Aceaaraor contrat iver {G3 sMarra8 Checking Injection Nozzle (Cont'd) 5. Check spray pattern by pumping tester handle one time per second 6. Inadequate fuel spray pattern or drips from nozzle are often due to improper contact of needle with seat, If such a failure is experienced, service injection nozzle When servicing nozzle, refer to Injection Nozzle Assembly in section EF & EC. Checking Idle Speed PREPARATION Make sure that injection timing is correct. Make sure that injection nozzles are in good condition. Make sure that the following parts are in good condition Air cleaner clogging Glow system Engine oil and coolant levels Air intake system (Oil filer cap, oll level gauge, etc.) Set shift lever in "Neutral" position. Engage parking brake and lock both front and rear wheels with wheel chacks Turn off air conditioner, lights and accessories. Peeeeene 6. Make sure that idle control knob is turned fully counter- clockwise and idle control lever adjusting screw does not contact with accelerator control lever. IDLE ADJUSTMENT 1. Tum idle contro! knob fully counterclockwise. 2, Start engine and warm it up until coolant temperature Indicator points to middle of gauge. 3. Attach tachometer’s pick-up to No. 1 fuel injection tube. In order to take accurate reading of engine rpm, remove clamps that secures No. 1 fuel injecti MA-16ENGINE MAINTENANCE Checking Idle Speed (Cont'd) 4, Adjust engine to specified idle speed with idle speed adjusting screw. Idle speed: 650 +60 rpm 5. After adjusting idle speed properly, tighten lock nut. CAUTION: a. Do not remove sealing caps unless absolutely necessary. b. Disturbing full-load adjusting screw adjustment will change fuel flow characteristics, resulting in an improperly ad- justed engine. Readjustment of fuel injection pump should be done using a pump tester. ©. If maximum speed adjusting screw Is turned in direction soe that increases control lever angle, engine damage may lust pala result. adjusting serow AIR CONDITIONER EQUIPPED MODEL 4, Turn idle control knob fully counterclockwise. 2, Make certain that the clearance between the idle control lever pin and the injection pump control lever is within the specttied limits Clearance: 1 mm (0.04 in) 3. Adjust idle speed to specified rpm without the air condi- tioner operating, 4. Then check the idle speed when the air conditioner is operating and make sure it is correct, Idle speed (Air conditioner 800 +50 rpm lf not, adjust it by turning F..C.D. actuator stroke adjusting screw. IN"): DASH POT ADJUSTMENT Adjust dash pot: 41,300 = 200 rpm MA-17ENGINE MAINTENANCE Replacing Timing Belt CAUTION: 2. Do not bend or twist timing belt too much. b. After removing timing belt, do not rotate crankshaft and camshaft separately because valves will hit piston head. ¢. Ensure timing belt, camshaft sprocket, crankshaft sprocket, idler pulley, injec pump pulley and belt tensioner are clean and free from oll or water. 4. Before installing timing belt, confirm that No. 1 cylinder is set at B.D.C. on expansion stroke. fe. Align arrow on timing belt forward. {. Align white lines on timing belt with punch mark on camshatt sprocket, crankshaft sprocket and injection pump pulley. {22-40 193-41,24-30) Wisner Fl r0-12100-12,7-9) as a (03 -05,22-3.6). (WE Q- cenit st § tat ett ae Crankshaft sprocket coke — 12) 142-152 (145-1535, 108-112), Ss We thom, MA-18ENGINE MAINTENANCE Replacing Timing Belt (Cont'd) 4. Remove radiator shroud, 2. Remove the following belts. Power steering drive belt AIC compressor drive belt © Alternator drive belt 3. Remove cooling fan coupling 4. Remove under cover. 5. Set No. 1 cylinder at bottom dead center (B.0.C.) on its| is shown, 6 Remove crankshaft pulley and water pump pulley. 7. Remove front cover. 8. Remove tensioner spring and loosen belt tensioner lock nut. 9. Remove timing belt. After removing timing do not rotate crankshaft and camshaft separately, because valves will hit piston heads. MA-19ENGINE MAINTENANCE Replacing Timing Belt (Cont'd) 10. Visually check the condition of the timing belt. Item to check Problem cause Belt is broken. Se © Improper handling # Poor belt cover sealing © Coolant leakage at water pump Tooth is broken! © Camshaft jamming trot rot © Distributor jamming oa © il leakage at camshatt/erankshatt oil seal | | Back surface is | © Tensioner jamming cracked/worn. © Overheated engine ‘© Interference with belt cover MA-20ENGINE MAINTENANCE Replacing Timing Belt (Cont'd) Item to check Problem Cause Side surface is worn, © Side surface of belt is worn to such an extent 98 original teace of its cut is un: clear © Belt corners are worn and round, © Wicks are frayed and coming Out. sog ‘© Improper installation of belt ‘© Malfunctioning crank pulley plate/timing belt plate Teeth are worn, © Canvas on tooth face is worn down, © Canvas on tooth is fluffy, rubber layer is worn down and faded white, or canvas texture is unclear © Poor belt cover sealing © Coolant leakage at water pump © Camshaft not functioning properly ‘© Distributor not functioning properly © Excessive belt tension seMa97 Oil/Cootant oF water is © Poor oil sealing of each oil seal suck tobe . © Coolant leakage at water pump '© Poor belt cover sealing MA-21ENGINE MAINTENANCE Replacing Timing Belt (Cont'd) ee ______ 11. Confirm that No. 1 cylinder is set at B.0.C. on its expansion stroke as follows: Confirm that crankshaft key is at the bottom. 12, Set timing belt. a. Ensure timing belt, sprockets and pulleys are clean and {ree from oll or water. Do not bend or twist timing belt too much. b. Align white lines on timing belt with matching mark on ‘camshaft sprocket, crankshaft sprocket and injection pump pulley. ¢. Point arrow on timing belt toward front. oo Camshaft sprocket TY Aligning markENGINE MAINTENANCE Replacing Timing Belt (Cont'd) 13, Install tensioner spring and tighten belt tensioner lock nut. ©: 32-40 Nem (8.3 - 4.1 kg-m, 24 - 30 ft-b) 14. Install front cover. 16. Install crankshaft pulley. 16. Install water pump pulley and cooling fan coupling, [ep atterator | Arceampreasee “crank pulley 17. Install drive belts and check drive belt deflections by pushing midway between pulleys. Units mm find LZ / Power seeing | { [i bt artecton Seana Limit [Adjusted detiection new belt Alternator 17(0.67) [2-14 dg aoe (047-055) | 10.35-0.43) Ai condone ae Te ee ‘compressor — (0.28 -0.35) (024-031) over wing s 10-18 ott it pump: — {0.39 0,47) (0.38 -0.43) Zope pio oc Sen 010,221) Inspect drive belt deflections when engine is cold. If engine is hot, check deflections in 30 minutes or more.CHASSIS AND BODY MAINTENANCE ————__ Checking Exhaust System Check exhaust pipes, muffler and mounting for improper at- tachment, leaks, cracks, damage, loose connections, chafing and deterioration. Checking Clutch Fluid Level and Leaks If fluid level is extremely low, check clutch system for leaks. = Checking Clutch System aN . Check fluid lines and operating cylinder for improper attachment, \\ = cracks, damage, loose connection, chafing ana deterioration mn) | ¢ fe 0 Checking M/T Oil Level Never start engine while checking oil level. 1. Check manual transmission for cll leakage. 2 Check cil level Filler plug: 1:25 - 34 Nem (2.5 - 3.5 kg-m, 18 - 25 ft-lb) Ae / sMa103_ } Changing M/T Oil Oil capacity: ~~ J }.9 liters (6-7/8 Imp pt) plug: @) 1:25 - 34 Nem (2.5 - 3.5 kg-m, 18 - 25 ft-lb) MA-24CHASSIS AND BODY MAINTENANCE eansrsion Checking Water Entry Check water entry in the clutch housing by removing the sealing grommet, whenever driving in deep water or mud. Checking Transfer Oil Level Never start engine while checking oil level. 1. Check transfer for oil leakage. 2. Check cil level Filler plug: 1:25 - 94 Nem (2.5 - 3.5 kg-m, 18 - 25 ft-1b) Changing Transfer Oil Oll capacity: 1.9 liters (1-5/8 Imp qt) Drain plug: 1:25 - 34 Nem (2.5 - 3.5 kg-m, 18 - 25 ft-lb) Checking Propeller Shaft Check propeller shaft for damage, looseness or grease leakage, Tightening torque: Refer to section PD. MA-25CHASSIS AND BODY MAINTENANCE Greasing Nipples of Propeller Shafts Apply multi-purpose grease to nipples of propeller shafts, Front suaceae Rear /— Grease nipples Checking Differential Gear Oil 1, Check differential carrier for oil leakage. 2. Check oil level, Filler plug: (91:59 - 98 Nem (6 - 10 kg-m, 43 - 72 ft-lb) Changing Differential Gear Oil Oil capacity: Front 5.4 liters (4-3/4 Imp qt) Rear 2.1 liters (1-7/8 Imp qt) Rear with differential lock 3.0 liters (2-5/8 Imp qt) Drain plug: (7): 59 - 98 Nem (6 - 10 kg-m, 43 - 72 ft-lb) Limited-slip differential gear © Use only approved or recommended limited-slip differential gear oil, © Limited-slip differential identification. (1) Lift both rear wheels off the ground. (2) Turn one rear wheel by hand, (3) If both rear wheels turn in the same direction simultaneously, vehicle is equipped with limited-slip differential. MA-26CHASSIS AND BODY MAINTENANCE BB: Munipurpoe | ene wen Season Bott (eine ? Checking Front Wheel Bearing Grease © Check that wheel bearings operate smoothly. © Check front wheel bearings for grease leakage and water or dust entry. © Replace front wheel bearings or front wheel bearing grease if wheel bearings do not turn smoothly. Repacking Front Wheel Bearing and Axle Joint Grease FRONT WHEEL BEARING GREASE Apply multi-purpose grease sparingly to the following parts: © Threaded portion of spindle © Contact surface between wheel bearing washer and outer wheel bearing © Grease seal lip © Wheel hub (as shown at the left) AXLE JOINT GREASE © Drain approximately 2 liters (1-3/4 Imp qt) of differential oil, @ Remove knuckle spindle © Slightly pull out axle and repack axle joint with recom- mended grease. Refer to FA section. Checking Free-running Hub Grease Check free-running hub grease for leakage and water or dust entry. Checking Water Entry in Knuckle Flange ‘© Check for water entry in knuckle flange by removing one bolt of lower knuckle flange bearing cap and probing with a suitable thin ber. © Alter checking, be sure to reinstall the bolt to a tightening torque of 30 to 40 N-m (3.1 to 4.1 kg-m, 22 to 30 ft-lb). MA-27CHASSIS AND BODY MAINTENANCE Checking Brake Fluid Level and Leaks If fluid level is extremely low, check brake system for leaks. Checking Brake System Check brake fluid lines and parking brake cables for improper attachment, leaks, chafing, abrasion, deterioration, etc. 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 section BR. © Refill with recommended brake fluid “DOT 3”. © Never reuse drained brake fluid. © Be careful not to splash brake fl on painted area: Checking Brake Booster Vacuum Hoses, Connections and Check Valve Check vacuum lines, connections and check valve for improper attachment, air tightness, chafing and deterioration Checking Disc Brake Check condition of disc brake components, ROTOR Check condition and thickness. Standard thickness: CL3BVA 20.0 mm (0.787 in) ‘AD20VC 18,0 mm (0.709 in) um thicknes: CL36VA 18.0 mm (0.709 in) AD20VC 16.0 mm (0.630 in) MA-28 MiCHASSIS AND BODY MAINTENANCE Checking Disc Brake (Cont'd) CALIPER Check operation and leakage. PAD Check wear or damage. Standard thickness: 1.0 mm (0.433 in) Minimum thickness: 2.0 mm (0.079 in) MA-29———_—_—_—_—_—_—_———————— CHASSIS AND BODY MAINTENANCE Let font coc Lett rear Balancing Wheels Adjust wheel balance using the road wheel center. Maximum allowable unbalance at rim flange: 10 g (0.35 oz) Tire balancing weight: 5 - 60 g (0.18 - 2.12 oz) Spacing 5 g (0.18 oz) Tire Rotation Wheel nuts: 118 = 147 Nem (12 - 15 kg-m, 87 - 108 ft-lb) Checking Power Steering System Fluid and Lines © Check fluid level, when the fluid is cold © Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. Checking Steering Damper Check steering damper for damage and oil leakage MA-30CHASSIS AND BODY MAINTENANCE Checking Steering Gear Box and Linkage STEERING GEAR © Check gear housing and boots for looseness, damage or grease leakage. © Check connection with steering column for looseness. STEERING LINKAGE © Check ball joint, dust cover and other component parts for looseness, wear, damage or grease leakage. Greasing Steering Linkage Apply multi-purpose grease to greasing points using suitable grease nipples. MA-31CHASSIS AND BODY MAINTENANCE Lubricating Hood Latches, Locks and Hinges Checking Seat Belts, Buckles, Retractors, Anchors and Adjuster (heck belts for demoye ———> ‘check anchors for tose mountingCHASSIS AND BODY MAINTENANCE Checking Body Corrosion Visually check the body sheet metal panel for corrosion, paint damage (scratches, chipping, rubbing, etc.) or damage to the anti-corrosion materials. In particular, check the following locations. Hemmed portion Hood front end, door lower end, trunk lid rear end, etc. Panel joint Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut tower in engine ‘compartment, ete. Panel edge Trunk {id opening, sun roof opening, fender wheel-arch flange, fuel filler lid flange, around holes in panel, etc. Parts contact Waist moulding, windshield moulding, bumper, etc. Protectors Damage or condition of mudguard, fender protector, chipping protector, etc. Anti-corrosion materials Damage or separation of anti-corrosion materials under the body. Drain holes. Condition of drain holes at door and side sil, When repairing corroded areas, refer to the Corrosion Repair Manual. MA-33ee SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Maintenance INSPECTION AND ADJUSTMENT Cooling system Drive belt deflection Fadlator cap rlietpresure Unit tn} Pa ar, kafem* sib. a, ied bet detiaction f (0.78-0.98,08-1.0,11-147 ee ‘Coating system leakage ee | ae tering pressure 98 (098, 1.0,14) tes Pe tbr, lem!) 12-4 on Aterntor 708m | i933 "hh5) | oss baa) Air conditioner , 70 6-8 compresor | 149) | (028-028) | 24-030 Power steering | 10-12 an citpme | OSS! | (029-047) | 1038-043) TIGHTENING TORQUE | ed push ni Nm fo ‘Asie puting 98.N (10 ko, 22 0) ea Sa ——_Avensiortobrciet—gg.77 a9 asa? Insect drive bel deco when engin oe Aternatortoasiustbor 168-21 18-21 12-15 Iengine shot check tlaeione in 30 minutes or more Powerstering gums 16-27 1.8-2.1 12-18 oi Air conatoner 43-58 4459 32.03 ec comoresior racket bolt ‘oa ction res Injsction pump fixing 16-21 4.6.21 42-15 ater tatem'soh | saan9. saa 1324-1402 rw 136. 143, 1.920. 2,039) Injection tube 22.25 22.28 16-18 ae 12.259. 13,299 (1228-1924, ae cee eee eee 125-195, 4.781.920) Injection nozse 89-69 60-70 43-51 it pn dain poe 79-39 30-49 22-20 | ' Tensioner pulley bolt 32-40 3-8.1 24.99 Injection timing and idle speed loupe oon oo (equivalent 19 8.7.0.6.) Front ever bolt 35 03-08 22-36 Injection ting (Purge tit 10882005 mm Crank pully bolt 142-152" 145-155 105-112 tt tat 50°50 ole sone tom ne Units @ timp at 6415570) ‘Without ob fiter change 576) Coolant capacity (With reservoir tank) Unit: € timp at) With rear heater 136 112) Without rear heater 12.4 10-78), MA-34——— SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance INSPECTION AND ADJUSTMENT Clutch Lnite_mm tind Pedal eight 202-212 (7988.35) Pedal fee pley 1.930 (0.029-0.198) Front axle and front suspension Whee! bearing preload ‘Wheel bee coe 0-008 10-0003 ‘Wheel bearing lock nuts Presghteningrorave Front wheel alignment (Unladen*1) Apolid model Herdtop Wapen Comber eeree or caster eeoree | 20-320 | r05'-3°05" ‘sence sesree cia ire 21001-0080 10R5LT 109N1 cee “IF 00 216/80816 1075 ‘Nem tkgm, feta) | 167° 198.07 20,129 145) Front whee! turning angle SS ear aed signing rau ter aia 30° <2" unvahten fo oe _f Nim thom tem) | 2°8108-05,22-36) Ousiae 2p 29 “Allowable whee! bearing prelond increment, meatures Nig.) | 0°18610-18,0-421 “1 Tanklul of fos, radiator evolant and engine ol fall Spare tre, jack, hand tools, mats in designed postion MA-35re mR SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance (Cont'd) Brake TIGHTENING TORQUE Unt mma) Un Nom cor euch sal Pedal stopper lock nut 16-22 16-22 12-16 a cueva | noes Meneroyinderpu 8-11 08-31 58-80 : 1004981 restock Wann euseva | 20 i007 Mert roainon ‘sek Soa] apo SO Drm ans terpage 25-24 25-35 18-25 Rotor —_ ~ Transfer | ranand herp 75-24 28-95 18.78 ‘Stenderd cLaBVA 20.0 (0.787) 2 e a | thickness To ee Cees | eer NS Tnane eras 59-98 6-30-72 nimi ———etaava | va 1a700) occ ‘Thickness “Rozove | 16.0 (0.630) suspension cee f wena rackeknit 78-98 80-100 88-72 Fess Tae 702 756-758) eons Feta ped eh 10167 ormere rsiecerwane 7-9 07-09 51-85 Faking wae Septenp mics 21812458 ‘Number of notches. ore Uepeting ees 95 ne Bake booverinpst 16-22 18-22 2-16 tangy sa roan ut ees nt a. 12.95 87-108 Wheel and tire (oxen atawae notre 1010381 Stemtnge ee Tire balancing weight — @ fozh Pe ae ‘Spacing 510.18) MA-36