QUICK REFERENCE INDEX ra emt womror————— ]o_| Le ee sunen |e | ceo aoe iam Se UTS AS or NISSAN 240SX Cl ol Sel Le ene sere [or] ee Lal CS eel Loe Le © 1990 NISSAN MOTOR CO.,LTD. Printed in Japan Not to be reproduced in whole or in part without the prior written permission of Nissan Motor Company Ltd., Toyo, Japan,FOREWORD This manual contains maintenance and repair procedures for the 1991 Nissan 240SX. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially impor- tant that the PRECAUTIONS in the GI section be completely under- stood before starting any repair task. All inform: this manual is based on the latest product inform: tion at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice. IMPORTANT SAFETY NOTICE ‘The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service proce- dures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the vehicle's safety will be jeopardized by the service method selected. c> NISSAN MOTOR CO, LTD. Overseas Service Department Tokyo, JapanGENERAL INFORMATION SECTION G l CONTENTS PRECAUTIONS . nnn . are HOW TO USE THIS MANUAL sennninnnnninnnnnn ones Gl S HOW TO READ WIRING DIAGRAMS Gh 7 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES alto IDENTIFICATION INFORMATION G13 LIFTING POINTS AND TOW TRUCK TOWING .w.csnmnnnnmnnnnnnnnnnnnnnnnnnnnne GAT TIGHTENING TORQUE OF STANDARD BOLTS... ses l-20PRECAUTIONS soa 01239 Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each indi- vidual section. 1. Do not operate the engine for an extended period of time without proper exhaust ventilation Keep the work area well ventilated and ‘tee of any inflam- mable materials. Special care should be taken when han- dling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properiy ventilzte the area before working with hazardous materials. Do not smoke while working on the vehicle. 2. Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving, After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. 4. Before starting repairs which do not require battery power, always tum off the ignition switch, then disconnect the ground cable from the battery to prevent accidental short circuit 5. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe and muffler. Do not remove the radiator cap when the engine is hot. GI-2PRECAUTIONS \ render cover soia3¢ 6. Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint. 7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set, 10. Arrange the disassembled parts in accordance with their assembled locations and sequence. 11. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. 42. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. 13. Use only the lubricants specified in MA section. 14. Use approved bonding agent, sealants or their equivalents when required. 18. Use tools and recommended special tools where specified for safe and efficient service repairs. 46.When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. 17. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. Precautions for E.F.I. or E.C.C.S. Engine 1. Before connecting or disconnecting E-F.|. or E.C.CS. har- ness connecter to or from any E.F.l. or E.C.CS. control unit, be sure to turn the ignition switch to the “OFF” position and disconnect the negative battery terminal. Otherwise, there may be damage to control unit. 2. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure to eliminate danger. 3. Be careful not to jar components such as control unit and air flow meter. GI-3Clean floor PRECAUTIONS Precautions for Catalyst a large amount of unburned fuel flows into the converter, the converter temperature will be excessively high. To prevent this, follow the procedure below: 1. Use unleaded gasoline only. Leaded gasoline will seriously damage the catalytic converter. 2, When checking for ignition spark or measuring engine ‘compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on inflammable material. Keep inflammable material off the exhaust pipe. Precautions for Fuel Use unleaded premium gasoline with an octane rating of at least 91 ‘AKI (Anti-Knock Index) number (research octane number 96). If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87 AKI (research octane ‘number $1) can be used, However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended. ‘CAUTION: Do not use leaded gasoline. Using | the catalytic converter. ded gasoline will damageHOW TO USE THIS MANUAL 1. A QUICK REFERENCE INDEX, a black tab (e.g) is provided on the first page. You can quickly find the first page of each section by mating it to the section’s black tab. THE CONTENTS are listed on the first page of each section. THE TITLE js indicated on the upper portion of each page and shows the part or system. ‘THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. “BR 5. THE LARGE ILLUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points and other information necessary to perform repairs. ‘The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. RON “Example” pyd casinos (Upper sided {0] 54.64 06.5 -6.5, 40-47) . Z 7 - 2 inpin tous PS EB Ws potion Torave. Fin boot ~ Copper 17-20 117-20,12-141 mers, “Se 4 Conard Brake hose 3 ‘ir bade 117-9 107-09,51-65) utr shim Pia bott 22.31 (22. Pas anseyeyli boy 172-98 (22-22, 18-29) eee ton sel CJ putea pee? BA: wo tig, fb) or SBRIGGA 6. THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, Knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. ‘Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle fr transmission, etc. are presented in a step-by-step format where necessary. 7. The following SYMBOLS AND ABBREVIATIONS are used: a Tightening torque wt Manual Transaxle/Transmission eB Should be lubricated with grease. A/T ‘Automatic Transaxle/Transmission Unless otherwise indicated, use Tool Special Service Tools recommended multi-purpose grease. LH.D. Left-Hand Drive no ‘Should be lubricated with oil RH. Right-Hand Drive a Sealing point ATF. Automatic Transmission Fluid a Checking point D, Drive range tst gear eo Always replace after every disas- D: Drive range 2nd gear sembly. Ds : Drive range Srd gear =e Apply petroleum jelly. Ds. : Drive range 4th gear aD Apply ATF. oo. Overdrive * Select with proper thickness. 2 2nd range 2nd gear * Adjustment is required. 2 2nd range ist gear SDS. Service Data and Specifications rn tet range 2nd gear LH. RH. : Left-Hand, Right-Hand 1 Ist range 1st gear" HOW TO USE THIS MANUAL The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. “Example” Tightening torque: 59 - 78 Nem (6.0 - 8.0 kg-m, 43 - 58 ft-lb) TROUBLE DIAGNOSES are included in sections dealing with complicated components, SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibilty of personal injury if instructions are not followed, CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.HOW TO READ WIRING DIAGRAMS WIRING DIAGRAM ‘Symbols used in WIRING DIAGRAM are shown below: Example ‘BRANCH MIT model @ + MIT mode! ®; Arr mode! + ABBREVIATIONS POVIER SUPPLY (This shows the iani- tien switch position Inwhich the system CONNECTOR ‘This shows tha these connectors are white 6 terminal cannector, an be operated Ses POWER SUPPLY ROUTING in EL Section forthe detailed \wiing diagram. SWITCH ‘This shows that conti- nuity exits between terminals (and @) when the sith turned t0 ON position. _[Tanitiow swirer ACC oF ON WIRE COLOR CODING Je = Block BR = Brown TOCATION NUMBER Grouno |W cyiite OR = Oraae “This number shows where the i Connectors ocate Ses Sl Green PU = Purple HARNESS LAYOUT in EL ora SY = Gr faction. The numbers daniel withthe one in HARNESS LAYOUT. Go! & 1 Instrument | Mt thames | Main hernese LG = Light Groen When the wire colori striped, the bare colors given fist, followed by the stripe {olor a shown below Example: LIW = Blue with White Stripe Normally open SWITCH POSITIONS Wiring diagram switches ere shown with the vehicle in the following condition es — S32 |e Ionition switch “OFF”. © Doors, hood and trunk lid/back door closed. © Pedals are not depressed and parking brake is released. Normally owed oeHOW TO READ WIRING DIAGRAMS CONNECTOR SYMBOLS Example © All connector symbols in wiring diagrams are shown from — the terminal side 1] 3 1 2f4 lconnectorsvmbol 2 3 a” ay : Connector so1202 Example © Male and female terminals Connector guides for male terminals are shown in black and Male terminal female terminals in white in wiring diagrams. Guide \ | Connector symbol Connector Female terminal BL oe | cute (Connector symbol Connector MULTIPLE SWITCH The continuity of the multiple switch is identified in the switch sci263] chart in wiring diagrams. Example wirer switcn fore nrfuofwwasn] Continuity ereuit of wiper switeh fl ° ‘UITGH POSITION CONTINUITY GIRGUTT —sv— z ) OFF a —R-@)D] [4 Belg INT 345-6 —weBlEp|it{s| [4[O]o) Lo 3-6 —wE lz] [s ° Hr 26 —B: l@|_lolejo[o WASH 1-6 —y Example: Wiper switch in LO position Continuity circuit: Red wire — @) terminal ~ (8) terminal — Wiper switch (@ ~ @. LO) — @ terminal ~ © terminal — Black wire GI-8HOW TO READ WIRING DIAGRAMS SUPER MULTIPLE JUNCTION (S.M.J.) © The ‘S.MJ.” indicated in wiring diagrams is shown in a simplified form. The terminal arrangement should therefore be referred to in the foldout at the end of the Service Manual. © The foldout should be spread to read the entire diagram, Example STARTING SYSTEM ‘STARTING SYSTEM ‘SUPER MULTIPLE JUNCTION (5) pe @ i Super Multiple Junction a sma) — is TRE Ey GE opera [azhe2|ca}= fealraloa| lrale),[calealad falealea}“lealea fesfealesmics}oofaa| — ‘ Paajes] [ra|oa| alr] fs4|aa| = sles] Fests] es} esis e—t oo-+— en: kaga | O Free sles mor (iain nares) instrument harp ere leven ear hares heloeleo}—feelralce [cereleoifcelselas hsjas|es|°*eslralas| leslesleo|°°[coleolaal Pojeclcojop feolro [solroleo) op [coleolaa| | on. i aa (instrument harmo) _ seL6sar|HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES INSPECTION START _) 7a €, CHECK POWER SUPPLY. ‘Check the following items. / 1) Tur gion swith “ON”, |¥-6,] 9) Harness contty between Mm D 2) Check voltage between crank angle sensor and battery. 3 = terminal ee gourd 2) B08 aay 1 (Gee pay EF \ (pBattery voltage should exist, C-106.) ‘® t = 3) “BR Tasbl ink I 4) Pomer source for CU. S61864 (See page EF & EC-104,) yd 5) laniton switch -_ CHECK GROUND GIRCUIT, | [Check the folowing ems © 1) Tur ignition switch "OFF | 1) Hares contnuty between il 2) Disconnect rank angle crank angle snr and sererharss conedtr. sround [2] 3) Cheat resence beween | |2) Ground cout for E.CU. 2 ‘terminal @) and ground. (See page EF & EC-104.) @& | | mene Approximately Of) souses Tor NOTICE The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing, 1) Use the flow chart after locating probable causes of a problem following the “Preliminary Check” or the “Symp- tom Chart”, 2) After repairs, re-check that the problem has been com- pletely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness con- nectors. 4) Refer to the Circuit Diagram for Quick Pin Point Check. it you must perform circuit continuity between harness connectors more detail, such as in case of sub harness Is used, refer to Wiring Diagram and Hamess Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be “OFF”. 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connec- tors are reconnected as they were. GI-10HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES Example View from terminal side Connector symbol ical omanen View from harness side ya Connector HOW TO FOLLOW THIS FLOW CHART (T) Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. a 4 CHECK POWER SUPPLY. J¢—— Check item being performed 1) Turn ignition switch “ON”. 2) Check voltage between Procedure, steps or terminal () and ground, measurement ‘esults Battery voltage should exist, lox. [2] Measurement results Required results are indicated in bold type in the corre- sponding block, as shown below. These have the following meanings: Battery voltage > 11 - 14V or approximately 12V Voltage: Approximately 0V -> Less than 1V 'B) Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. For example, symbol [EJ indicated in the lett upper portion of each illustration corresponds with the symbol in the flowchart for easy identification. More precisely, the proce- dure under the "CHECK POWER SUPPLY” outlined previ- ously is indicated by an illustration BY [) Symbols used in illustrations ‘Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, farrliarize yourselt with each symbol. Direction mark A direction mark is shown to clarify the side of connector (ter- minal side or harness side). Direction marks are mainly used in the illustrations indicating terminal inspection, Sina Direction mark Connector syibot Direction mark A $1084) ay A | View from terminal side .. TS. © All connector symbols shown from the terminal side are enclosed by a single lin View from harness side ... H.S. © All connector symbols shown from the harness side are enclosed by a double line. GI-11HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES Key to symbols signifying measurements or procedures ‘Symbol explanation ‘Symbol explanation ‘Check after disconnecting the . ‘connector to be measured. AIC switch is “OFF ‘Check after connecting the connector to be measured. AIC switch is “ON Insert key into ignition switch, EC switch Is “ON” ‘Turn ignition switch to “OFF” position, REC switch Is “OFF”. Turn ignition switch to "ON position. DEF switch is "ON" Turn ignition switch to "START" ~ position, VENT switch is “ON’ Turn ignition switch from “OFF” to giggs 2s) | Fan awitch is “ON”. (At any post “ACC” position. ticn except for “OFF” position) Turn ignition switch from “ACC” to gp “OFF” position, Fan switch is “OFF” (3) € Gs) @& ) @) @« & | emer’ | [Ga] | gatas ome & & _ % % Turn ignition switch from “ON" to Terr? postion: Drive vehicle eens tet GB) | err mn tee Sa ro, rhein rare “i onrse trate peal Apply parking brake Release brake pedal Check after engine Is warmed up LX sufficiently Aalease accelerator pedal Pin terminal check for SMA type ECU. and A/T control unit connectors, For details regarding the ‘es T | Release parking brake. | Depress accelerator pedal 4 Stas) tJ Voltage should be measured with a voltmeter. terminal arrangement, refer lau is) EL Current should be measured with a an ammeter. | GI-12 4 =IDENTIFICATION INFORMATION Model Variation — Transmission Destination Body Engine Sspeed manual |4-speed automatic FSSw71c REAROIA Coupe ML-FU ML-AU Non-Celifornia RMLFU AML-AU Fastback RMLK-FU RMLK-AU USA. Coupe MLFV MLAV LHD, California KA24DE RML-FV RML-AV Fastback RMLK-FV RMLK-AV Coupe ML-FN ML-AN Canada RML-FN RML-AN Fastback RMLK-FN RMLK-AN Prefix and suffix designations: zo x a RM LK Si FU root] + Coupe KA24DE engine Lefthand drive HICAS IRS ‘means no indication. GI-13 Us For Non-California V = For California N-: For Canada F + S:speed manual transmission ‘A + 4-speed automatic transmissionIDENTIFICATION INFORMATION Identification Number 1 Vehicle identiiaton pate \ Vehicle ideniiaton number (Chassis number) Cems. conteston ae Emission contol information label L Venice iseniiation number pate VEHICLE IDENTIFICATION NUMBER ARRANGEMENT wNIHS36PXMW duntenree ————_] INT: Nissan, Passenger vehicle Vehicle serial number Manufacturing plant W: Kyushu Engine type H: KA24E Model year Vehicle tine M: 1991 year model S: NISSAN 2408x Check digit (0 t0 9 or X) The code for the check digi determined by mathema ‘computation. Model change (0 to 9) Body type 4: Coupe 6: Fastback Restraint system S: Standard P: Automatic GI-14jentification Number (Cont'd) IDENTIFICATION PLATE Vehicle identification number (Chasis number) Body color code ‘Trim color code Engine model Engin displacement “Transmission model Axle model Ese ER AMER ARH wena | soars ENGINE SERIAL NUMBER KA2ADE engine i067 AUTOMATIC TRANSMISSION NUMBER 01690 soist3 GI-15IDENTIFICATION INFORMATION Dimensions Unit: mm (in) Coupe Fastback (Overall length 4,520 (178.0) 4,520 (178.0) Overall width 1,890 (66.5) 1,690 (665) Overall height 1,290 (60.8) 1,290 (60.8) Front tread 1,465 (57.7) 1,465 (67.7) Rear tread 1,460 (57.5) 1,460 (57.5) Wheelbase 2,475 (97.4) 2,475 (97.4) Wheels and Tires Road wheel Stee! 6x15, 4Tx15*1, 4Tx16"1 ‘Aluminum 6x15 Offset mm (in) 40 (157) Tire size Convention: P195/60R15 86H Spare P205/60R 15 89H*2 7125/70D15 7135/70D16 1: For spare tire "2: Option GI-16LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand WARNING: © Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat. \ 7 a Front towing hooks — Rear \ towing hooks 4 GI-17LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines. Lirepas PETRI inthe slit of the lft pad to prevent si ‘heal from deforming. Ifthe pad does not have / asi rea sta tachment wh Now: Liftup point ara the so a8 pantograph jack points. scisee Tow Truck Towing CAUTION: @ All applicable state or Provincial (in Canada) laws and local laws regarding the towing operation must beyed. @ It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. © When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral CN” position). NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated. GI-18LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont'd) TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (With rear wheels on ground) Observe the following restricted towing speeds and distances. Spee Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) It the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. TOWING POINT Always pull the cable straight out from the vehicle. Never pull on the hook at a sideways angle. GI-19TIGHTENING TORQUE OF STANDARD BOLTS i ening torque (Without lubricant) Grade | pottsize | BOIS | pitch mm | —_Tishaning trae meter* mm Hexagon head bolt Hexagon flange bolt Nm | kom | fb | Nm | kom | fb Me 60 19 5A ose | 38 | a1 | o | 45 125 13 13 ° 5 15 1 me 80 10 3 13 ® 16 16 12 15 3 25 18 2 30 | 2 at | mio | 100 125 Ed 28 19 30 34 2 178 2 43 3 3 52 | #8 m2 120 125 46 a7 2 56 a7 | m1 4 140 15 74 75 54 88 90 | 6 M6 60 19) 34 oes | 62 10 19 7 125 2 2a 15 2% 25 8 me, 80 19) 2 22 16 26 27 | 2 18 41 42 20 48 49 | 35 m™ | mo | 100 125 «3 a4 2 3 32 | 3 175 7 72 52 a a6 |e m2 120 125 77 79. 57 2 oa | 8 mia 140 15 127 130 | 7 | 150 | 108 M6 60 10 2 12 2 18 15 n 125 29 30 2 3 36 | 26 we 80 10. a 32 2 7 38 | 27 18 9 60 a 70 7A 31 ot | mo 10.0 125 @ 63 «6 7% 75 | 5 175 8 10.0 7m | 18 | 120 | a7 m2 120 125 108) 110 | 17 | 140 | 101 mia 140 15 7 veo | 190 | 208 | 210 | 152 ‘Special parts are excluded. ‘This standard is applicable to bolts having the following marks embossed on the bolt head. *: Nominal diameter Grade Mark no a L_ Nominal diameter of bot threads (Unit: mm) n Loan or GI-20MAINTENANCE SECTION M A CONTENTS GENERAL MAINTENANCE ses . senmnnnnsrnnnnee MA® 2 PERIODIC MAINTENANCE sonnnn renee MAS RECOMMENDED LUBRICANTS AND FLUIDS. ese . MA- 7 ENGINE MAINTENANCE ..... sev setts senses Me 9 CHASSIS AND BODY MAINTENANCE ...... MA-15 SERVICE DATA AND SPECIFICATIONS (S.0.S)) ...... aoe seeniinneees MAB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. tem Reference page ‘OUTSIDE THE VEHICLE ‘The maintenance items listed here should be performed from time to time, unless otherwise specified 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 Wheel nuts When checking the tires, make sure no nuts are missing, and check for any loose ruts, Tighten if necessary. ‘Tire rotation Tires should be rotated every 12,000 km (7,500 miles.) MA19 Wheel alignment and balance If the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. MANE FAT Windshield wiper blades Check for eracks or wear if they do net wipe properly. Doors and engine hood Check that all doors and the engine hood operate smoothly as well as ‘the trunk lid and back hatch, Also ensure, that all latches lock securely. Lubricate hinges, latches, rollers and links if necessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check lubrication frequent: y. 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. Lights Make sure that the headlights, stop lights, tal lights, turn signal lights, and other lights are all operating properly and installed securely. Also check headlight aim, MA2t ‘Warning lights and buzzers/chimes Make sure that all warning operating properly. lights and buzzers/chimes are Windshield wiper and washer Check that the wipers and washer operate properly and that the wipers do not streak. _ Windshield defroster Check that the air comes out of the defroster outlets properly and in sufficient quantity when operating the heater or air condition ‘Steering wheel Check that it hat the specified free play. Be sure to check for changes in the steering condition, such as excessive free play, hard steering or strange noises. Free play: Less than 35 mm (1.38 in) ‘Seats Check seat position controls such as seat adjusters, seatback recliner, etc. to ensure ‘they operate smoothly and that all latches lock securely in every position. Check that the hhead restraints move up and down smoothly and that the locks (if so equipped) hold secure- ly im all latched positions. Check that the latches lock securely for folding-down rear seat backs. 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, Maz MA-2GENERAL MAINTENANCE Item Reference page ‘Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free ag travel. Brakes Check that the brake does not pull the vehiele to one side when applied. - = Brake pedal Check the pedal for smooth operation and make sure ithas the proper distance under it when depressed fully. Check the brake booster function, Be certain to keep floor BR? mats away from the pedal Parking brake Check thet the lever has the proper travel and confirm that your vehicle is ars hold securely on a fairly steep hill with only the parking brake applied. ‘Automatic tansmission “Park” mechanism Check that the lock release button on the selector lever operates properly and smoothly. On a fairly steep hill check that your vehicle Is held securely with the selector lever In the "P” position without applying any brakes. UNDER THE HOOD AND VEHICLE ~ ‘The maintenance items listed here should be checked per the engine oil or refuel). ically (e.. each time you check Windhied water id Check tat there adequate fd in the tank = rane cotant eel Check the coolant evel when the engines ol Wat Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, exe, thet may have sosmlatd, Make sire the hows have no erst, deformation, roto : laos connection, Brake and eth dv Make wre hat the rake ad Gch uid lvl ae between te Wain “MAX” and “MIN” lines on the reservoir. we Bary Check te fd ee in each el shoud be butween the "WAX" and “MIN” ies, = Engine drive ls Make we that nob red wor, cracked orally. WAS Engine of eel Check te level on the pk after parking the wile on a eve spot and wana turing te engine. Power serng fi level and lines heck the lvl when te fui Gol and te engines wane turned off Check the ine for proper attachment, leaks, each, ee “Rutomate taramfalon Td Weve Chek the level on the dpntck afar pang We aecor wate tever "Pith the nine ling Exhaust sytem Make sre tere sr no loot suppor, asks o ols. the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble MA19 and correct it, Underbody The underbody is frequently exposed to corrosive substances such as those used (on icy roads or to control dust. It is very important to remove these substances, otherwise ust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end ‘of winter, the underbody should be thoroughly flushed with plain water, being careful to clean those areas where mud and dirt can easily accumulate. Fluid leaks Check under the vehicle for fuel, oll, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. MA-3PERIODIC MAINTENANCE ‘Two different maintenance schedules are provided, and should be used, depending upon the conditions in which the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic maintenance at the same mileage/time intervals. SCHEDULE 1 Follow Petiodic Maintenance Schedule 1 if your driving habits frequently includes one or more of the following driving conditions: © Repeated short trips of less than 5 miles (8 km). Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below freezing Operating in hot weather in stop-and-go “rush hour" traffic Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door delivery use. © Driving in dusty conditions. © Driving on rough, muddy, or salt spread roads. © Towing a trailer, using a camper or a car-top carrier. SCHEDULE 2 Follow Periodic Maintenance Schedule 2 if none of the driving conditions shown in Schedule 1 apply to your driving habits. MA-4PERIODIC MAINTENANCE Schedule 1 {qu q00'0e Ausre a8 Yo (200dsu!ysn{ y0U) eBueyD‘speos Appnus Jo YBNOL Uo BuIALp 40 "411109 dos “sou jeoes sosmoeynuewi 40 AIUeLIeM UO!SS}WO olf UJELULEWY OF 49Ps ‘hq papususiwose:o1e ,,.,, yn SJEALEVU] puE swe} SOUBUEDUN ()) :3L0N ahs von waNS bed sounsaen oo (96) (06) (va) 9 s205 ozs eo oO we am (22) (22) (99) (08) (5) (6) (eH (9e)_ (081 seer sp sziv uc scee oO stor gee sL'8l Si sz JAUSINI_3ONYNSINIVI “Avestan 9 901082 Ter aLON 5 jLON 205 116) SON #95 ‘soueuayuIeU WaysAS jO;UOD Ue Taun o00"t * w) (000s x san 20 9608 TaURsEH ONEN SNS squow 40 sarewe ‘eo jo sequinu ve woyed NoLLWYad0 ZONYNBINIVIL 1 soeideu =u 00n ac MA-5PERIODIC MAINTENANCE Schedule 2 “postrbos ore sjeasayur pue swion} souewen ‘oueuaruyeus yons wo}ied 10u peou 18umMo oY, "94 ‘ybty Arowionnxe 10 mo} Ajouenx nesodo efo1yer 91GeII4 40} NYSSIN Aq pepuEUIUIOde! ee “00 awn oz T aya ev suBTETTEAT Apo pus SSD Tie) LON auesnaa enon nee OUI wi al u _s @ u a eT wu eo @ © oF mm o @ Ee (so) toa) ze) 09) ev @ sz oy gue ee se AWAUSINI 3ONVNBLNIVAL “Aue stensnu oe NoLWuad0 ZONVNSINIVI. ‘Aaesa00u 9] sees 20 1981/09 “08GHu| =| eaejd04 = W :suONeMDAGY MA-6RECOMMENDED LUBRICANTS AND FLUIDS Lubricants and Fluids Capacity (Approximate) 7 = Flecommanded lubricants and fuide measure measure Liter Engine of (Rett) With ol fiter saat 34/8 qt 35 mmotier SS Energy Conserving Oils of API SG*2, *3 Without oi iter 30a 27/Bat 32 Cooling system (with reservoir tank) 7-1/8 at 5-7/8 at 7 ‘Antifreeze coolant (Ethylene glycol base) Manual tanamission oi Sept 44/ape 24 APLGL4*2 Differential gar ol 2alapt 21/4 pe 13. API GLS2 (Genuine Nisan ATF*1 or equivalent \stomatie transmission fu * 74 A ftuid 83/84 114 at 33 Eeptieralal Pow steering fluid = = 5 Type DEXRON™ oar _ _ _ ‘Genuine Nissan Brake Fluid? or equivalent Brake fluid DOT 3 (US FMVSS No. 116) Multi-purpose grease = B 5 NLGI No.2 (Lithium soap base) ‘Avallable In mainland U.S.A. through you Nissan dealer : For further details, se “SAE Viscosity Number”. 3: Energy Conserving 01 ‘These oils can be identified by auch labels as EC, EC-I, energy conserving, energy seving, improved fusl economy, ec. MA-7RECOMMENDED LUBRICANTS AND FLUIDS SAE Viscosity Number Dustide Temperature Range ‘Outside Temperature Range Anticipated Before Next Ol Change Aaticipated Before Next Oil Change ENGINE OL raEaR OL Wi “10008 Tre003 5W-30 Is preferable for all ambient temperatures. __75W-90 for the transmission and 80W-90 for the 20W-40 and 20W-50 are usable if the ambient differential are preferable it the ambient temp. temperature is above 10°C (50°F) for all seasons. _ture Is below 40°C (104°F). MA-8ENGINE MAINTENANCE Checking Drive Belts TWAS pump rear lok nut (wth SUPER FICAS) i pump Water pump pulley Air conationer ‘compressor ‘eer pulley ohm pont | / [Ress vx Hin born 1. Inspect for cracks, fraying, wear or oil adhesion. If neces- sary, replace with a new one. 2. Inspect drive belt deflections by pushing on the belt midway between pulleys. Adjust if belt deflections exceed the limit. Belt deflection: Inspect drive belt deflections when engine is cold. vai Used bo dation Detain Limit adjustment new belt re 3-7 erator 100 | eaten | escce fi onion 75-05 | 65-75 compressor ee (0.295 - 0.335) | (0.256 - 0.295) Power stering ol amo vtnou SUPER ys-0s | es-75 HICAS naa (0.295 - 0.335) | (0.256 - 0.295) ith SUPER os-75 | 85-65 HICAS ad) (0.256 - 0.295) | (0.217 - 0.256) Aped pasa 2 N10, 221) MA-9ENGINE MAINTENANCE 7 a pg | j— raatr X RO My fia (oy Changing Engine Coolant WARNING To avoid being scalded, never change the coolant when the engine is hot. 2. on zoen Move heater “TEMP control lever all the way to "HOT" position. Open drain plug at the bottom of radiator, and remove radiator cap. Remove drain plug on cylinder block Close drain plug and tighten drain plug securely. Apply sealant to the thread of drain plug. 9:34 - 44 Nem (8.5 - 4.5 kg-m, 25 - 33 ftb) Open air relief plug. Fill radiator with water and close air relief plug and radiator cap. Run engine and warm it up sufficiently. Race engine 2 or 3 times under no-load. Stop engine and wait until it cools down, Repeat step 2 through step 9 until clear water begins to drain from radiator. 11. Drain water. MA-10ENGINE MAINTENANCE suas) suasoa| “4p 3 mm (0-12 in) ssuasoas) W Fle Pres RELEMGE FUEL FUP WILL sre es| lraucnrhis” staRY ~DURINS rove, CRria a FEU TIMES AF-| ITER Ene. STALL, Changing Engine Coolant (Cont’d) 12. Open radiator cap and air relief plug. 18. Fill radiator with coolant up to specified level Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity (With reservoir tank): 6.7 ¢ (7-1/8 US qt, 5-7/8 Imp qt) Pour coolant through coolant filler neck slowly to allow air in ‘system to escape. 14, Close air relief plug. 1. Remove reservoir tank, drain coolant, then clean reservoir tank 16. Install reservoir tank and fill it with coolant up to “MAX” level and then install radiator cap. 17. Run engine and warm it up sufficiently. 18. Race engine 2 or 3 times under no-load. 419. Stop engine and coo! it down, then add coolant as neces- sary. Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deteri- oration. If necessary, repair or replace faulty parts. Changing Fuel Filter CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is ‘3 mm (0.12 in) from hose end. Ensure that screw does not contact adjacent parts. WARNING: Before removing fuel filter, release fuel pressure from fuel line. 1. Perform "FUEL PRESSURE RELEASE” in “WORK SUPPORT" mode to release fuel pres- sure to zero. 2. Turn ignition switch off. MA-11ENGINE MAINTENANCE Changing Fuel Filter (Cont'd) ve! pump —| fuse (104) 1. Remove fuse for fuel pump, ® 2. Start engine. 3, After engine stalls, crank engine two or three times to make sure that fuel pressure is re- lease 4, Turn ignition switch off and install fuse for fuel pump. Loosen fuel hose clamps. Replace fuel filter. ‘© Be careful not to spill fuel over engine compartment. Place shop towel to absorb fu © Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. © When tightening fuel hose clamps, refer to “Checking Fuel Changing Air Cleaner Filter The viscous paper type filter does not need cleaning between renewals. Changing Engine Oil WARNING: Be careful not to burn yourself, as the engine oil is hot. 1. Warm up engine, and check for oil leakage from engine components. Remove drain plug and oil filler cap. Drain oil and refill with new engine oil. fitter Refill oil capacity (Approximate): Unit: liter (US at, Imp at) eae ‘swagesc] With ol iter change 3.8 (4, 3/8) Without ol iter change 35 (6-8/4, 3178) CAUTION: Be sure to clean drain plug and install with new washer. Drain plug: 10:29 - 39 Nm (8.0 - 4.0 kg-m, 22 - 29 ft-Ib) ¢ Use recommended engine ©The refill capacity changes depending on the oll tempera- ture and drain time; use these val a reference and be certain to check with the dipstic anging the oil. MA-12ENGINE MAINTENANCE Epi otto tava a not overt suasese} sunoro Changing Engine Oil (Cont'd) 4. Check oil level. 5. Start engine and check area around drain plug and oil filter for oil leakage. 6. Run engine for a few minutes, then turn it off. After several minutes, check oil level. 9 Oil Filter 1. Remove oil filter with a suitable tool WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot. 2. Before installing new oil filter, clean the oil filter mounting surface on cylinder block, and coat the rubber seal of oil filter with a little engine oil. 3. Screw in the oil filter until a slight resistance is felt, then tighten additionally more than 2/3 turn. 4. Add engine oil Refer to Changing Engine Oil. Changing Spark Plugs 1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire. MA-13.ENGINE MAINTENANCE Changing Spark Plugs (Cont'd) Q 6mm 7 eam y R- Side electrode Gam \ _— 2, Remove spark plugs with spark plug wrench. ‘Spark plu Standard type BKRSE-11 Cold type BKRGE-11 BKR7E-11 Check plug gap of each new spark plug. Gap: 1.0 - 1.1 mm (0.039 - 0.043 in) Install spark plugs. Reconnect ignition wires according to Nos. indicated on them. ‘Spark plu: $20 - 29 Nem (2.0 - 3.0 kg-m, 14 - 22 ft-lb) Checking Vapor Lines 1 Visually inspect vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deteriora- tion. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, ete. Refer to EVAPORATIVE EMISSION CONTROL SYSTEM IN- ‘SPECTION in section “EF & EC”. Checking Valve Clearance Refer to “CYLINDER HEAD" in section “EM”, if engine runs with unusual mechanical noise. MA-14CHASSIS AND BODY MAINTENANCE suaa2on Fi to tis ca! Filler plug tara SMA2S5A) Checking Clutch Fluid Level and Leaks © If fluid level is extremely low, check clutch system for leaks. Checking M/T Oil 1. Check for oil leakage, 2. If leakage is found, check oil level. Never start engine while checking oil level, Filler plug: 1:25 - 34 Nem (25 - 3.5 kg-m, 18 - 25 ft-lb) Changing M/T Oil 4. Drain oil and refill with new gear oil 2. Check oil level Oil capacity: 2.4 Q (5-1/8 US pt, 4-1/4 Imp pt) Drain plug: ©): 25 - 34 N-m (25 - 3.5 kg-m, 18 - 25 ft-lb) MA-15,CHASSIS AND BODY MAINTENANCE HOT [50- 80°C (122- 176"FI] saTo79e Check fluid for contamination. ‘SMags98 Checking A/T Fluid 1. Check for fluid leakage. 2. If leakage is found, check fluid level Fluid level should be checked using “HOT” range on dipstick at fluid temperatures of 50 to 80°C (122 to 176°F) after vehicle has been driven approximately 5 minutes in urban areas after engine is warmed up. But it can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on disstick for reference after engine is warmed up and before driving. However, fluid level must be rechecked using “HOT” range. 4) Park vehicle on level surface and set parking brake. 2) Start engine and then move selector lever through each gear range, ending in "P”. 3) Check fluid level with engire idling 4) Remove dipstick and wipe it clean with lint-free paper. 5) Reinsert dipstick into charging pipe as far as it will go. 6) Remove dipstick and note reading. If level is at low side of either range, add fluid to the charging pipe. Do not overfill. 3. Check fluid condition, Check fluid for contamination. If fluid is very dark or smells, burned, or contains frictional material (clutches, band, etc.). check operation of A/T. Refer to section AT for checking operation of A/T. Changing A/T Fluid 4. Drain fluid by removing oil pan. 2. Replace gasket with new one. 8. Refill with fluid and then check fluid level. Oil capacity (With torque converter): 83 © (8-3/4 US qt, 7-1/4 Imp qt) MA-16CHASSIS AND BODY MAINTENANCE @) Filler plug Drain pug ‘sMaaesa TOUT UUUT 1 sensor @ + sMa7a20 Checking Differential Gear Oil 1. Check differential carrier for oil leakage. 2. If leakage is found, check oil level. Filler plug: 7):59 - 98 Nem (6 - 10 kg-m, 43 - 72 ftb) Changing Differential Gear Oil 4. Drain oll and refill with new gear oil 2. Check oil level Oil capacity: R200 13: (2-9/4 US pt, 2-1/4 Imp pt) R200V 4.5 Q (34/8 US pt, 25/6 Imp pt) Drain plug: ©): 59 - 98 Nem (6 - 10 kg-m, 43 - 72 ft-lb) Checking Brake Fluid Level and Leaks © If fluid level is extremely low, check brake system for leaks. Checking Brake Lines and Cables © Check brake fluid fines and parking brake cables for im- Proper attachment and for leaks, chafing, abrasions, deteri- oration, ete. MA-17CHASSIS AND BODY MAINTENANCE Checking Disc Brake © Check condition of disc brake components. ROTOR © Check condition and thickness. Unit: mm (in) — Front Rear Dise brake type ci2ave | cizsvar | cin swazooa] Standard thickness 20.0 (0.787) | 22.0 (0,866) | 9.0(0.354) Minimum thickness 18,0 (0.709) | 20.0(0.787) | 8.0 (0.315) + With ABS. CALIPER ‘@ Check operation and for leakage. i sma9228) PAD @ Check for wear or damage. Unit: mm (ind Front Rear Disc brake ype | cL22vB cLasvat cis Standard thickness | 10.0(0.394) | 11.0(0.433) | 9.5 (0.374) ‘Minimum thickness 2.0 (0.078) 1.5 (0.059) swasave| 7 WihABS, Balancing Wheels © Adjust wheel balance using road wheel center. Wheel balance (Maximum allowable unbalance): Reter to S. MA-18CHASSIS AND BODY MAINTENANCE FRONT (h A 1X I ' U 2 Check ozo teakase GE Check intening Orewa sei ere (1a2- 176 F) HOT: 50. OK. Bo re 3912738 “8 ssr1078 Tire Rotation ‘© Do not include the T-type spare tire when rotating the tires. Wheel nuts: 7:98 - 118 Nem (10.0 - 12.0 kg-m, 72 - 87 ft-lb) Checking Steering Gear 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. Checking Power Steering Fluid and Lines CHECKING FLUID LEVEL (WITHOUT SUPER HICAS SYSTEM) Fluid level should be checked using “HOT” range on dipstick at fluid temperatures of 50 to 80°C (122 to 176°F) or using “COLD” range on dipstick at fluid temperatures of 0 to 30°C (32 to 86°F). ‘CAUTION: Do not overfill CHECKING FLUID LEVEL (WITH SUPER HICAS SYSTEM) Maintain the fluid level so that the lower surface of the float is maintained between the "L” and "H’” marks on the gauge rod. The fluid level should be checked when the engine is stopped and the fluid temperature is normal CAUTION: Do not overfill, CHECKING LINES Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. MA-19CHASSIS AND BODY MAINTENANCE Cc) Checking SUPER HICAS Linkage (With SUPER HICAS system) . © Check power cylinder and linkage for damage, looseness and 2 « 9 leakage of oll or grease. 1: Chock tightening roraue Check ol or great enkane Checking Exhaust System @ Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. MA-20CHASSIS AND BODY MAINTENANCE LUBRICATING LOCKS, HINGES AND HOOD LATCHES Trunk tia sulker suacoee CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS Taint ba amano, ican eaten (Cheek anchors fo loose mounting. (check retractor for smooth operation. — Rear seat belt check funetion of buckles ~/ snd tongues when buckled tnd released Front soat bolt smaasoc MA-21SERVICE DATA AND SPECIFICATIONS (S.D.S.) INSPECTION AND ADJUSTMENT Drive belt deflection Engine Maintenance Coolant capacity Unit € (US ab Im Unit own (inj reserve tank e777, 878) seapen aetecton |, Detection ot Spark plug Limit ater sew bet _—— adjustment pet Standard ype BARSET 7-8 6-7 BKRET Alternator 1104) | goseay | o2e.029 Cola ype ee ‘Air conditioner 75-65 | 65-78 Plug 989 10= 1 mm (0099 - 0.04 nd compressor 20047) | voz05 -0:335)| (0256-0205) ee TT me'_—: Power steering cil pump Ignition wire winout wos | 75-85 | 65-75 Resistance Less than 90 SUPER HICAS (0.286 - 0398) | (256 0.295) winsuPER | gag | ea-75 | 85-05 HicAS: (0.256 -0226)| (0217-025, TIGHTENING TORQUE Arps puting mencneeeey ni Nm 1m mo Spark plug 20-2 «20-302 | Deain plug Oil capacity (Refill) Engine block 35-45 25-38 _———— ee it pan 29-39 30-40 22-29 With ot iter 386.938) Without oi fi 35681, 518) MA-22SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance INSPECTION AND ADJUSTMENT Brake Unit in Clutch = Unit: mmtis) Gas Pedal re heh 186-196 (722-7.72) ee a ee ay “A 10-80 (0080-0. cue 10.09 (0298) Pedal tro pley peso moe =e) ciasva 110 (0422) cia 35 a7) Front axle and front suspension (Uniaden)* Ninimom amen conber cour area e cuzave = feaae 2010079) cater oe 00" Fa9 orca oy 15 (0068) Kitgoinncination _digren ae Rotor Toein com in) ‘Standard hikes ———— ‘cLzave 2000787) (ote toein) degree Paw cuzsva 2200866) From whet tring wale cian 20 0%0) allan ae Trudeousice 30" 49°18 Minimo thickens cuzve 12.0 (0708) “7 Tonkful of fue redistor coolant ad engine a fal Sper te, euz5va 20010787) Iie, hard took, matin ergata portion. — a000315) : Pel Rear axle and rear suspension (Untaden)* Fro heght 5 wr 177-187 (897-726) Comber degree =1"96" 19-036" | 166-106 732-7, Toon ‘emtin | 08-45 (0020-0477) aa ss i Fre pley woe 1-3 (004-012) ‘Fora wen) aren 3-28 Fee oy Deore hight +: Tankful of fuel, raditor coolant and engine ol fl, Spare tir, jack, hand tools, mats in designated position [under force of 490, " (60g, 110 1) with engine running 100 (3.94) or more Porkra ba Wheel bearing Number of notches: {et puting force 198 N 6-8 Front eer (20%, 44) We! bearingane end | 0.08 00012) | 05 0.0020) ploy fmm tind | ort ore Wheel bearing lock nut Wheel balance ee 147-216 206-278 Dyromie Tomeningroraue || 5-22, (2-28 Mximum foci flange {1030 . 108 - 159) 152 - 203) allowable a oz) yao sided Stance amie ate) | goa MA-23SERVICE DATA AND SPECIFICATIONS (S.D.S.) TIGHTENING TORQUE w ‘outeh Pda! stopper lock mut Clutch switch lock nut Manual transmission Dain end filler pgs Final drive Drain plug Filer pio Front axle and front suspension “Tiered lock nut Fear axle and rar suspension “Toe adjusting pin Camber adjusting pin (Wodele without super HICAS) Lower tink ook not (odels with super HICAS) Brake systom ‘Air bleed valve ‘Brake lamp switch lock rake booster input rd lock nut ‘Whee! and tire Wheel nut tem 16. 2 25 ae a 6. a7 2 16 4 a8 1-9 12 98-118 6 2 kom 16 12 25 22 15 as 6-10 6-10 38 70 70 28. 07 12 an 20 90 a7 09 15 22 Chassis and Body Maintenance (Cont'd) fu 12-16 on n 2 BB 27-38 5 51-65 g 27-36 51-65 on 12-16 100-120 72-87 MA-24ENGINE MECHANICAL SECTION E M CONTENTS PRECAUTIONS ....... ee PREPARATION ...ccsoscssnssnnnennntnnseete ee EM> OUTER COMPONENT PARTS a EM- 6 COMPRESSION PRESSURI EM 8 OIL PAN EM- 9 TIMING CHAIN ..rssensese - EM-11 OIL SEAL REPLACEMENT ... EM-21 CYLINDER HEAD srsssntnnsnnsesnansen somtntnatnnnnnntensenee EM23 ENGINE REMOVAL, vtnsennttnnntnnsiese : EM-34 CYLINDER BLOCK ....seose osmenenneensense EMT SERVICE DATA AND SPECIFICATIONS (S.D.S.) 0. EM-49Bolt hole PRECAUTIONS Parts Requiring Angular Tightening Some important engine parts are tightened using an angular-tightening method rather than a torque setting method. IC these parts are tightened using torque selling method, dispersal of the tightening force (axial bolt force) will be two or three times that of the dispersal produced by using the correct angular tightening method, Although the torque setting values (described in this man- ual) are equivalent to those used when bolts and nuts are tightened with an angular-tightening method, they should be used for reference only. To assure the satisfactory maintenance of the engine, bolts and nuts must be tightened using an angular tightening method, Before tightening the bolts and nuts, ensure that the thread and seating surfaces are clean and then coated with engine oll The bolts and nuts which require the angular-tightening method are as follows: (1) Cylinder head bolts (2)Connecting rod cap nuts. Liquid Gasket Application Procedure a Before applying liquid gasket, use a scraper to remove al traces of old liquid gasket from mating surface. Apply a continuous bead of liquid gasket to mating sur- faces. (Use Genuine Liquid Gasket or equivalent.) © Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide (for oil pan). © Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). Apply liquid gasket to inner surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) Wait at least 30 minutes before refilling engine oil and engine coolant. EM-2PREPARATION SPECIAL SERVICE TOOLS ‘Too! number (Kent-Moore No.) Tool name Description ‘3705018000 on) Engine stand assembly @ sT0s011000 on) Engine stare @ sT0s012000 c=) Base Disassembling and assembling KV10705001 (-) Engine attachment kvi0r08280 (=) Valve spring compressor @ Kvt0109210 ne) Compressor @ Kvt0109220 (> D Disassembling and assembling valve components, Adapter - rev 16900 Totaling valve ol seal (-38085) co Valve oi ea it z iev10110900, Disassembling and assembling c-)> Piston pin press stand assembly ® kvtor10810 (=) Cap @ Kvt0110830 (-) ‘Spacer @ sT130300% C=) Pross stand @ sT190300%¢ t=) Spring ® Kvt01 10340 (>) Dritt @ Kv10110820 (>) Center shat piston with connecting rod EM-3PREPARATION Toot number (KentMoore No.) Tool nat 'EN03470000 (8037) Piston ring compressor (36467) Valve oil seal remover Description Ay Displacement valve oil seal v10111100 (-) Seal cutter 1ws39930000 (-—) Tube presser Removing oll pan , 5 Pressing the tube of liquid gasket ‘sT16630001| (23907) Pilot bushing puller a _ ‘sT 10120000 (9-24298.01) Cylinder head bolt wrench Loosening and tightening eylinder x head bolt Kv10115180 Litter stopper set @ kvtoris110 Camshat pliers @ Kv10115120 Litter stopper ‘Changing shims Kv10112100 ‘Angle wrench ‘Tightening bolts for bearing cap, ey- indar head, ete EM-4PREPARATION COMMERCIAL SERVICE TOOLS Toot name Description Spark plug wrench | Removing and installing spark plug Pulley holder Holding camshaft pulley while tight- ening or loosening camshatt bolt Valve seat cutter set Finishing valve seat dimensions Piston ring expander 19 piston ring Removing and installing val guide Diameter: om in) Re Tae Baa SF EB 10.5 (0.473) [1.5 (0489) = 65 (0.260) | 7.610200) Valve guide reamer 2 Reaming valve guide (@)) or hole for Oo — oversize valve guide (@) 2 = Diameter: re tin a ine Exhaust : 3, | 71028 | _@voa0 [112 0.480 | 12.2 (0.480) @® EM-52000 OUTER COMPONENT PARTS Ps -26 (6235007, 17-20) an > engine tront Bee oy "oy op Ss - jae. as (039-048, Vacuum galery jre-aae Oe ~ | ¥ | WW “Tyotte chamber tightening procedure”. TD: Nem ho, sen90 Ful injector @ EGA. control valve @ Air regulator BLT. valve @ IAA. unit ‘@ Exhaust gas temperature sersor Swiclcontrol valve @ Intake manifold collector ® Breather separator Intake manifold @ Theotle chamber ®@ oi titerOUTER COMPONENT PARTS a Engine font we a 6 = 1.9, 12 - 14) 0-2 20-30, ez \ Emm tom me ns Intake manifold tightening procedure Intake manifold collector tightening procedure Engine front > Figen nna ree mL Tighten In nurercal order. ‘senens0 Throttle chamber tightening procedure Exhaust manifold tightening procedure 1 OG, PEE o een nnn| a ee Tatton panel ore EM-7fuse (108) serene COMPRESSION PRESSURE Measurement of Compression Pressure 10. Warm up engine. Turn ignition switch off. Release fuel pressure. Refer to “Releasing Fuel Pressure" in section EF & EC. Remove all spark plugs. Disconnect distributor center cable. Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle valve wide open Crank engine and record highest gauge indication. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution. Compression pressure: ‘Standard 1,236 (12.6, 179)/300 Minimum 1,040 (10.6, 151)/300 Difference limit between cylinders 98 (1.0, 14)/300 If cylinder compression in one or more cylinders is low, Pour a small amount of engine oil into cylinders through spark plug holes and retest compression. It adding oll helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat is damaged excessively, replace them. Hf compression in any two adjacent cylinders is low and if adding oil does not help compression, there Is leakage past the gasket surface. If so, replace cylinder head gasket. Pa (kglcm?, psi)/rpmOIL PAN Remove bots or mu oy Removal 1. Raise vehicle and support it with safety stands. 2. Drain engine oil 3. Remove the following parts. © Power steering tube © Front stabilizer bar securing bolts and nuts from side member. © Both left and right side engine mounting bolts. Refer to “ENGINE REMOVAL” © Gussets 4. Disconnect lower steering joint. 5. Remove front suspension member. 6. Remove oil pan. (1) Insert Too! between cylinder block and oil pan. © Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. © Do not insert screwdriver, or oil pan flange will be de- formed. (2) Slide Too! by tapping its side with a hammer, and remove oil pan. EM-9OIL PAN Removal (Cont'd) 7. Pull out oil pan from the front. Installation 1. Before installing oil pan, remove all traces of liquid gasket from mating surface using a scraper. @ Also remove traces of liquid gasket from mating surface of cylinder block. 2. Apply a continuous bead of liquid gasket to mating surface of oil pan. © Use Genuine Liquid Gasket or equivalent. © Be sure liquid gasket bead is 3.5 to 4.5 mm (0.138 to 0.177 in) wide. Liquid gasket 3. Apply liquid gasket to inner sealing surface as shown in figure. a F | 6 attaching should be done within § minutes after coating. | 4 Install ot pan. Fi toner | @ Wait at least 30 minutes before refilling engine oil. sae Groove Bok hole sexooe EM-10TIMING CHAIN Fs a ts-t9, 12-10) ov un ee ey) co O.. sprocket i wes oe teh ne PE | 7 (Se Fears (a8 hm * “ ee . we) uy? eter Or Seen rect com tightening ane pal sea act, ne id \ y | Lees | Bisa Fe eh tt \ penser t fon over pen ng procedure’ ¥ \. crancshatt putey \aie se ies Nes, ay Fem tem eos sexaeo0 EM-11TIMING CHAIN [Front cover ‘Camshaft sprocket cover rd 16-19 \ e492. / \ Whea-75 Oe. 19 parcel e492 0) hime agen ty (O85 509 sensieo Liquid gasket application places 2.3mm &) 2-3 (008 - 012) dia (0.08 -0.12 tn) ota. Unit: mm (i) sewonan senae40 — ™= rN 2 to 3. me (0.08 to 0.12 In) ‘ameter (Iquld gasket) EM-12TIMING CHAIN ‘Remove nuts and bots Indicated ty artows VES ANN senate CAUTION: ‘After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. Removal UPPER TIMING CHAIN 1 2. 3, ween Drain coolant from both cylinder block drain plug ang radiator drain cock. Refer to MA section. Drain engine oil from drain plug of oil pan. Remove vacuum hoses, fuel tubes, wires, harness and connectors and so on. Remove front exhaust tube and A.|.V. pipe. Remove the following parts. ‘Air duct Cooling fan with coupling Radiator shroud Disconnect injector harness connector and remove injector tube assembly with injectors. Remove all spark plugs with high-tension cords. Set No. 1 piston at T.D.C. on its compression stroke. EM-13TIMING CHAIN Removal (Cont'd) 9. Remove rocker cover. 10. Remove distributor. |. Remove cam sprocket. 12. Remove cam brackets and camshafts. © These parts should be reassembled in their original posi- tions, Exhaust camenatt Loosen in numerical order. eon E2050 exhaust camshaft bracket nine tront the same procedure ‘senars0) 18. Loosen cylinder head bolts. Head warpage or cracking could result from removing in incorrect order. © Cylinder head bolts should be loosened in two or three steps. EM-14TIMING CHAIN Removal (Cont'd) 14, Remove cam sprocket cover ©” Upper timing chain will not be disengaged from idler sprocket. For this reason, a stopper need not be used. Cast portion of cam sprocket cover is located on lower side of idler sprocket so upper timing chain need not be disengaged from idler sprocket. 15. Remove upper chain tensioner and upper chain guides. 16. Remove upper timing chain. 17. Remove idler sprocket bolt. 18. Remove cylinder head with intake manifold, intake manifold collector and exhaust manifold assembly. 19. Remove cylinder head gasket. ¢ Lower timing chain will not be disengaged from crankshaft sprocket. For this reason, a stopper need not be used. Cast portion of front cover is located on lower side of crankshaft sprocket so lower timing chain need not be di from Idler sprocket. LOWER TIMING CHAIN 1, Remove upper timing chain. Refer to "UPPER TIMING CHAIN “in” Removal. EM-15TIMING CHAIN Removal (Cont'd) 2. Remove oil pan. Refer to “Removal” in “OIL PAN”. Remove oil strainer. Remove the following parts. Power steering drive belt Alternator drive belt Air compressor drive belt Air compressor idler pulley Remove crankshaft pulley. Remove front cover Remove the following parts. Lower timing chain tensioner Tension arm Lower timing chain guide Remove lower timing chain and idler sprocket. semsrso} EM-16TIMING CHAIN seaar] [tawer ting chain Mating mar ve spacer (siven ae Crankshaht sprocket -semiso} Inspection Check for cracks and excessive wear at roller links. Replace chain it necessary. Installation LOWER TIMING CHAIN 4. Install crankshaft sprocket. ‘© Make sure that mating marks of crankshaft sprocket face front of engine. 2. Position crankshatt so that No. 1 piston is set at T.D.C. 3, Install idler sprocket and lower timing chain. © Set lower timing chain on the sprockets, aligning mating marks. © Be careful not to damage cylinder head gasket when installing lower timing chain. 4, Install chain tension arm and chain guide. 5. Install lower timing chain tensioner. EM-17Front cover seuseao Cinder head bolt washer Cy) + Cylinder head side Mating mark} {OS (Goi) OT semers0} TIMING CHAIN Installation (Cont'd) 6. Install front cover. ‘© Apply a continuous bead of liquid gasket to front cover. Be careful not to damage cylinder head gasket. Be sure to install oil seal. Install the following parts: Crankshatt pulley Oil strainer Oil pan Component parts below the engine Air compressor idler pulley New cylinder head gasket Idler shaft 8. Install cylinder head and temporarily tighten cylinder head bolts when installing front cover. © Temporarily tighten cylind. id bolts. This is necessary to avoid damaging cylinder head gasket. © Be sure to install washers between bolts and cylinder head. UPPER TIMING CHAIN 1. _ Install lower timing chain Refer to "LOWER TIMING CHAIN” in “Installation” 2. Install upper timing chain, chain tensioner and chain guide. ‘© Set upper timing chain on the idler sprockets, aligning mating marks. EM-18a Engine front in the same procedure. Triako camshaft “Tighten in numerical order. Exhaust camshaft Tighten exhaust camshaft bracket Mating mare TIMING CHAIN Installation (Cont'd) 3. Install cam sprocket cover. ‘© Apply a continuous bead of liquid gasket to front cover © Be careful not to damage cylinder head gasket. Be careful upper timing chain does not slip or jump when installing cam sprocket cover. 4, Tighten cylinder head bolts. Tightening procedure ten all bolts to 29 N-m (3.0 kg-m, 22 ft-lb). ten all bolts to 79 N-m (8.1 kg-m, 59 ft-lb). bolts completely bolts to 25 to 34 N-m (2.5 to 3.5 kg-m, 18 to 25 Turn all bolts 86 to 91 degrees clockwise, or if an angle wrench is not available, tighten bolts to 75 to 84 N-m (7.6 to. 8.6 kg-m, 55 to 62 ft-lb). 5. Install camshafts and camshaft brackets. 6. Install camshatt sprockets. 7. Install chain guide between both camshaft sprockets. EM-19senosse} ‘Tiahtan in numerical order. TIMING CHAIN installation (Cont'd) 8. Install rubber plugs as follows. (1) Apply liquid gasket to rubber plugs. (2) Install rubber plugs, then move them by hand to uniformly spread the gasket on cam sprocket cover surface. © Rubber plugs should be installed flush with the cylinder head surface. 9. Install chain guide between both camshaft sprockets. 10. Install distributor. © Make sure that No. 1 piston is set at T.D.C. and that distributor rotor is set at No. 1 cylinder spark position. 11, Install rocker cover. 12. Install all spark plugs with high-tension cords. 13. Connect injector harness connector and replace injector tube assembly with injectors. 14. Install the following parts. © Radiator shroud Cooling fan with coupling © Air duct 15, Install vacuum hoses, fuel tubes, wires, harness and con- nectors and so on, EM-20OIL SEAL REPLACEMENT VALVE OIL SEAL 1. Remove rocker cover. 2. Remove camshaft. Refer to “TIMING CHAIN”. 3. Remove valve spring and valve oil seal with Tool or a suitable tool, Piston concerned should be set at T.D.C. to prevent valve from falling. 4. Apply engine oil to new valve oil seal and install it with Tool. : 4 ‘Unt: mm (a) Engine Engine inside outsige Oi eat io ust sea io OIL SEAL INSTALLING DIRECTION FRONT OIL SEAL 1. Remove radiator shroud and crankshaft pulley. 2. Remove front oil seal © Be careful not to damage crankshaft. EM-21OIL SEAL REPLACEMENT 3. Apply engine oll to new oil seal and install it using a suitable tool REAR OIL SEAL 1, Remove drive plate or flywheel 2. Remove rear oil seal retainer. 3. Remove traces of liquid gasket using scraper, 4, Remove rear oil seal from rear oil seal retainer. 5. Apply engine oil to new oil seal and install it using a suitable tool, 6. Apply a continuous bead of liquid gasket to rear oil seal retainer. EM-22CYLINDER HEAD Py peter to in “TAMING CHAIN". Fa uicuia gasket seuasn0 ® Oil filler cap @® Vaive titer ® Intake valve @ Rocker cover @ Valve cotter ® Exhaust valve @ Camshatt bracket ® Spring retainer ® Rubber plug @ Intake camshatt ® Valve spring ® Oylinder head @® Exhaust camshatt ® Spring seat @ Cylinder head bolt @ Shim EM-23CYLINDER HEAD CAUTION: When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. When tightening cylinder head bolts, intake camshaft sprocket bolts and camshaft bracket bolts, apply new engine oil to thread portions and seat surfaces of bolts. Attach tags to valve liters so as not to mix them up. Removal © This removal is the same procedure as those for timing chain. Refer to "Removal in “TIMING CHAIN" Disassembly 1. Remove intake manifold, collector assembly and exhaust manifold. Refer to “Outer Component Parts”: 2. Remove vaive components with Tool 3. Remove valve oil seal with a suitable tool. EM-24CYLINDER HEAD Inspection CYLINDER HEAD DISTORTION Head surface flatness: ‘Standard: Less than 0.03 mm (0.0012 in) Limit: 0.1 mm (0.004 in) I beyond the specified limit, replace it or resurface it. Resurfacing limit: The resurfacing limit of cylinder head is determined by the cylinder block resurfacing in an engi Amount of cylinder head resurfacing is “A’ ‘Amount of cylinder block resurfacing is “B The maximum limit is as follows: ‘A + B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced. Nominal cylinder head height: 126.3 - 126.5 mm (4.972 - 4.980 in) CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear. CAMSHAFT RUNOUT 1. Measure camshaft runout at the center journal Runout (Total indicator reading): Standard: Less than 0.02 mm (0.0008 in) Limit: 0.04 mm (0.0016 in) 2, If it exceeds the limit, replace camshaft. CAMSHAFT CAM HEIGHT 1, Measure camshaft cam height. Standard cam height: Intake 42.415 - 42.605 mm (1.6699 - 1.6774 in) Exhaust 42.415 - 43.005 mm (1.6699 - 1.6931 in) Cam wear limit: Intake & Exhaust 0.2 mm (0.008 in) 2, I wear is beyond the limit, replace camshatt EM-25CYLINDER HEAD Inspection (Cont'd) CAMSHAFT JOURNAL CLEARANCE 4. Install camshaft bracket and tighten bolts to the specified torque. 2. Measure inner diameter of camshatt bearing, Standard inner diameter: 28,000 - 28.025 mm (1.1024 - 1.1033 in) 3. Measure outer diameter of camshaft journal. ‘Standard outer diameter: #1 journal 27.935 - 27.955 mm (1.0998 - 1.1006 in) #2 to #5 journals 23.935 - 23.955 mm (0.9423 - 0.9431 in) 4. If clearance exceeds the limit, replace camshaft and/or cylinder head Camshaft journal clearance: Standard 0.045 - 0.080 mm (0.0018 - 0.0035 in) Limit 0.15 mm (0.0059 in) CAMSHAFT END PLAY 4. Install camshaft and thermostat housing in cylirder head. 2, Measure camshaft end play. ‘Camshaft end pl Standard 0.070 - 0.148 mm (0.0028 - 0.0088 in) Limit 0.20 mm (0.0079 in) CAMSHAFT SPROCKET RUNOUT 1. Install sprocket on camshaft. 2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.15 mm (0.0059 in) 3. If it exceeds the limit, replace camshaft sprocket. EM-26