o 5 3 az z m a m a nm 2 9 m 2 3S m x a a Ta rm [Ma Pct Ea Pre Re nic ee cH ENGINE FUEL & EMISSION CONTROL SYSTEM — TT ee eae ca eC N ISSAN MANUAL TRANSMISSION a ae D E R AUTOMATIC TRANSMISSION MODEL D21 SERIES TRANSFER a TaMe eS ae ag Ua a) ae CRS Uy a] Ss As] Dee ae ay Pitta ii il © 1989 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., Tokyo, Japan.This manual contains maintenance and repair procsdures for the 1990 Nissan TRUCK and PATHFINDER. 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 information in this manual is based on the latest product informa- tion at the time of publication. The right is reserved to make changes in specifications and methods at any time without noti IMPORTANT SAFETY NOTICE ‘The proper performance of service is essential for both the safety of the ‘technician and the efficient functicning of the vehici 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. ce NISSAN MOTOR CO, LTD. Overseas Service Department Tokyo, JapanGENERAL INFORMATION Cc | SECTION G i” CONTENTS PRECAUTIONS . .. es HOW TO USE THIS MANUAL ..... HOW TO READ WIRING DIAGRAMS IDENTIFICATION INFORMATION ... RECOMMENDED FUEL AND LUBRICANTS .. Gia7 LIFTING POINTS AND TOW TRUCK TOWING G19 TIGHTENING TORQUE OF STANDARD BOLTS . G24sora 2. Before jacking up the vehicl so1292 so1239 PRECAUTIONS The following precautions should be observed to ensure safe and proper service operations. These precautions are not described in each individual section. 1. Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any in. flammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on 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, take care not to lose your balance and drop it. Also, do not allow it to hit against adjacent parts, especially brake tube and brake master cylinder. 4, Before starting repairs which do not require battery power, always turn 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 \ Fender cover sca 6. To prevent scratches and soiling, protect fenders, upholstery and carpeting with appropriate covers before starting servi ing. 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. as instructed and discard used ones. 9, Tapered roller bearings and needle bearings should be re placed as a set of inner and outer races. 10. Arrange the disassembled parts in accordance with th assembled locations and sequence. 11, Do not touch the terminals of electrical components which utilize microcomputers such as electronic control units Static electrical charges stored in your body may damage internal electronic components. 12. After disconnecting vacuum hose or air hose, attach tag which indicates the proper connection to prevent incorrect connection. 13. Use only the lubricants specified in the applicable section or those indicated under “Recommended Fuel and Lubricants”. 14. Use approved bonding agent, sealants or their equivalents when required. 15. The use of the proper tools and recommended essential tools should be used where specified for proper, safe and efficient service repairs. 16. When effecting repairs on the fuel, oil, water, vacuum or exhaust systems, make certain to check all affected lines for leaks. 17. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. GI-3PRECAUTIONS Precautions for E.F.I. or E.C.C.S. Engine 1. Before connecting or disconnecting E.F.I. or E.C.C.S. harness connector to or from any E.F.I. or E.C.C.S. 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 eliminete danger. 3. Be careful not to jar components such as control unit and air flow meter. Precautions for a Catalyst If 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 com- pression, make tests quickly and only when necessery. sciz90} 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. (lean floor GI-4HOW TO USE THIS MANUAL 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 is 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 desianate the particular section, and a number (2.9. “FA-S"). THE LARGE ILLUSTRATION is an exploded view (See below) and contains tightening torques, lubrica- tion points and other information necessary to perform repairs, The illustration should be used in reference to the service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. “Example” Drive sat Drive sett Gece et sie OSV Pack sea ip with recommended EB yo Kowa ; spacer / [titan a sel } "/— Greate so outs) e vc ge! ) / Peck sa lip with recommended KES (inside) [Oy a, va 4 ise rotor nen” : ss Vn Wosnee Wee bearing outside” ME {(¢ inairat (UY) scaurion: ‘hen pacing wheel baring 70-157 (8. 16,58. 110) A {ner and cuter whee bearings a the Toate that tare time to provrt med oe of bse using ex snemmas venmare! | Rnmtamse 6. THE SMALL ILLUSTRATION shows 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 illustration. Assembly, inspection and adjustment procedures for the complicated units such as the automatic trans- axle or transmission, etc, are presented in a step-by-step format where necessary. ‘The following SYMBOLS AND ABBREVIATIONS are used: ©: Tightening Torque S.DS. Service Data and Specifications + Should be lubricated with grease, LH, R.H.: LeftHand, Right Hand Unless otherwise indicated, use wy Manual Transaxle/Transmission recommended multipurpose grease, AIT: Automatic Transaxle/Transmission 1 Should be lubricated with oil ool ocean celia : Sealing point : Checking point e@ & Always replace when disassembled. GI-5HOW TO USE THIS MANUAL 10. 1. The UNITS given in this manual are primarily expressed with the SI UNIT (International System of Unit), and alternately 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 AND CORRECTIONS are included in sections dealing with complicated components. SERVICE DATA AND SPECIFICATIONS is 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. GI-6HOW TO READ WIRING DIAGRAMS WIRING DIAGRAM ‘Symbols used in WIRING DIAGRAM are shown below. Example ‘BRANCH MIT model @ = rT moder @®: NT moos! +t ABBREVIATIONS CONNECTOR ‘This shows that those connectors are white, terminal connectors (wie) ‘nee oN elses SaEgrUse & aa ‘BLOCK POWER SUPPLY (This shows the fn tion switeh position in which the system can be operated, 1# See POWER SUPPLY ROUTING in EL section for the de wiring eiagram switcH This shows tht cont- nuity exits between terminals © and @), when the snitch ie turned t9 ON position. TSNITION SWITCH HE LOCATION NUMBER “This number shows where the connector located. Soe HARNESS LAYOUT in EL fection, The number i identical with tha one in HARNESS LAYOUT, 1: Instrument | mt harmed | Main hacness ‘SWiTER WIRE COLOR CODING 8 Black BR = Brown We = Wie OF = Orange GROUND f= Rea Po Pink G =Green PU Purple Lo ete Gy = Gray Y= Yellow 5B = Sky Blue LG = Light Green Wien the wire colar is striped, the base color is given fit, followed by the stipe ‘olor a shown below: Example: L/W = Blue with White Stripe soi2er| GI-7HOW TO READ WIRING DIAGRAMS Normally open Se Normally closed ae Ft cm : C Connector ‘ Example a oe Connector Guide Guide Connector Connector symbol sci269 SWITCH POSITIONS Wiring diagram switches are shown with the vehicle in the following condition: © Ignition switch “OFF”, © Doors, hood and trunk lid/back door closed. © Pedals are not depressed and parking brake is released. CONNECTOR SYMBOLS © All connector symbols in wiring diagrams ar2 shown from the terminal side. ‘¢ Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.HOW TO READ WIRING DIAGRAMS Example View from terminal side. connector symbol Connector Direction mark & ‘View from harness side Connector symbol a Goa od ‘Double tines DIRECTION MARK A direction mark is shown to clarify the side of connector (terminal side or harness side). Direction marks are mainly used in the illustrations indicating terminal inspection. rea) iS ‘* All connector symbols shown from the terminal side are enclosed by a single line. [SA view om sie ‘* All connector symbols shown from the harness side are enclosed by double lines. View from terminal side... TS. HS. Connecor MULTIPLE SWITCH The continuity of the multiple switch is identified in the switch 861364) chart in wiring diagrams. Example wren swircn Torr) ni]of wasn] Continuity circuit of wiper switeh 1 SWITCH POSITION CONTINUITY CIRCUIT —ev—, 2 lol OFF a —r-@D] [FO Dolo iNT 34,506 —weBlEf|1]5| [4[olo 10 3-6 —u fe 2] [s|_lo a 76 —B: ll |o oO WASH 1-6 —y Example: Wiper switch in LO position Continuity circuit: Red wire ~ @) terminal ~ @) terminal — Wiper switch (@— @ LO) ~ © terminal ~ © terminal — Black wireHOW TO READ WIRING DIAGRAMS SUPER MULTIPLE JUNCTION (S.M.J.) © The “S.M.J." 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 wiring diagram. “Example” ‘STARTING SYSTEM STARTING SYSTEM. SUPER MULTIPLE JUNCTION (6) heck i ow) ARSE RAR BRE ep eter oh page fea ca}. e2lralea| Kbalezleal > fealealaa (Foldout page). J |a3je3|c3}—fe3|F3|ca| Jo3|F3|e3 emg 3]83]A3] a o L ale [rs|c4] shes] irsica ted in fara Olas harness) OD Dery fe slr else [sefralee/ojceleelas| . 4 mo a tee ent GI-10IDENTIFICATION INFORMATION Model Variation 2WHEEL DRIVE TRUCK ; i ransmission ‘SSW7IC (Floor shift) (Column shift) ‘SBROA (Floor shift) i | ‘Regular Cab | E | standara wheelbase | SLD21FBU ‘SLD21YBU_ - - ge e ksuGo21FeU | KSLGD21KBU - - - 83) crocm g? SE | Long wheelbase - - - KHLGD21PFBU | KHLGO21PKBU = [Heavy duty | & = = - EHUGD21FBU | EHLGD21KBU & | Heavy duty | & - - - EHUGD21FBV | EHLGD21KBV Bfeuce LE = 4-WHEEL DRIVE TRUCK een <8 ee 8a Body Hereniat carrier RIBOA 200 2008 +2338 200A 12338 2 | Regular cab e ‘Standard wheelbase SLYD21FBU. HLYD21FBU HLYD21KBU i be 23] King cab ‘Long wheelbase f¢ a B>| King cb Lone wheebse SE - KHUMO2IPFeV | KHLMO2IPKBV nase = GI-11IDENTIFICATION INFORMATION Model Variation (Cont’d) 4.WHEEL DRIVE PATHFINDER Engine ‘VGu0E: 5 Teaamision FSSRI0A REAROTA i easter p10 x10 Dittereni earier Fee ea come Ps 80a 200A, wane 200 1038 x waLyo2iFBu WaLyo21sKBU Weson se WaLYD21PFBU waLyo2teKeu | oe watyo2iev waLyo21sKev Wao se WHLYo2iPFBV watyo2teKev| 3 xe VHLYD21JFaN vHLYo21aKBN F | ven 6 se VHLYo2teFeN VHLYD21PKBN Prefix and suffix designations: KHL Moa PF BU a vince ____| LL. Non California, US.A. K 5 King Cab L—v : California, U.S.A E : Heavy duty Ln : Canada We: Wagon: EFI engine Vv: Ven——— * S + KA24E engine F Manual transmission Hs VG3OE engine —J (Ssspeed floor shift) [——Y = Automatic transmission (Column shit) Se ie Lx : Automatic transmission Cl: Standard wheelbase (20D) (speed Ror srt G = Long wheelbase (2D). o:e Y + Standard wheelbase (4WD) ore M = Long wheelbase (4WD) Lp: se Note: [1 means no indication, GI-12IDENTIFICATION INFORMATION Identification Number Emission control << information label Venice , one "7 a ‘number pi 7 ‘entification number (Chassis number) Con VEHICLE IDENTIFICATION NUMBER ARRANGEMENT wN6-H.D 11S * LW C0001 Vehicle serial number LE Manufacturing plant We: Kyushu © + Smyrna, Tennessee Manufacturer: JN6: Truck NB: U.S.A. produced truck LNB: Multi purpose passenger vehicle Engine type Hs VG30E S: KA4E Model year L: 1990 year mode! ‘Check digit (0 to Sor X) ‘The code for the check digit is determined by mathematical computation. Vehicle line D = Nissan Truck, Nissan Pathfinder Model change (0 to 9) Other information Bodh ad S : Standard 1+ Standard wheelbase Ys wheel drive 2 + Long wheelbase Te tee dan 2 Heavy duty 4: Van v 6 + King Cab, Wagon GI-13IDENTIFICATION INFORMATION Identification Number (Cont'd) IDENTIFICATION PLATE NISSAN MOTOR CO,, LTD. JAPAN Bt to A ro ons 4a ocr = A 1 yee 9-08 2 Vane entation number Ocean een AA (Chassis number) = 00m 2. owe aad AA 4 ody color code Coe as. me 5 Trim sao ose 35 eo aa & Erne moda =e Ut 4 Ercineduleent s 2 Traronsen moe! BEB RRS Ht woes 8 Axle model soiats ENGINE SERIAL NUMBER \VGR0€ engine KA2GE engine OF TRANSMISSION SERIAL NUMBER Manual transmission number RLAROIA < Automatic transmission number TRANSMISSION SERIAL NUMBER RE4RO1A, TRANSFER SERIAL NUMBER sourIDENTIFICATION INFORMATION Dimensions Truck Units mm ind Bawheel drive “heel drive Regular Cab King Cob Heavy duty Regular Cab King Cab Standard ‘Standard wheeibase Co wets Lone whelbase = 4,495 4825 ‘4825 4825 4.435 4825 (74s) (190.01 (190.0) (190.0) 117461 (190.01 overall width 1.550 1,550 1,950 1,650 1,690 1.590 (65.0) (65.0) (60) (60) (66.5) (605) Overall eight 1575 1575 1575 1,695 1,695 (cA24E engine motels), 20) (20) 0) - an an Overall height _ - 1575 1575 1,695 4,708 (VG30E engine models), (2.0) (20) (68.7) ey Front teed 1,395 1,395 1,395 . 1425 1428 (KA24E engine models) 649) a9) as) (56.1) (66.1) Front teed . 1415 1,396 1425 1485 (VG30E engine models) - (5.7) as) (56.1) (669) Rear tread 1,385 1,385 1,385 _ 1.205 1,386 (KAZAE engine models) 645) a5) as) was) as) Fear ead _ _ 1.430 ato 1410 1430 (VGS0E engine models) (66.3) (555) 55) (66.3) Wheelbase 2.650 2.360 2360 2,950 2850 2.950 (04.3) wien) (16.1) 6.0) (08.2) 16.) ace Length 1375 2.265 11895 2.266 1875 1,996 Cote a 038) ‘eo2) as) (92) (33) (748) wrath 1520 1.520 11520 1.520 1.520 1,520 a8) oa) 98) soa) 08) 98) eight 435 435 435 435 435 438 2 a7 any a) a7 i) a7) Tr On step bumper equipped madely, the bumper odds 140 mim TSB ia tothe Overal Torah Pathfinder Unit:_mm (in) Wagon & Van VG30E Overall length “1 4,965 (171.9) Overall width 1,690 (665) Overall height 1,670 (65.7)/1,680 (66.1)"2 Front tread 1,425 (56.1)/1,445 (56.9)"2 Rear tread 1,410 (65.5)/1,430 (56.3)*2 Wheelbase 2,660 (104.3) |}: On models with a spare tire carrier, the overall length is increased by the following lengths depending on the spare tire. 230 mm (9.1 in) for P215/7R tires, 260 mm (10.2 in) for P296/75R tires, 275 mm (108 in) for 10.5R tires. "2: SE model GI-15IDENTIFICATION INFORMATION Wheels & Tires Body Grede Road wheel/offset_ mm (in) Tire 5-4x14/40 (1.57) e etuiciarse isis P198/75R14 Regular and King Ca —§ $$" 42 6 49x14/90 (1.18) se {610x414 Aluminum/30 (1.18)* eee Heavy duty E 5.Jx14/40 (1.57) LT195/75R14 5-1/2-Kx18/40 (1.57) e 6-JUx15/30 (1.18) ence xq Regular, King Cab P215/75R15 44 and Pathfinder xe ceca P236/75R 15" 5 (6:4dx15/90 (1.18) 236/75R15 7lde15 Aluminurn/25 (0,98)" 31x10.5R1" Option GI-16RECOMMENDED FUEL AND LUBRICANTS Fuel and Lubricants Capacity (Approximate) Recommended Fuel/Lubricants core a= a) ual 187/8go1 _—13-1/4ge1— 0 ‘Unleaded gasoline with an octane 2Va/Bgal") 175/88!" 801 rating of st leat 87 AKI (RON 91) Engine ot (Refi) 'VGI0E-2WO—Withoilfiter aalagt sarzat 40 Without oit iter 31784 37Bat 36 VGa0E © 4WD——_Withoilfiter 35/aa¢ Bat 34 Without ot fiker 3a7B qt zea 3.0, Energy Conserving Ois*3 KA2E 2WD—Withoil fier 41/8 at 3/8. 39 of APISG Without oi ier saiaqe—3-4/8ar 35 KAZE AWD Withoilfiter Bide -27/8at 33 Without ol iter 38a Zara 23 {Coating system (With heater) Vo30E ND 13/Bqt_—83/8.at 107 a0 129/8qt tote 117 ‘Antitroeze coolant KAME = ND BSBqt | 74/B.at ai (Ethylene aiveo! bose) 40 12g Tage 910 anual raamision —-FSWT1G—« WO ANAL = BABE 20 7 avo -B1/2er Tat 40 ae Cr FSSRS0A -2WO | S1/B pt At/apt 2 APEGLa2 aw 78/Bot GBT 88 “ranstor gear oi! 25a 2at 22 ‘Type DEXRON™ Manual steering gsr ol! 34pt sap 033 API GLA"? Differential carrier gear oi Raat: #11908 31 ——25/B pt 15 ‘Standard differentia gear e200 23/4 21/4 13 API GL-S°2 2336 7p 47e 2B Limitedslip iffrontal(L.S.0.) ar: Use only LSD gear oil APIGLS Front (AWD): R608 23/4 2-118 13 and SAE 80W.90°5 approved 2008 1B 25/8 15 for Nissin LSO*6, “Automatic transmission 2WD 83/84 Tat 79 Genuine Nisin ATF*4 or equivalent fluia ao 9at Tia 85 ‘Typa DEXRON™ Power steering fuld 2178p 13/4 pt 10) “Type DEXRON™ ‘Genuine Nisan Grake Fluld"4 or ‘rake and clutch fluid = = 5 equivalent OT 3 (US FMVSS No, 116) ‘Mult-purpose grease = = = NUGI No. 2 (Lithium soap base) Free-running hub grease (Auto-lock) = = = Genuine Nissan grease or equivalent 2: +3: 4: +5: ‘VG30E engine models except 20D Truck SE mode For further details, se the recommended SAE viscosity number char. “These oll can be identified by suc labels es EC, EC, energy conserving, enargy saving, improved ful economy, ete. Availabe in mainland U.S.A. through your Nissi deal [SAE 90 is accoptabie in ambient temperatures above —18°C (OF. Contact a Nison dealer for list of proved oil, GI-17RECOMMENDED FUEL AND LUBRICANTS. SAE Viscosity Number ‘Outside Temperature Range Aotieipated Before Next Oil Change ‘Outside Temperature Range Aaticipated Before Next Oil Change PREFERRED Tr0008 0003 5W-30 is preferable for all ambient temperatures. 20W-40 and 20W-50 are usable if the ambient temperature is above 10°C (50°F) for all seasons. ‘75W-90 for transmission, and 80W-90 for differ- ential are preferable if the ambient temperature is below 40°C (104°F). GI-18LIFTING POINTS AND TOW TRUCK TOWING WARNING: ‘a. Never get under the vehicle while i the frame when you have to get under the vehicle. b. Place wheel chocks at both front and back of the wheel which is diagonally opposite the jack position. Example: If the jack is positioned at the L.H. front wheel, place wheel chocks at R.H. rear wheel. Screw Jack is supported only by the jack. Always use safety stands to support Front (2-whoel drive model) Front (4-whesl drive model) Rear Front ce0os6M CAUTION: Garage Jack and Safety Stand '* Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat. 2WHEEL DRIVE 4 WHEEL DRIVE ~ GI-19LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift WARNING: When lifting the ‘open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines. GI-20LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing CAUTION: © All applicable state or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. * 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. ‘© Attach safety chains for all towing. © When towing, make sure that the transmission, steering system and power train are in good order. If any unit is dam- aged, a dolly must be used. ‘© When towing with the front wheels on the ground: Turn the ignition key to the “OFF” position and secure ‘the steering wheel in a straightahead position with a rope or similar device. Never place the ignition key in the “LOCK” position. This will result in damage to the steering lock mechanism. ‘© When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral (“N” position). © Never tow vehicle from the rear (ie., backward) with four ‘wheels on the ground as this may cause serious and expensive damage to the transmission. * For 4-wheel drive model: Set the free-running hubs to the free position and move both the gearshift and transfer levers to neutral (”"N” position). 2WHEEL DRIVE MODELS NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated. ‘Towing with four wheels on ground or towing with front wheels ed (With rear wheels on ground) Observe the following restricted towing speeds and distances, ‘Automatic transmission model: Speed Below 50 km/h (30 MPH) Distance Less than 65 km (40 miles)LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont'd) Manual transmission model with KA24E engine: Speed Below 95 km/h (60 MPH) Distance Less than 800 km (500 miles) Manual transmission model with VG30E engi Speed Below 95 km/h (60 MPH) Distance Less than 320 km (200 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the trans- mission, 4WHEEL DRIVE MODELS NISSAN recommends that a dolly be used as illustrated when towing 4-wheel drive models. ‘Towing with four wheels on ground or towing with front or rear wheels raised Observe the following restricted towing speeds and distances. ‘Automatic transmission model: Speed Below 50 km/h (30 MPH) Distance Less than 65 km (40 miles) Manual transmission model: Speed Below 95 km/h (60 MPH) Distance Less than 800 km (500 miles) If the speed or distance must necessarily be greater, remove the front and rear propeller shafts beforehand to prevent damage to the transmission. GI-22LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont'd) TOWING POINT © Never tow the vehicle using only the towing hooks. Use proper towing equipment when towing. Otherwise, the vehicle body will be damaged. © Always pull the cable straight out from the vehicle, Never pull on the hook at a sideways angle. Front (x2) ear (TRUCK) ) Rear PATHFINDER) | 20 NOT Use tor toning. eros GI-23TIGHTENING TORQUE OF STANDARD BOLTS jolt dia. Tightening torque (Without lubricant) + Grade | Botesize | BONS | Pitch mm - ——— = meter? mm Hexagon head bolt Hexagon flange bole Nem kom | feb | Nm | kom | felb me | 60 10 51 052 38 61 | oe | 45 | 125 18 13 9 16 15 1 Me 80 10 3 13 8 16 16 2 [15 2 25 18 2 30 2 at | omio 100 + 125 25 26 19 30 31 2 175 a2 43 3 3 52 8 m2 120 — 125 46 a7 34 56 87 at m4 140 18 74 75 54 88 90 6 Me 60 10 a 086 62 10 10 7 125 2 21 6 Ey 25 8 Me 80 10 2 22 16 26 27 20 18 a 42 30 48 49 35 a | mo 100 125 a a4 2 5 52 | 38 175 7 72 2 4 86 a m2 120 125 | 77 79 87 9 94 6 140 18 127 130 ay va7_| 180 | 108 60 10 2 12 2 15 15 n | 125 29 30 2 35 36 26 Me 80 10 a 32 23 37 38 2 18 59 60 a3 70 7 5 ot | M10 100 125 2 63 46 74 75 =a 178 8 700 7 vie | 120 | a7 m2 120 + 125 108, 110 20 va7_| 140 | 101 mia 140 18 7 780 v0 | 206 | 210 | 152 1. Special parts are excluded. ‘his standard is applicable to bolts having the following marks embossed on the bolt head. + Nominal diameter Grade Mark m6 AT cessniinnnnnincnee T— Nominal diameter of bolt threads (Unit: mm) my ee ceorene or 8 24| | | te CONTENTS PREPARATION . . aneett PERIODIC MAINTENANCE . GENERAL MAINTENANCE .. ENGINE MAINTENANCE CHASSIS AND BODY MAINTENANCE SERVICE DATA AND SPECIFICATIONS (S.D.S.) ........00.000cc0eeeeeeeee eee MAINTENANCE SECTION MAFor engine maintenance PREPARATION SPECIAL SERVICE TOOL Too! number Engine Application (KentMoore No.) Description Tool name ves0e | KA2IE kv 10105900 Removing oil filter (434274) i filter cap wrench x - MA-2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 Periodic 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. Maintenance for off-road driving (EZYonly) Whenever you drive off-road through sand, mud or water, more frequent maintenance may be required of the following items: Brake pads and discs Brake lining and drums Brake lines and hoses ‘Wheel bearing grease and free-running hub grease Differential, transaxle and transfer oil Steering linkage Propeller shaft and drive shafts Air cleaner filter Clutch housing (Check water entry. Refer to MA-22.) Pr rrr rrr MA-3PERIODIC MAINTENANCE Schedule 1 Ta s1ON ms EOI (@ 310N #5 amedemsnPl “Gg vas ze suey ay Sib GUE GLEE OF Sze Gz SM SI se AWAWBINI_ZONVNAANIVHE sean auy Ht 1PERIODIC MAINTENANCE Schedule 2 -pouinbo1 ove syensequs pue stor) soueuort soueuazuyews yons wo}sad you peou soumo ayy. "uoresedo 0 a 20420 “A “yBiy Ajoonxe 40 mo} Ajowa.n%: joes sesmaejnuew 0 Au 20) NVSSIN Aa papuounooes ave verpaun wou aejdos “ue 10 eve soumeseduo yotquse e104 s0r8 uy 40 suoRpUOD JeNIEEM esienpeAJoulenx®Hepun paveiodo Jem Uoyss}U9 a4p urerUIeW 0% JF MBM syeAs9)U pul Sura)! soUEUERUIEWY.(Z) tue ons U} paBBo}2 euloseq 14B1U 51 Te H 7 7 r ans are avn ¥ 1 @ 1 ESE) ea rg BUT ssa Beg vO TW 7 1 : (ea) nS Bg UM TUOES wav 1 sewn 1 i H i a SE zw 1 o scwn = 7 z T paar i o 4 aeEWW 1" 1 1 1 “evn o 1 1 1 ‘sauBUaTUTeU ApoG pue erwa ‘five soon 30BDAT ecw i eT zc¥n z u Tivejebe 209d WHIMS WSN ST) Town! a a evn = Tew! SIONS onwn! SEW | - a ~ TE aLON eS Pwo onan SpE) MD TROD iw! en BT Boon ‘SouBUayUTEU WaNSAS [OHIO W wo ao 7 (98) ee) (2A) (00) (8H) (90) we) (eH) oo gs gy su of sz st SL TWAUBINI JONVNSINIV NoIv¥ad0 3ONYNSLNIV Thesaoou jy aoeKdan ia oae9 “weeshuy =| Soeday =H HONENBIGEY MA-5GENERAL MAINTENANCE General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the checks and inspections themselves or they can have their NISSAN dealers do them for a nominal charge. them ‘OUTSIDE THE VEHICLE ~ ‘The maintenance items listed here should be performed from time to time, unless otherwise specified. Reference page ‘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 nuts, Tighten if necessary. Tire rotation Tires should be rotated every 12,000 km (7,500 miles.) MA43 Wheel alignment and balance If the vehicle should pull to either side while driving on a ht 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. MA.30 Windshield wiper blades Check for cracks or wear if they do not wipe propery 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. Lubicate 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: h INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, ete. 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. Ma46 Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are ‘operating properly. 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 conditioner. ‘Steering wheel Check that it has the specified free play. Be sure to check for changes in the steering condition, such as excessive free play, hard steering or strange nolses. 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 head restraints move up and down smoothly and that the locks (if so equipped) hold securely in all latched positions. Check that the latches lock securely for foldingdown 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 webbing for cuts, fraying, wear or damage. MA-6 Maa?GENERAL MAINTENANCE em Reterence page Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free travel. Brakes Check that the brake does not pull the vehicle to one side when applied MA21 Brake pedal Check the pedal for smooth operation and make sure it has the proper distance: under it when depressed fully. Check the brake booster function, Ma39 Parking brake Check that the lever has the proper travel and confirm that your vehicle is held securely on a fairly steep hill with only the parking brake applied. Ma39 ‘Automatic transmission “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 periodically (e.9, each time you check the engine oil or refuel). Windshield washer fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant level when the engine is cold. Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, fte., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or loose connections. MA-10, 16 Brake and clutch fluid levels Make sure that the brake and clutch fluid levels are between the MAX" and “MIN” lines on the reservoir. Battery Check the fluid level in each cel. Itshould be between the "MAX" and "MIN" lines Engine drive belts Make sure that no belt is frayed, worn, cracked or oily MAS, 15 Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and arate turning off the engine. " Power steering fluid level and lines Check the level when the fluid is cold and the engine is maa ‘turned off. Check the lines for proper attachment, leaks, cracks, ete. “Automatic transmission fluid level Check the level on the dipstick after putting the selector a lever in “PY with the engine idling Exhaust system Make sure there are no loose supports, cracks or holes, Ifthe sound of the ‘exhaust seems unusual or there is @ smell of exhaust fumes, immediately locate the trouble mat and correct it. Underbody The underbody is frequently exposed to corrosive substances such as those used fn icy roads or to control dust. It is very important to remove these substances, otherwise rust 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 hhas 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-7ENGINE MAINTENANCE VG30E Checking Drive Belts V check point 2 FB pan essen N steering ‘bump pulley _~ compressor pulley \ (4-17 (1447, 10-12) Whve-21 08-24,12-18) Ne c \L sttrnatrputey \Lerank pulley TD: Ne keen, fe) sMa20sc 1. Inspect for cracks, fraying, wear or oil adhesion. if necessary, replace with a new one 2. Inspect drive belt deflection by pushing on the belt midway between pulleys Adjust if belt deflection exceed the limit. Belt deflectio Unit: men {in} Used belt deflection Deflection of lDetiection after] — new belt Limi " adjustment 6-8 8-7 Alternator 121047) | (924-0.31) | (020-0.28) ‘ir conditioner an 7-9 compressor 16(063) | (9,350.43) | (0.28 -0.35) Power steering oil 11-13 on pump 17(087) | (943-051) | (0:35 -0.43) ‘Applied pushing force 98 N (10 ka, 22 1b) Inspect drive belt deflection when engine is cold. MA-8ENGINE MAINTENANCE © 2018 ECE (eS ee) a sua206c Bottom left side [Swazoee VG30E Changing Engine Coolant WARNING: To avoid being scalded, never change the coolant when the engine is hot. 1, Move heater “TEMP” control lever all the way to “HOT” position. 2. Open drain cock at the bottom of radiator, and remove radiator cap. Be careful not to allow coolant to contact drive belts. 3. Remove drain plugs on both sides of cylinder block. 4, Close drain cock and tighten drain plugs securely 1: 34 - 44. Nem (8.5 - 4.5 kg-m, 25 - 33 ftb) ‘Apply sealant to the drain plug thread. MA-9ENGINE MAINTENANCE VG30E ‘Changing Engine Coolant (Cont'd) Open air relief plug Fill radiator with water and close air reliet plug Start engine and warm it up sulticientl Stop engine and wait until it cools down. Ropeat step 3 through step 8 until clear water begins to drain from radiator. 10. Drain water 114. Open air relief plug again. 12. Fill radiator with coolant up to specified level. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. eee = ‘Goolantcapscity 20 ao ‘Without reservar tank 9.911012, 83/4) 10911172, 957) 'sMaie26| max. — wn smaai2e on ® 4p 3mm (0.12 in) i! Fost hom clamps eer (0:0-0.15kem, oF rem Revervoir tank 0.8 718,318) Pour coolant through coolant filler neck slowly to allow air in system to escape 19. Remove reservoir tank, drain coolant, then clean reservoir tank 14, Fill reservoir tank with coolant up to "MAX" level 16. Close air relief plug again 16. Run engine and warm it up. 17, Stop engine and cool it down, then add coolant as necessary Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. Hf necessary, repair or replace malfunctioning parts. CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Tightening torque specifications ar clamps. Ensure that screw does not contact adjacent paris the same for all rubber hose MA-10ENGINE MAINTENANCE GSIE Changing Fuel Filter WARNING: Before removing fuel filter, release fuel pressure from fuel line to eliminate danger. 1. Remove fuse for fuel pump. Fuel pump 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is released, 4, Turn ignition switch off and install fuse for fuel pump. 5. Loosen fuel hose clamps. 6. Replace fuel filter. © Be careful not to spill fuel over engine compartment. Place a 10p 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 Lines”. Changing Air Cleaner Filter The viscous paper type filter does not need cleaning between renewals. Changing Engine Oil WARNING: Be careful not to burn yoursel, as the engine oll is hot. 1. Warm up engine, and check for oll leakage from engine components. 2. Remove drain plug and oil filler cap. Drain plug ~ swaarzc MA-11ENGINE MAINTENANCE GSE efi of to "A" lve. Do not overfl a suasa26| (sa274) Kv10105900 suaoro Changing Engine Oil (Cont'd) 3. Drain oll and refill wth new engine oi ll capacity (Refill): (US at, Imp at ——— ‘wD 4wD With oil filter change 4.01414, 3-1/2) | 3.4(3-5/8, 3) Without oll filter change 3.6 (37/8, 3-1/8) | 3.0(3-1/8, 2-5/8) CAUTION: © Be sure to clean drain plug and install with new washer. ll pan drain plug: 1:29 - 39 Nem (8.0 - 4.0 kg-m, 22 - 29 ft-b) Use recommended engine oll. The refill capacity changes depending on the oil temperature and drain time, use these values as a reference and be certain to check with the dipstick when changing the oil. 4. Check oil level. 5. Start engine and check area around drain plug and oil filter for oll leakage. 6. Run engine for a few minutes, then turn it off, After several minutes, check oll level Changing Oil Filter 1. Remove oll filter with Tool WARNING: Be careful not to burn yourself, as the engine and engine oil are hot. 2. Before installing a new oil fier, clean the oil filter mounting surface on cylinder block, and coat the oil filter rubber seal with a little engine oil MA-12ENGINE MAINTENANCE 219 of ane fe ‘Do not hold the cab suaoese Wench with 2 magnet te hold spark plug sem toss ia) semaoen Side electrode Smaa7s Va Tanition wre fixing pin VV ‘VG30E Changing Oil Filter (Cont'd) 3. Screw in the oil fiter until a slight resistance is felt, then tighten additionally more than 2/3 turn. 4, Add engine cil Refer to Changing Engine Oil. Changing Spark Plugs 41. Disconnect ignition wires from spark plugs at boot. Do nct pul on the wire 2. Remove spark plugs with spark plug wrench, Spark plu Standard type BKREY Hot type BKRSEY Cold type BKRTEY 3. Check spark plug gap of each new spark plug. Gay (0.8 - 0.9 mm (0.031 - 0.035 in) 4, Install spark plugs. Reconnect ignition wires according to Nos. indicated on them, ‘When installing spark plugs to No. 2 and 4 cylinders, securely fit ach ignition wire mounting hole onto the ignition wire fixing pin. Spark plug: 20 - 29 Nem (2.0 - 3.0 kg-m, 14 - 22 ft-lb) MA-13ENGINE MAINTENANCE cee Checking Vapor Lines 4. Visually inspect vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration 2. Inspect vacuum relief valve of fuel tank filer cap for clogging, sticking, etc Rofer to “EVAPORATIVE EMISSION CONTROL SYSTEM" in EF & EC section. MA-14ENGINE MAINTENANCE eae Power steering oil pump. Checking Drive Belts f 4, Inspect for cracks, fraying, wear or oil adhesion. If necessary, (PTE wer cume replace with a new one 2. Ingpect drive belt dstoctions by pushing on the belt midway between pulleys ‘Adjust I belt deflections exceed the limit Belt deflection: Lanereaior cond Inspect drive belt deflections when engine is cold. 1: Tensioncheckingpoint COMPTHEE Unit: mu fin) TAL: Adjusting bates smaooe Used belt deflection Gee Deflection after of Kine adjustment | new belt 10-12 8-10 Alternator 171067) | (39.0.7) | (031-039) Air conditioner me 10-12 8-10 ‘compressor | (039-047) | (031-039) Power steering | 9-11 7-9 cil pump 18059) | (935-043) | (028-035) ‘Applied pushing faa 98 N (10 kg, 22 1b) Changing Engine Coolant WARNING: To avoid being scalded, never change the coolant when the engine is hot. 1, Move heater “TEMP” control lever all the way to “HOT” position 2. Open drain cock at the bottom of radiator, and remove radiator cap. MA-15ENGINE MAINTENANCE OZ ZN SS = lug Radiator KAZ4E Changing Engine Coolant (Cont'd) 3. Remove cylinder block drain plug 4. Close drain cock and tighten drain plug securely. © Apply sealant to the thread of drain plug. 1:34 - 44 Nem (85 - 4.5 kg-m, 2 - 33 fb) Open air relief plug Fill radiator with water and close air relief plug and radiator cap. 7. Run engine and warm it up sufficiently 8. Race engine 2 or 3 times under no-load 9. Stop engine and wait until it cools down. 10. Repeat step 2 through step 9 until clear water begins to drain from radiator. 411. Drain water oe 12. Open radiator cap and air relief plug, 13, Fill rafdiator with coolant up to specified level Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Unit: @(USat, Imp att = ‘Gaotantcapacrty 2D 7.3 (7-314, 53/8) Without reervoir tank suaarze Fuel line ® suanisc Sesesaeavsenseenstaevensevied Reservoir tank 08 178, 374) TOOT PEP TreT Pour coolant through coolant filler neck slowly to allow air in swaisze| system to escape. 44. Close air relief plug, 415. Remove reservoir tank, drain coolant, then clean reservoir tank. 416. 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. 19. Stop engine and cool it down, then add coolant as necesary. Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterio- ration. Ht necessary, repair or replace faul'y parts. MA-16ENGINE MAINTENANCE 3mm (0.129) smagoea Fuel pump Zz 5ma2008 Swazsae KA2aE Chee! 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. ig Fuel Lines (Cont'd) Changing Fuel Filter WARNING: Before removing fuel filter, release fuel pressure from fuel lin 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 released 4. Turn ignition switch off and install fuse for fuel pump, 5. Loosen fuel hose clamps. 6. Replace fuel filter ‘@ Be careful not to spill fuel over engine compartment. Place shop towel to absorb fuel. © Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filte ‘@ When tightening fuel hose clamps, refer to “Checking Fuel Lines”. Changing Air Cleaner Filter The viscous paper type filter does not need cleaning between renewals. MA-17ENGINE MAINTENANCE [KA24E 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. 2. Remove drain plug and oil filer cap. 3. Drain oil and refill with new engine oil Refill oil capacity (Approximat Unit: @ (US at, Imp at) o not overfill suaoro) — 20D 4wD With ol filter change 3.9 (4-1/8, 3-9/8) | 3.3 (3-1/2, 2-7/8) Without oil filter change | 3.5 (33/4, 3-1/8) | 2.9(3-4/8,2-1/2) ‘CAUTION: © Be sure to clean drain plug and install with new washer. Drain plug: 1): 29 - 39 Nem (8.0 - 4.0 kg-m, 22 - 29 ft-lb) © Use recommended engine oil. © The refill capacity changes depending on the oll temperature and drain time, use these values as a reference and be certain to check with the dipstick when changing the oll. 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. Changing Oil Filter 1. Remove oil filter with a suitable tool. WARNING: Be careful not to burn yourself, as the engine and the engine re 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 MA-18ENGINE MAINTENANCE [kazae] Changing Oil Filter (Cont'd) 213 of turn 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. cK. Changing Spark Plugs 1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire. sewzo4n 2. Remove spark plugs with spark plug wrench. Spark plug: ‘Standard type ‘ZFRSE-11 Hot type ZFRAE-11 Cold type ‘ZFRGE-11 side electrode suaare) 3, 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 plug 1:20 - 29 Nem (2.0 - 3.0 kg-m, 14 - 22 ft-tb) 4 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, etc. Refer to EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION in EF & EC section. z ML All MA-19ENGINE MAINTENANCE KA24E Changing Air Induction Valve (A.LV.) Filter Remove air induction valve case and take out air induction valve fiter. Then install new air induction valve fier. Changing Positive Crankcase Ventilation (P.C.V.) Filter Remove air cleaner cover and take out P.C.V. filter located inside air cleaner cover. Then install new P.C. filter. MA-20CHASSIS AND BODY MAINTENANCE © Pod Dash floor ~/ panel 7 Floor caret Dash neulator 7 smaaaes! &)) TS > = xB J Checking Exhaust System Check exhaust pipes, muffler and mounting for improper at- tachment and for leaks, cracks, damage, loose connections, chafing and deterioration, Checking Clutch Pedal Operation Check clutch pedal height, free play and smooth operation. Pedal height “H”: KA24E engine 236 - 246 mm (9.29 - 9.69 in) VG30E engine 227 - 237 mm (8.94 - 9.33 Pedal free play “A” 1.0 - 3.0 mm (0.039 - 0.118 in) If necessary, adjust clutch pedal height and pedal free play. Refer to Section CL. Checking Clutch System If fluid level is extremely low, check clutch system for leaks. MA-21CHASSIS AND BODY MAINTENANCE Fillr plug ~L x0 nis evel smaios 1 @) Drain plug vaeal sor. sMaaaoa Checking M/T Oil 1. Check manual transmission for oil leakage. 2. If leakage is found, check oil level. ©: Filler plug 25-34Nem (2.5- 3.5 kg-m, 18 - 25 ftlb) CAUTION: Never start engine while checking oil level. Changing M/T Oil Oil capacity: FSSW71C 2WD = 2.0 liters (4-1/4 US pt, 3-1/2 Imp pt) AWD 4.0 liters (8-1/2 US pt, 7 Imp pt) FS5R30A, 2WD 2.4 liters (5-1/8 US pt, 4-1/4 Imp pt) AWD 3.6 liters (7-5/8 US pt, 6-3/8 Imp pt) Drain ph ©: 25-34N.m (2.5- 3.5 kg-m, 18 - 25 ft-lb) Checking Water Entry — For 4WD model Check water entry in the clutch housing by removing the sealing grommet, whenever driving in deep water or mud. Checking A/T Fluid 1. Check automatic transmission for fluid leakage. MA-22CHASSIS AND BODY MAINTENANCE wD ‘Frontside HoT [50 as Ey C1122 (6 -127°F 1) Ox. ‘COLD [30 -50°e ‘aw Frontside HoT [50 80" (122 -176"F)] (86 122°F) COLD [30-50°e smaeses Chock fai for sal Checking A/T Fluid (Cont’d) 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 dipstick for reference after engine is warmed up and before driving. However, fluid level must be rechecked using “HOT” range. (1) 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 engine 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 overfi 3. Check automatic fluid condition. Check fluid for contamination. If fluid is very dark or smells burned, or contains the frictional material (clutches, band, etc.), check operation of A/T. Refer to section AT for checking operation ot A/T. MA-23CHASSIS AND BODY MAINTENANCE surasaal in to ani veh sMaaooe venicle Changing A/T Fluid 1. Drain fluid by removing oil pan. 2. Replace gasket with new one. 3. Refill with fluid and then check fluid level. (With torque converter): 7.9 liters (8-3/8 US at, 7 Imp at) 4wo 8.5 liters (9 US qt, 7-1/2 Imp qt) Checking Transfer Oil 1. Check transfer for oil leakage. 2. If leakage is found, check oil level “DEXRON™” type Automatic Transmission Fluid is used for the transfer in the factory. Never add gear oil (75W-90) to ‘Automatic Transmission Fluid. Never start engine while checking oil level. Filler plug: DL: 25-34.N-m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) Changing Transfer Oil When changing transfer oil completely, either "DEXRON™” type Automatic Transmission Fluid or gear oil (75W-90) may be used, Do not mix Automatic Transmission Fluid and gear oil. Oil capacity: 2.2 liters (2-3/8 US qt, 2 Imp qt) Drain plug: ©) : 25-34 Nem (2.5- 3.5 kg-m, 18 - 25 ftlb) MA-24CHASSIS AND BODY MAINTENANCE lear _ Check journal for ‘wear or damage, Check catar esing forpcim orders Check tbe sures fovaensor erie creck somtningtraue Front (cheek journals for wear or damage, 7 so (Chock tube surfaces for ants or evecke,. Check sotenng trav Ci: Gomis suase Front Front te _| Fill 0 this level Checking Propeller Shaft Check propeller shaft for damage, looseness or grease leakage. Tightening torque: Refer to section PD. Checking Differential Gear Oil 1. Check differential carrier for oil leakage. 2. If leakage is found, check oil level. Filler plug: Front 1): 39-59 Nom (4-6 kg-m, 29 - 43 ft-1b) Rear 190A, H2338 ©: 59-98Nm (6-10 kg-m, 43 - 72 ft-lb) 200 ©): 39-59N-m (4-6 kg-m, 29 - 43 fb) MA-25CHASSIS AND BODY MAINTENANCE Front sMatos ‘9Ma240 Changing Differential Gear Oil Oil capacity: Front 180A 1.3 liters (2-3/4 US pt, 2-1/4 Imp pt) R208 1.5 liters (3-1/8 US pt, 2-5/8 Imp pt) Drain plug: ): 39-59N-m (4-6 kg-m, 29 - 43 ft-1b) Oil capacity: Rear H1908 1.5 liters (3-1/8 US pt, 2-5/8 Imp pt) 200 1.3 liters (2-3/4 US pt, 2-1/4 Imp pt) 2338 2.8 liters (5-7/8 US pt, 4-7/8 Imp pt) Drain plu ©: 59-98 N-m (6 - 10 kg-m, 43 - 72 ft-lb) Limited-slip differential gear © Use only approved 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. Checking Front Axle and Front Suspension Parts * Check front axle and front suspension parts for looseness, cracks, wear or other damage. (1) Shake each front wheel to check for excessive play. (2) Make sure that cotter pin is inserted. (3) Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to section FA. (4) Check front axle and front suspension parts for wear, cracks or other damage. ‘© Check shock absorber for oil leakage or other damage. MA-26CHASSIS AND BODY MAINTENANCE ©: Multipurpose ‘reat point SFASIEA Checking Front Axle and Front Suspension Parts (Cont'd) © Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage. 19) Front Wheel Bearing © 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, '* Adjust wheel bearing preload after installing wheel bearings or replacing wheel bearing grease. PRELOAD ADJUSTMENT (2WD Trucks) Adjust wheel bearing preload as follows: 1. Before adjustment, thoroughly clean all parts and check them for wear, cracks or other damage. 2. Apply multi-purpose grease sparingly to the following parts: Rubbing surface of spindle Contact surface between lock washer and outer wheel bearing * Hub cap (as shown at the left) © Grease seal lip 3. Tighten wheel bearing lock nut to the specified torque. ©): 34-39 Nem (3.5 - 4,0 kg-m, 25 - 29 ft-lb) MA-27CHASSIS AND BODY MAINTENANCE With caste nut Return angle: Within 45" swar20 'SMAS74A Checking (Replacing) Front Wheel Bearing Grease (Cont'd) 4. Turn wheel hub several times in both directions to seat wheel bearing correctly. 5. Again tighten wheel bearing lock nut to the specified torque. ©: 34-39 Nom (3.5 - 4.0 kg-m, 25 - 29 ft-lb) 6. Turn back wheel bearing lock nut 45 degrees, 7. Fit adjusting cap and new cotter pin. Align cotter pin slot by loosening nut 15 degrees or less, 8. Measure whee! bearing preload and axial end play. Axial end play: 0 mm (0 in) Wheel bearing preload (As measured at wheel hub bolt): [New grease seal] 9.8 - 28.4.N (1.0 -2.9 kg, 2.2 -64 Ib) [Used grease seal] 9.8 -23.5.N (1.0 -24kg,2.2-5.3 Ib) Repeat above procedures until correct bearing preload is ob- tained. 9. Spread cotter pin. 10, Install hub cap, MA-28CHASSIS AND BODY MAINTENANCE sFA99 Checking (Repla Grease (Cont'd) PRELOAD ADJUSTMENT (Except 2WD Trucks) Adjust wheel bearing preload as follows: 1. Before adjustment, thoroughly clean all parts and check them for wear, cracks or other damage 9) Front Wheel Bearing 2. 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 © Whee! hub (as shown at the left) 3. Tighten wheel bearing lock nut with Tool. ©: 78-98Nm (8 - 10 kg-m, 58 - 72 ft-lb) 4, Turn wheel hub several times in both directions. 5. Loosen wheel bearing lock nut so that torque becomes ON-m (0 kg-m, 0 ft-lb). 6. Retighten wheel bearing lock nut with Tool. ©: 05-1.5Nm (0.05 - 0.15 kg-m, 0.4- 1.1 ft-tb) 7. Turn wheel hub several times in both directions. 8. Retighten wheel bearing lock nut with Tool. ©: 0.5-1.5Nm (0.05 - 0.15 kg-m, 0.4 - 1.1 feb) 9. Measure wheel bearing axial end play. Axial end play: 0 mm (0 in) 10, Measure starting force “A” at wheel hub bolt. MA-29CHASSIS AND BODY MAINTENANCE ao Enna x on Checking (Replacing) Front Wheel Bearing Grease (Cont'd) 11. Install lock washer by tightening the lock nut within 15 to 30 degrees. 12. Turn wheel hub several times in both directions to seat wheel bearing correctly. 13. Measure starting force “B’’ at wheel hub bolt. Refer to proce- dure 10. 14, Wheel bearing preload “'C”’ can be calculated as shown below: Wheel bearing preload “C”: 7.06 - 20.99 N (0.72 - 2.14 kg, 1.59 - 4.72 Ib) 15, Repeat above procedures until correct axial end play and wheel bearing preload are obtained. 16. Install free-running hub and brake pads. Checking Front Wheel Alignment Before checking front wheel alignment, be sure to make a pre- liminary inspection. PRELIMINARY INSPECTION 1. Check tires for wear and proper inflation. 2. Check wheel runout. Lateral runout: Refer to Wheel Inspection in section MA. Check front whee! bearings for looseness. Check front suspension for looseness. Check steering linkage for looseness. Check that front shock absorbers work properly by using the standard bounce test. ona 7. Measure vehicle height (Unladen): Vehicle height: Refer to S.D.S. Exercise the front suspension by bouncing the front of the vehicle 4 or 5 times to ensure that the vehicle is in a neutral height attitude. 2) Measure wheel alignment. (Refer to ALLOWABLE LIMIT on S.D.S.) 3). If wheel alignment is not as specified, adjust vehicle posture. (Refer to ADJUSTING RANGE on S.D.S.) MA-30 H=A—B mm (in) 1CHASSIS AND BODY MAINTENANCE ‘Steering topper bracket end AT Kiran Inclination camber ‘SFAGOS ‘canter Checking Front Wheel Alignment (Cont'd) 4) Adjust wheel alignment. (Refer to ADJUSTING RANGE on S. 8.) CAMBER, CASTER AND KINGPIN INCLINATION Before checking camber, caster or kingpin inclination, move vehicle up and down on turning radius gauge to minimize fric- tion, ‘Measure camber, caster and kingpin inclination of both right and left wheels with a suitable alignment gauge and adjust in accordance with the following procedures. Camber (Untaden): Refer to S.D.S. Kingpin inclination (Unladen): Refer to S.D.S. Caster (Unladen): Refer to S.D.S. ADJUSTMENT Both camber and caster angles are adjusted by increasing or de- creasing the number of adjusting shims inserted between upper link spindle and frame. MA-31CHASSIS AND BODY MAINTENANCE Adjusting shim 8 Frame bracket Ajusting shim A Upper tink spindle ‘Austng shim & (or Fie adjustment) Shim thine ie tuskeee 1.0 (0.039) ren 20,0079) ose 23 0.18 f2n0 ony) mh aoie.6n land Unt Checking Front Wheel inment (Cont'd) Before removing or installing adjusting shim(s), be sure to place a jack under lower link. Adjusting shim standard thickness: 2WD Trucks 2.9 mm (0.11 Except 2WD Trucks 4.0 mm (0.157 in) ‘© Do not use three or more shims at one place. ‘© When installing shim B, always face the paw! towards spindle and insert them from bracket side. Use only one shim in a place. Total thickness of shims must be within 8.0 mm (0.315 in). Difference of total thickness of the front and rear must be within 2,0 mm (0.079 in). ‘© Determine thickness and number of shims necessary for ad- justing camber and caster, in acoordance with the following graph. [Example] (1) When service data value minus measured value is equal to: Caster angle: —30" Camber angle: +30° (2) Obtain the intersecting point of lines in accordance with the graph. (3) Choose shims which are nearest to the intersecting point. (4) For the above example: 2WD Trucks: ‘Add 2.0 mm (0.079 in) shim on front side. ‘Add 3.0 mm (0.118 in) shim on rear side. Except 2D Trucks: ‘Add 1.0 mm (0.039 in) shim on front side. ‘Add 3.0 mm (0.118 in) shim on rear side. MA-32/D Trucks sras7oa|CHASSIS AND BODY MAINTENANCE swaiz3 Lines parte 10 canter line of body Front @ Front sFA807 Checking Front Wheel Alignment (Cont'd) TOE-IN 1, Mark a base line across the tread. After lowering front of vehicle, move it up and down to eli nate friction, and set steering wheel in straight ahead position. 2. Measure toe-in. Measure distance “A” and “Bat the same height as hub center. Toe-in (Unladen): Refer to S.D.S. 3. Adjust toe-in by varying the length of steering ti (1) Loosen clamp bolts or lock nuts. (2) Adjust toe-in by turning the left and right tie-red tubes an equal amount. Make sure that the tie-rod bars are screwed into the tie-rod tube more than 35 mm (1.38 in). rods. Make sure that the tie-rods are the same length. Standard length A = B 2WD Trucks: 344 mm (13.54 in) Except 2WD Trucl 281 mm (11.06 in) (3) Tighten clamp bolts or lock nuts. Clamp bolts (2WD Trucks) 1: 14-20 Nem (1.4-2.0 kgm, 10 - 14 ftb) Lock nuts (Except 2WD Trucks) ©): 78-98 Nem (8.0 - 10.0 kg-m, 58 - 72 ft-lb) WHEEL TURNING ANGLE 1. Set wheels in straight ahead position and then move vehicle forward until front wheels rest on turning radius gauge properly. MA-34CHASSIS AND BODY MAINTENANCE Front A: Inside 5 Outside Checking Front Wheel Alignment (Cont'd) 2. Rotate steering wheel all the way right and left; measure turning angk Wheel turning angle ~-———--seo= 2wo | Feet Trucks | trons [21x10.5R15* Inside wheet | 36°-a8° | a3°-35° | 27°-20° Full turns Outside whee! | 33°-a5° | s1°-aa® | 25°-27° 7 Five size 3. Adjust by stopper tolt if necessary. [2WD Trucks} Standard length “L, ": 20 mm (0.79 in) [Except 2WD Trucks] Standard length “L2"*: 26.5 mm (1.043 in) [Except tire size 31x10.5R15] 37.5 mm (1.476 in) [Tire size 31X10.5R15] Checking Free-running Hub Grease © Check free-running hub for grease leakage and water or dust entry. ‘* When installing free-running hub, use multi-purpose grease for manual-lock free-running hub and NISSAN GENUINE GREASE (KRC19-00025) or equivalent grease for auto-lock free-running hub, Refer to Section FA. MA-35CHASSIS AND BODY MAINTENANCE sFA901 TOUT TUT) Ul seneos ri Check boot and drive shaft for cracks, wear, damage or grease leakage. Checking Rear Axle and Rear Suspension Parts © Check axle and suspension parts for looseness, wear or damage. (1) Shake each rear wheel to check for excessive play. (2) Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to section RA. (3) Check axle and suspension parts for wear, cracks or other damage. © Check shock absorber for oil leakage or damage. Checking Brake Fluid Level and Leaks If fluid level is extremely low, check brake system for leaks. MA-36CHASSIS AND BODY MAINTENANCE SMATS2A sMa2eoa smagz2a Checking Brake System Check brake fluid tines and parking brake cables for proper attachment, leaks, chafing, abrasion, deterioration, ete, Changing Brake Fluid Drain brake fluid from each air bleeder valve. a 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”. © Do not reuse drained brake fluid. © Be careful not to splash brake fluid on painted areas. Checking Vacuum Hoses Check vacuum lines, connections and check valve for proper attachment, air tightness, chafing and deterioration. Checking Disc Brake Check condition of disc brake components, ROTOR Check condition and thickness. Minimum thickness: CL28VA 20 mm (0.79 in) CL28VD 24 mm (0.94 in) AD14VB 16 mm (0.63 in) CALIPER Check operation and leakage. MA-37CHASSIS AND BODY MAINTENANCE Checking Disc Brake (Cont'd) PAD Check wear or damage. Minimum thickness: 2 mm (0.08 in) . Qt Checking Drum Brake Check condition of drum brake components. WHEEL CYLINDER Check operation and leakage. DRUM Check condition and inner surface. Drum repair limit (Inner diameter): LT26B 261.5 mm (10.30 in) LT30A 296.5 mm (11.67 in) DS17H_ = 191.0 mm (7.52 in) Check condition of inner surface of drum, LINING Check wear or damage. Lining wear limit (Minimum thickness): 1.5 mm (0.059 in) sMa3e PARKING DRUM BRAKE Adjust lining and drum as follows: (1) Set the transfer lever in the “2H” position. Using either low or 2nd transmission speed, drive the unloaded vehicle at approximately 30 km/h (19 MPH) on a safe, level and dry road. (2). Depress the release button of the parking brake lever and pull the lever back with a force of 98 N (10 kg, 22 Ib). (3) While holding the lever back, continue to drive the vehicle 100 m (328 ft). (4) Repeat steps 1 through 3 two or three times. MA-38CHASSIS AND BODY MAINTENANCE ete sheet / Dash insulator / seR002A smaozae senos24| Checking Foot Brake Pedal Operation Check brake pedal free height, depressed height and for smooth operation. Hi: Free height A/T 212-222 mm (8.35 - 8.74 in) M/T 209 - 219 mm (8.23 - 8.62 in) D: Depressed height Under force of 490 N (50 kg, 110 Ib) with engine running 115 mm (4.53 in) or more (2WD VG30E) 120 mm (4.72 in) or more (Except 2WD VG30E} A: Pedal free play 1.0 - 3.0 mm (0.039 - 0.118 in) If necessary, adjust brake pedal free height and depressed height. Refer to section BR. Checking Brake Booster Function © Depress brake pedal several times with engine off, then check that there is no change in pedal stroke. © Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal. Checking Parking Brake 1, Pull lever with specified amount of force. Check lever stroke and for smooth operation. Number of notches [At pulling force of 196 N (20 kg, 44 Ib)) : Refer to S.D.S. 2. Use adjuster to adjust lever stroke. (1) Loosen lock nut @ , rotate adjuster ®. (2) Tighten lock nut ® . MA-39CHASSIS AND BODY MAINTENANCE Checking Tire Condition TIRE CONDITION © When tread wear indicators appear, replace tire with new “read wear indiestor Tce teed one. woe © Check tread and side walls for cracks, holes, separation or damage. © Check tire valves for air leakage. TIRE INFLATION Tire pressure should be measured when tire is cold. Tire pressure should be set to the specifications on the tire placard located into the glove box, ABNORMAL TIRE WEAR Correct abnormal tire wear according to the chart shown below: Condition Probable cause | Corrective ation Condition Probable cause | Corrective action ‘*Underinfiation | « Measure and a ‘Incorrect toe = Adjust toni, (oth sides weer! Feathered oéoe «Incorrect whee! ‘camber (one side wear) | ‘sHord cornering | @ Lack of rotation | « Rotate ter ‘Overinflaion | ® Measure and ‘incorrect camber |» Repair, or replace adjust pressure, oreaster ‘axle and suspen ‘eLackof rotation | « Rotete tres, sion parts. ‘eMifunctioning | e Repair, replace or, suspension necessary, + Unbelanced whee! Correct or replace center wear Other mechanical | @ Correct or replace conditions sMa1978 ‘Lack of rotation _ | e Rotate tires.CHASSIS AND BODY MAINTENANCE Tire Replacement CAUTION: * Do not mix different types of tires, such as bias, bias belted and radial tires under any circumstances. © When replacing a tire, use a tire of the same size and type (Bias, Belted or Radi Use recommended tires and wheels. Do not mix tires of different brands, tread patterns or type. © When repli: standard tires ‘those tires of an of al recommended size and of different diameter, the speed- ‘ometer requires to be recalibrated. © _ Install road wheel using the wheel hub boss. Wheel Nut CAUTION: ‘© Be careful not to smear threaded portion of bolt and nut as well as seat of nut with oil or grease. © Tighten wheel nuts in crisscross fashion. Be sure to check wheel nuts for tightness, after aluminum wheel hhas been run for the first 1,000 km (600 miles) (also in case of repairing flat tires, tire rotation, etc.). Retighten if necessary. MA-41CHASSIS AND BODY MAINTENANCE Tire Repair CAUTION: When replacing tire, take extra care not to damage tire bead, rim- flange and bead seat. When installing tire, note the following items: a, Install valve core and inflate to proper pressure. Check the locating rings of the tire to be sure they show around the rim flanges on both sides. b. Check valves for leakage after inflating tires. ¢. Be sure to tighten valve caps firmly by hand. WARNING: To avoid serious personal injury, never stand over tire when inflating it. Never inflate to a pressure greater than 40 psi (275 kPa). If beads cate it again, and then reinflate it. If the tire is overinflated, the bead might break, possibly resulting in serious personal injury. Wheel Inspection © Check wheel rim (especially rim flange and bead seat) for rust, distortion, cracks or other damage. ‘© Examine wheel rim for lateral and radial runout with dial gauge. Refer to S.D.S. © Replace wheel when any of the following conditions occur. Bent, dented or heavily rusted Elongated bolt holes Excessive lateral or radial runout Air leaks through welds Whee! nuts will not stay tight MA-42CHASSIS AND BODY MAINTENANCE Balancing Wheels Adjust whee! balance using the road wheel center. cme | Sree “moore Wheel balance (Maximum allowable unbalance at et one rim flange): | teem | mate Refer to S.D.S. avec | oom vasany | nen armeneny Tire batancing weight: Refer to $.D.S. Soontoe ‘non Tire Rotation S WHEELS MA-43CHASSIS AND BODY MAINTENANCE Spare Tire T-TYPE SPARE TIRE AND SMALL SIZE SPARE TIRE The T-type/Small size spare tire is designed for emergency use only. ‘The spare tire can be used repeatedly for emergency situations Precautions when using T-type/Small size spare tire ‘© Periodically check tire inflation pressure, and always keep (415 kPa) [T-type spare tire] . inflation pressure, and always keep ize spare tire] Do not drive vehicle at speed faster than 80 km/h (50 MPH). The Ttype/Small size spare designed only for tempo- rary use as a spare. Dismount it and keep it as a spare as, soon as the standard tire repair has been completed. Do not attach a tire chain. Do not use the T-type/Small size spare tire on other cars, sharp turn, or apply the brake suddenly while ¢ As soon as the tread wear indicator becomes visible, replace the tire with a new one, © Mounting and dismounting to and from the road wheel can be carried out in the same manner as any ordinary tire, © Use of wheel balance is unnecessary. CAUTION: If the vehicle is equipped with aluminum wheels, be sure to use ‘the wheel nuts for steel wheel on the T-type/Small size spare ti wheel. Never use the wheel nuts for aluminum wheel on the spare tire wheel, The spare tire wheel may come off the axle and cause personal injury if the wheel nuts for aluminum wheels are used. MA-44CHASSIS AND BODY MAINTENANCE Checking Steering Gear and Linkage © Steering gear: (1) Check gear housing for looseness, damage or grease leakage. (2) Check connection with steering column for looseness. © Steering linkage: (1) Check ball joint, dust cover and other com- Ponent parts for looseness, wear, damage or grease leakage. (2) Check for missing parts (cotter pins, washer, etc). swaza28, Checking Power Steering System Fluid and Lines 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) or using “COLD” range ‘on dipstick at fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: © Do not ove © Recommended fluid is Automatic Transmission Fluid “DEXRON™ “ type. Check lines for proper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. smazsec Checking Steering Gear © Check steering gear for oil level and leakage. © Check oil level. Oil level: Distance “A” 43 mm (1.69 in) or less Be careful not to overflow gear oil when filling up. (Onvehicle) —smassos MA-45CHASSIS AND BODY MAINTENANCE Body LUBRICATING HOOD LATCHES, LOCKS AND HINGES Fa Buacse MA-46CHASSIS AND BODY MAINTENANCE Body (Cont'd) CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS | Check bets for \, samose, ‘Check buckle and tongues for || funetion when for smooth operation. ln ~ __\Yorfunetion when bucked ar ~/ WW / cna ais for Jump seat ‘Wing ca) Spee a tome are the ame the front sat, For front sat belt, shock absorber type belt hasbeen Fplece the belt when loop been pulled out and REPLACE BELT" ie vie becuse this seatbelt hs loop of webbing under the sleeve. Front bench wt (including spit sat) IF Check anchors 15) loote mauntiog, check buckles and tongue for function when baci "aloo, (Cheek belts for damage sot (Wagon and Van) ome are the same caurion: 1. It the vehicle is collided or over turned, replace the entire belt tssombly, ropardess of nature of 2. It the condition of any compo: rent of a sat belt is quostionsbe, do" not ropair stat belt, but re: place it aba bet axe 5. IE webbing is cut, frayed, oF damaged, replace belt assembly 4, Do not spill drinks, oll, ete, on 264-336 fb) | MA-47SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Maintenance INSPECTION AND ADJUSTMENT Drive belt deflection Unit: me find red batt detietion | petection Detection of Limit ser ew belt achusiment vat 6-8 57 are 12047) | (024-0301 | (020-028) ‘Ar conditioner on 7-9 compressor 16063) | 19.35..0.43) | (0.28035) Powersteoring cil | yy ¢qgy) | 11-19 | 9-19 pum 7087) | (o.43-050 | (0.25-0.49) “Applied pushing ne 88. (10s, 2216) Oil capacity (Refill) me ‘20 40 34 With ot fter chan a (414,312) | (2578,3) 36 30 eae (378, 3.1/8) | (3-1/8, 25/8) Coolant capacity Unit: ¢(USat, Im at) 2wo ao Without eservoir tank | 9.9 (10-172, 8.3/4) | 109 (11-172, 9.5/8) Reservoir tank 0.8 (7/8, 3/4) Spark plug ‘Sandard pe ‘BKREY Howe CRE Cold vee eKR7EY MA-48 VG30ESERVICE DATA AND SPECIFICATIONS (S.D.S.) [KA24E | Engine Maintenance (Cont'd) INSPECTION AND ADJUSTMENT ‘Spark plug Drive belt deflection Standard type ZFREE-N1 Lots mm tn) ot type 2FRaET Used belt deflection | sex detiec- Cold type ZPREEAT cer] tench Psa To: i mm 0659-00091 time | Adare’ | bet —S Alternator 17 (0.67) en La (0.39-0.47|(0.31-0.39) Air conditioner w-12 | a-10 161083) li0.39-047)|1031-0.30) compressor ower steering om | 7-9 cil pump 18 (059) }i935 -0430]10.28 -0.35) ‘oped pushing force 196 N (10 kg, 22 1) Oil capacity (Refill) Unit: & (US 4, Imp ad it ot titer 20D NO) 3.9(4-18,39) | 330-172, 27/8) Without ot fiter Coolant capacity 35133/4,318) | 2918-118, 21/2) Unit: @ (US at, Im at) 20> 4wo Without reservoir tank 7.3:17314,638) | 82 (65/8, 7-1/4) 0.8 (78, 3/4) MA-49SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance INSPECTION AND ADJUSTMENT Clutch Units me fin Engine Kame vG30e teem Pedal height 236-246 | 227-237 (929-969) | (8:94-9:23) Pedal fro play A Front axle and front 1.03.0 (0.039-0.178) t suspension Wheel bearing preload (2WD Trucks) Whoo! bearing axial play mm tin) eo Winee! bearing nut “Tightening torque 34-39 Nam tkgen, (t40) (35 -40,25.-29) Return angle degree ‘Whoo! bearing starting toraue [At wheal hub bolt With nw grease seat 98-264 Nike.) (1.0.29,22-64) With used grease seal 98-235 Nikg,to)] — (1.0-24,22-83) Wheel bearing preload (Except 2WD Trucks) Whee! bearing lock nut Tightening torque Nem kom, Retightening torque af uw) | 78-98 (8-10,58-72) lootening whee! bearing 05-15 Nev ikon, ‘Axial end play ‘Starting Fores at whee! hub bolt 1 tkg, to) Turning angle degree 18° -30° (0.05 -0.18,04-1.1) feb) vm fin) 20) a ‘Starting Fores at wheel hub bolt NN tkg, tb) ‘Whee! bearing preload at wheel hub bolt tka, tb BA 7.06 - 20.09 (0.72-2.14,1.59-4.72) MA-50SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance (Cont'd) WHEEL ALIGNMENT (Unladen*1) . ‘ALLOWABLE LIMIT. [ADJUSTING RANGE ‘Applied model = 2WO Truck Except WD Truck 2W0 Truck Except 2WD Truck camber dearer 0°20" 10 10" 0°05" t0 1°25" =0°S' 10 0°55" 710-110" caster gree 0°23" to 1°07" 33-03" =0°8' 10 0°52" aa" - 1°48" Kingpin inclination degree 2°20'-9°60" rv -8°61 8°5'-9°35" 736-836" ‘Camber, caster, and kingpin inetination diference becween ad both sides degree Total oesn Bio tie mmiin) | 3-7(0.12-0.28) 3-7(0.12-0.28) 4-6 (016-024) 4-6 (016-024) doproe 187-35" 18-95" 2-20 20-30" adil tre mmiin) | 1-8 (0.08-0.20) 2-6 (0.08 -0.24) 2-4 (008-0.16) 3-5 (012-020) deree ae 1yeae wea wear Front wieel turning angle ull turn? ore Except 31 x 105815 aside 34° 38° a1 38° 26 38° 33-38" Outside a wa" ae 35° 30-3 Fx TORTS tire Teside = 25°29" = 2-28 Outside = wo = 28-27 Vehicle posture Lower atm pivot 108-118 41-51 mas. 44-48 hight (HD om ind (425-465) (161-201) (437-459) (173-189) ‘2WD Trucks Except 2D Trucks Lower link spindle enter — “1: Fue, radiator coolant and engine ol full. Spar tie, jock, hand tools and mats in designated positions, "2: On power stering models, wheel turning fore (at cireurnferance of saering wheel] of 98 0 147 W (10 to 18 ks, 22 t0.23 Ia) with engine ile MA-51SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance (Cont’d) Brake Unit: mom tnd ‘ Wheel and tire Disc brake Tire inflation et reeai a aaa Proper tire pressures are shown on the tire placard Rotor thickness repair iit affixed into the glove box of vehicle. cuzeva 200.70 i Id be checked when tires are a Be Tire pressure should be aD 1610.83) coLD. Drum brake ‘rum inner, repsic iit ras 261.5 1030) L208 2965 (1.67) osi7H 191.0 (782) {ning wer tint 15 (0.059) ra ar 212-222 (8.36 0.74) free height wit 200 -210 (825 662) Pedal depress] _2WD VGI0E 115 (459) or more a Except 200 VG30E | 120 (4.72) or more Pedal foe play 4-12 (0:6-047) Track 10-12 Center ter -————} ype Van & Wooon iad stick over | 240 ioe type ‘ano ot WHEEL RUNOUT TIGHTENING TORQUE Stel Unit Nm kom ft Wee ype ‘Aluminum 14 inches Manual wansminion 15inches Droinand filerplugs 25-24 25-85 18-25 | Painted | Plates i | os | os [os | 12 cere Radial runout Drain and fier pi 25.95 18.25 time mm tin) | (0.012) | (aaa | coczor | (oosn pines 25-98 Ditters carie Lert runout os | os | of | 12 Drain and filer ps tit etn | toner | oan | ween | ven Drain fil le Front 39-59 4.6 9-49 Re 59.98 6.10 43.72 BALANCING WHEELS Brain uae? 0-98 6-10 43-72 ——$____ Filler plug"? 30.59 4.6 20-48 Whee blanace(Meximom allowable own rom seo ome aloe! suspension 5-60 (018-212) Tierod lock nut (@WO) 78-98 80-100 88-72 Tire bloncing weight (02! ae | soaring 5 (0.18) Tievodclamp bot 14-20 14-20 10-14 (ano) Wea! nat Single tie 118-147 12-18 87-108, Aluminum whest 118-147 12-18 87-108 "2: Model equipped with €200 MA-52ENGINE MECHANICAL SECTION E M CONTENTS PRECAUTION EM. 2 PREPARATION a EM. 3 c 1 V@306 L 1 OUTER COMPONENT PARTS sen EM. 6 COMPRESSION PRESSURE ses EM. 8 OIL PAN Eu. 9 TIMING BELT EMA3 OIL SEAL REPLACEMENT 7 EMA CYLINDER HEAD sen EM-21 ENGINE REMOVAL . seven EMS CYLINDER BLOCK sent EM-40 SERVICE DATA AND SPECIFICATIONS (S.D.S.) soonnnnnesennnees EMESt i ] KA24E[ = 1 OUTER COMPONENT PARTS . EM-58 COMPRESSION PRESSURE . EM-59 OIL PAN eet senescence EMBO TIMING BELT ne smn senses EMER OIL SEAL REPLACEMENT ..nrssnnnnnmnnnnnnnne EM-68 CYLINDER HEAD . asnnanenttnnnnnnnnnnnnsn EM-70 ENGINE REMOVAL 0 sen EM-B4 CYLINDER BLOCK nnn soe EM-86 SERVICE DATA AND SPECIFICATIONS (8.0.8.) sevccnrsonnns EM-97loner side semarie PRECAUTION Parts Requiring Angular Tightening © Some important engine parts are tightened using an angular- tightening method rather than a torque setting method. @ If these parts are tightened using a torque setting 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-tightenitny method. @ Although the torque setting values (described in this manual) 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 oil. © The bolts and nuts which require the angular-tightening method are as follows: (1) Oylinder head bolts (2) Connecting rod cap nuts Liquid Gasket Application Procedure ‘@ Before applying liquid gasket, use a scraper to remove all traces of old liquid gasket from mating surface. b. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.) © Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide (tor oll pan). © Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oll pan). c. Apply liquid gasket to inner surface around hole perimeter are (Assembly should be done within 5 minutes after coating.) 4. Wait at least 30 minutes before refilling engine oll and engine coolant.PREPARATION SPECIAL SERVICE TOOLS Toot umber (Kent Moore No.) Too! vame Description Engine application G30 KA2E ‘ST0501S000 t- 9 Engine stand assembly @ $705011000 a) Engine stand @ s105012000 C=) Bae Disassembling and assembling KV 10106500 (- Engire stand shaft KV 10105001 C=) Engire attachment Kv10110001 an) Engie sub, attachment ‘sT10120000 (424239-01) Gylinder head bolt wrench Loosening and tightening cylinder head bolt v10110600 (433986) Valve spring ‘compressor Disassembling and assembling valve components va v10109280 an) Valve spring compressor: @ Kv10109210 t- Compressor ® kv10109220 t- 9 Adapter Disassembling and assembling Q kv10107501 (= Valve oil seal driftPREPARATION oo! number Engine application (Kent-Moore No.) Description Tool name ve30e | KA24E KV 10980010 Installing valve oil seal an) _ " Valve oil seal drift KV10110300 Dissssembling and assembling C- 9 piston with connecting rod Piston pin press stand assembly @ Kv10110310 c=) cop @® Kvi0110330 c= Spacer @ 713030020 (9 Press stand @ s113030030 (=) Spring © Kvtor10340 ) Drift © Kvt0110320 a) Center shaft EM03470000 Installing piston assembly into (8037) cylinder bore Piston ring compressor x x (336467) | Displacement valve oil seal Valve oil seal remover ‘516610001 (123907) Pilot bushing puller KV10111100 Removing oil pan (=) Seal cutter x x 39930000 Pressing the tube of liquid gasket () ‘Tube presserPREPARATION COMMERCIAL SERVICE TOOLS Engine application Tool name Deseription vas0E | KA24E Spark plug wrench Removing and installing spark plug x Tem (ossin) U— Pulley holder Holding camshaft pulley while tightening or loosening camshart bolt <= x x Valve seat cutter set | Finishing valve seat dimensions x x Piston ring expander | Removing and installing piston ring x x Valve guide drift Flemoving and installing valve guide Diameter tin) Toiake | Exhourt vea0e LA 705 10.413), ae x x e 6.6 (0.260), € kaze |-A_[ 108 (0413) [11.5 10489) 8 | 6610260) | 7.610.209) Valve guide reamer Reaming valve guide @) or hole for oversize valve guide () o », x x Ana: ee 1, = 7.0mm (0.276 in) dia. = Dy = 11.2 mm (0.461 i) da. Esha: @ 1D, = 8.0 mm (0.315 in) die, Dy = 12.2 mm (0.480 in) da >, EM-5OUTER COMPONENT PARTS VG30E Power wansstor. 29-38) 1°58) 18-25 (15-2, 11-18) 24,0 ‘Air eegultor {F)8.4-10.8 10.86-1.1,6.2-8.0) ~~ Exheust gas fp temperature sensor ~——— P.CV. val (0) 29-39 (3.0-4.0, 22-29) ! 3 fk, P 7-8 07-03: 78 (0.7-08,5.1-8.8) Ls Z (a \ Nec vale i {| 4 JK a4 a0 35-45, 28-30) 3 : ON con. ute Fuel tube bd 78 Sensi AAG he 28 aes na) Ye 1 9-11(09-1.1,65-8.0) Gasket OH, (07-08, Ware out s ; S&S ©) Refer to page Em.36. “Thermal transmit Wand | 18-22 (1.8 -22, 13-16) \ asker 69 == ara) Paes mee Ws-21018-24, ay we BS Cy, ae s nuocke Se “ ee as, < Feath sir init! 10-12) Onin ‘ oy a SQ / Set, Sankey 1295) BY sitemator Lechause cod (39-22, manifold R 13-16) -oo8en an ~ tighten in correct order) 1) en. thee, feb) scuerzeOUTER COMPONENT PARTS NG30E a 22-27 =e RH. exhaust manifold TD: Wm kom, fet) EM-7COMPRESSION PRESSURE wes 20.men (0.790) dia. head during removal. Use compressor tester whats end (rubber | ‘portion is tess than 20 mm (0.79 in) eta (Otherwise, it may be caught by cylinder Measurement of Compression Pressure 1 2 3, 4 5. 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 specitied engine revolution. Compression pressure: kPa (kg/cm’, psi)/300 rpm Standard 1,196 (12.2, 173) Minimum 883 (9.0, 128) Difference limit between cylinders 98 (1.0, 14) 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, if adding oil helps compression, piston rings may be worn or damaged. it 80, replace piston rings after checking piston. It pressure stays low, @ 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. HW compression in any two adjacent cylinders is low and it adding oil does not help compression, there is leakage past the gasket surface. If so, replace cylinder head gasket.OIL PAN WOE) Removal shown on the righ peg. semzoss WARNING: a. Place vehicle on a flat and solid surtace. b. Place chocks at front and rear of rear wheels. . You should not remove oil pan until exhaust system and cooling system have completely cooled off. Otherwise, you may burn yourself and/or fire may break out in the fuel tine. d. When remove front and/or rear engine mounting bolts or nuts, lift up slightly engine for safety work. ‘CAUTION: ‘a. In lifting engine, be careful not to hit against adjacent parts, especially against accelerator wire casing end, brake tube and brake master cylinder. b. For tightening torque, refer to sections AT, MT and PD. 9OIL PAN Removal (Cont'd) VG30e Removal order and poiets ‘2NO model | AWD mode! 1 Remove undercover, ° ° 2 Drain engine oi ° ° ‘Remove stebilzer bracket bolts 2 RH a LH. J - 1g Flemowe front proplir shaft from _ ° front differential eacier ‘Remove front driveshaft Fixing _ 5 © bolts (RH. & LH Remove front diferential earsier © mmamber bolt (R.H.& LHL) - J Remove front diferenial earier 7 fixing bolts and suppor it - ° Remove front differentia errier ® leder hoe. - 0 Remove front suspension eros _ member 0 ‘Remove differential front mounting - ° 7 pots (AH. & LH.) 11 Remove tront diferent carrier. 5 ° Remove front diferential earrier 12 mounting brecket - ° 413. Remove idler arm ° ° 14 Remove starter motor. ° ° Remove transmission to rear engine 15 mounting bracket nuts S ° (H&L, ‘Remove engine mounting bolts or 7 ° 16 outs (.H.& LH 17 Remove engine gues. ° ° Litt up engine. 18 if necestery, disconnect exheust = ° tube 19 Remove il pan. 5 . Refer to next page. EM-10 VG30EOIL PAN NG30E. Q : setoa pone Removal (Cont'd) 1. Remove oi! pan bolts. 2. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. ‘@ Do not drive seal cutter into oil pump or rear oll seal retainer portion, or aluminum mating face will be damaged. © Do not insert screwdriver, or oil pan flange will be deformed. (2) Slide Too! by tapping its side with a hammer, and remove oil pan Installation 1. Before installing oll 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 sealant to oll pump gasket and rear oil seal retainer gasket. EM-11OIL PAN VG30E ‘cuthere. Liquid gasket 7 me (0.28 in} Bott hote Installation (Cont'd) 3, Apply a continuous bead of liquid gasket to mating surface of oil pan. © Use Genuine Liquid Gasket or equivalent. © Be sure liquid gasket is 3.6 to 4.5 mm (0.138 to 0.177 in) wide. 4, Apply liquid gasket to inner sealing surface as shown in figure. @ Attaching should be done within 5 minutes after ccating 5. Install oil pan. ‘© Install bolts/nuts in their reverse order of removal. © Wait at least 30 minutes before refilling engine oll. EM-12TIMING BELT WEE! CAUTION: a. Do not bend or twist timing belt. b. After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike piston heads. c. Make sure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free from oil and water. 3 € : & a | g o8 é : 3 de 3 cl J ies 4 z 8 ej i 2 3 28 8 e c fe \ Font ppt om 2 KK S semaosctae Intake tube Woterinietose sl bracket Timing bee front upper ‘Timing bet loner cover nkshaft pulley bolt paren upper cover semzaoa| TIMING BELT wewE) Removal Remove engine under cover. Drain engine coolant from radiator. careful not to spill coolant on drive belts. Remove radiator. (Refer to LC section.) Remove engine cooling fan and water pump pulley. Remove the following belts. Power steering pump drive belt Compressor drive belt Alternator drive belt Remove all spark plugs. Remove distributor protector. Remove compressor drive belt idler bracket, Remove fresh-air intake tube for rocker cover. 10. Remove water hose for thermostat housing 11. Remove crankshaft pulley bolt 12. Remove crankshaft pulley with 2 suitable puller. 18. Remove front upper and lower belt covers. gee e PON2eeerse 14, Set No. 1 piston at T.D.C. on its compression stroke by rotating crankshaft. © Align punchmark on LH. camshaft sprocket with punchmark ‘on timing belt upper rear cover. @ Align punchmark on crankshaft sprocket with notch on oil pump housing. © Temporarily install crank pulley bolt on crankshaft so that crankshaft can be rotated. 15. Loosen timing belt tensioner nu:, turn tensioner, then remove timing belt EM-14TIMING BELT wean) Inspection Visually check the condition of timing belt. Replace if any abnormality is found. Item to check Problem Cause Tooth is broken/ tooth root is cracked. © Camshaft jamming © Distributor jamming ‘© Damaged camshaft/erankshaft oll seal semas4a Back surface is ‘© Tensioner jamming crackediworn. © Overheated engine © Inte-ference with belt cover semaosa| Side surface is worn, ‘© Improper installation of belt ‘© Malfunctioning crankshaft pulley plate/ timing belt plate ‘© Belt corners are worn and round. © Wicks are frayed and coming out. semso6al Teeth are worn Poor belt cover sealing Coolant leakage at water pump Camshaft not funetioning properly Distributor not funetioning properly Exeassive belt tension Rotating direction ‘© Canvas on tooth face is worn down, © Canvas on tooth is fluffy, rubber layer is worn down and faded white, or weft is worn down and invisible. a Oil/Coolant or water is stuck to bolt ‘© Poot oil sealing of each oil seal © Coolant leakage at water pump ‘© Poor belt cover sealing EM-15Crankshaft ining Aligning marks é a top dea cont Oil pumpin compression] stroke camehatt! sprocket (aH) Crankhat timing socket hy ‘No. # cylinder at T.0.C. In-compresion stoke TIMING BELT wG0E) Inspection (Cont'd) BELT TENSIONER AND TENSIONER SPRING 1. Check belt tensioner for smooth turning. 2. Check condition of tensioner spring. Installation 1. Confirm that No, 1 piston is set at T.D.C. on its compression atroke, 2. Install tensioner and tensioner spring. If stud is once removed, apply locking sealant to threads of stud before installing. 3. Turn tensioner fully clockwise with hexagon wrench, and temporarily tighten lock nut 4. Set timing belt (1) Align white lines on timing belt with punchmarks on camshaft ‘sprockets and crankshaft sprocket. (2) Point arrow on timing belt toward front belt cover. Number of teeth (reference| Number of timing belt teeth 133 Number of Between LH. and RH. camshaft sprockets | 40 teeth between |” Between L.H. camshaft sprocket and timing marks _| crankshaft timing sprocket —EM-169eN (10, 22 1) Tensioner puley Crankshaft sprocket semee7e, woah: 12:7 mm (0.500 in) Feclor gouge ‘Thickness: (0.35 mm (0.0138 in) semasec VG30E TIMING BELT Installation (Cont'd) 5. Loosen tensioner lock nut, keeping tensioner steady with hexagon wrench, 6. Turn tensioner 70 to 80 degrees clockwise with hexagon wrench, and temporarily tighten look nut. 7. Turn crankshaft clockwise at least 2 times, then slowly set No. 1 piston at T.D.C. on its compression stroke. 8, Push middle of timing belt between R.H. camshaft sprocket and tensioner pulley with force of 98 N (10 kg, 22 Ib). 9. Loosen tensioner lock nut, Keeping tensioner steady with hexagon wrench, 10. Set feeler gauge as shown in figure which is 0.35 mm (0.0138 in) thick and 12.7 mm (0.500 in) wide. EM-17TIMING BELT WEHTE Installation (Cont'd) 11. Turn crankshaft clockwise, and set feeler gauge as shown in figure. © Timing belt will move about 25 teeth. 42, Tighten tensioner lock nut, keeping tensioner steady with hexagon wrench. 18. Turn crankshaft clockwise or counterclockwise, and remove feeler gauge. 14, Turn crankshaft clockwise at least 2 times, then slowly set No, 1 piston at T.D.C. on its compression stroke. 16. Install lower and upper belt covers. Bal cover font Tupper a Bete cover (ear feenie — Bat cover ean) gp | anaes (PeHo]S ce mane EE | Tao) (@ wae pu foe we ‘mec on rere) Tawar] Gas rae on A 78) aoevane [ite | Bette Si sacmrton |18 ye I ® ‘eee ie Soe oO | TF ic coves eo) ond nt pe) Bett cover front lower ‘SeM2EBA EM-18OIL SEAL REPLACEMENT WGmE| v10107501 woh 23 (000 10 (01039) Engine outside Dust sal in __semnasa, VALVE OIL SEAL 1. Remove rocker cover. 2. Remove rocker shaft assembly and valve lifters with valve lifter guide. 3. Remove valve springs and valve oil seal. ‘@ Piston concerned should be set at T.D.C. to prevent valve from falling, © When removing intake side valve oll seal, use Tool or suitable tool. © When removing exhaust side valve oil seal, pull it out with suitable tool 4. Apply engine oil to new valve oil seal and install it © Before instaling valve oil seal, install inner valve spring seat © When instaling intake side vaive oil seal, use Too! © When instaling exhaust side valve oil seal, set it by hand OIL SEAL INSTALLING DIRECTION EM-19OIL SEAL REPLACEMENT wen CAMSHAFT OIL SEAL 4. Remove timing bet. 2. Remove camshaft sprocket. 3. Remove camshaft 4, Remove camshaft oil seal Be careful not to scratch camshaft. 5. Apply engine oil to new camshaft oll seal. FRONT OIL SEAL 1. Remove timing belt and crankshaft sprocket. 2. Remove oil pump assembly. 3. Remove front oil seal from oll pump body. 4. Apply engine oil to new oil seal and install it using suitable tool. REAR OIL SEAL 1. Remove flywheel or drive plate, 2. Remove rear oil seal retainer. 3. Remove rear oil seal from retainer. 4. Apply engine oil to new oil seal and install it using suitable tool. 5. Install rear oll seal retainer with a new gasket to cylinder block. EM-20VG30E CYLINDER HEAD exraun | 91-3101-03,07-22)—_ ana ar Suez , 1.8-2.2, 13-16 eR vtinder Heiner ip ‘ heed front. head front Intake rocker amar | an \ \Q Bewreroaien \ \G Intake eupononte | f : oon \ Valve liter aide Covinder ned bot ater to “ietalation” of CYLINDER HEAD. Inner vate rng Vat oie 9 Vat ide Eeiarmarer Samer ~ Otter — BP _ IP ~ ‘ et sO head assembly Valve sat ‘Outer spring seat \,__ \Rear cover sosker 69 \q0) 70-8 18.0-9.0, 58.65) [tem koe, fb) seMo128 EM-21CYLINDER HEAD Wome 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 and rocker shatt bolts, apply new engine oil to thread portions and seat surfaces of bolts. © If hydraulic valve lifter is kept on its side, there is a risk of air entering it. After removal, always set hydraulic valve lifter straight up, or when laying it on its side, have it soak in new engine oll. © Do not dis: © Attach tags ymble hydraulic valve litt valve lifters so as not to mix them up. Removal 1, Release fuel pressure. Refer to “Releasing Fuel Pressure 2. Remove timing belt. Refer to “TIMING BELT — Removal”. in section EF & EC. 3. Drain coolant by removing drain plugs from both sides of cylinder block. EM-22CYLINDER HEAD VG30E Loosen bolts in omeriea! order me ola semarec, Removal (Cont’d) 4. 5. Separate AS.C.D. and accelerator control wire from intake manifold collector. Remove intake manifold collector from engine. The following parts should be dsconnected to remove intake manifold collector. Harness connectors for AAC. valve Throttle sensor and throttle valve switch Ignition coil Power transistor E.G. control solenoid valve Air regulator Exhaust gas temperature sensor (California model only) Water hoses from collector Heater hoses P.C.V. hose from R.H. rocker cover Vacuum hoses for Canister Master brake cylinder Pressure regulator Purge hose from canister, EGR. tube Earth harnesses Air duct hose Remove fuel feed and fuel return hoses from injector fuel tube assembly. Disconnect all injector harness connectors. Remove injector fuel tube assembly. Remove intake manifold from engine. ‘The following parts should be disconnected to remove intake manifold, Engine temperature switch harness connector Thermal transmitter hamess connector Water hose from thermostat housing EM-23CYLINDER HEAD VG30E Looten in numeri order, _semszea} Removal (Cont'd) 10. Remove both camshaft sprockets 11, Remove rear timing belt cover. 42, Remove distributor and ignition wires. After pulling out distributor from cylinder head, do not rotate distributor rotor. 19, Remove harness clamp from RH. rocker cover. 14, Remove front exhaust tube from exhaust manifold, 1. Remove compressor from its bracket. 16. Remove alternator from its bracket. 17. Remove compressor and alternator bracket. 18, Remove both rocker covers. 19. Remove cylinder head with exhaust manifold. © Head warpage or cracking could result from removing in incorrect order. © Cylinder head bolts should be loosened in two or three steps. EM-24CYLINDER HEAD VG30E RH, exhaust manifold Oo, O13 LH. exhaust manifold tm HOS e om aig® @® oF SEMe22¢ Loosen in eumerial order semaoca| semasea, Disassembly 1, Remove exhaust manifolds from cylinder head. 2. Remove rocker shafts with rocker arms. Bolts should be loosened in two or three steps. 3. Remove hydraulic valve lifters and lifter guide. © Hold hydraulic valve lifters with wire so that they will not drop from lifter guide. Remove oil seal and camshaft ‘© Before removing camshaft, measure camshaft end play. 5. Remove valve components with Tool 6. Remove valve oll seals with Tool or suitable tool. Inspection CYLINDER HEAD DISTORTION Head surtace flatness: Less than 0.1 mm (0.004 in) It 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 engine. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. EM-25semsaoa| semeoaa) im CYLINDER HEAD VG30E Inspection (Cont'd) ‘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 heigl 106.8 - 107.2 mm (4.205 - 4.220 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): Limit 0.1 mm (0.004 in) 2, Iit exceeds the limit, replace camshaft CAMSHAFT CAM HEIGHT 1. Measure camshaft cam height. ‘Standard cam height: 39.597 - 39.727 mm (1.5566 - 1.5641 in) ‘Cam wear limi 0.15 mm (0.0059 in) 2. It wear is beyond the limit, replace camshaft CAMSHAFT JOURNAL CLEARANCE 1. Measure inner diameter of camshaft bearing. ‘Standard inner diameter: ‘A 47.000 - 47.025 mm (1.8504 - 1.8514 in) B 42.500 - 42.525 mm (1.6732 - 1.6742 in) © 48.000 - 48.025 mm (1.8898 - 1.8907 in) EM-26Dial gauge End play Locate pate 0.06 (0.002) + @ Punched identification mark semas08, CYLINDER HEAD VG30E Inspection (Cont'd) 2. Measure outer diameter of camshaft journal Standard outer diameter: ‘A. 46.920 - 46,940 mm (1.8472 - 1.8480 in) B 42420 - 42.440 mm (1.6701 - 1.6709 in) © 47.920 - 47,940 mm (1.8866 - 1.8874 in) 3, If clearance exceeds the limit, replace camshaft and/or cyinder head Camshaft journal clearance limit: 0.48 mm (0.0089 in) CAMSHAFT END PLAY 1. Install camshaft and locate plate in cylinder head 2. Measure camshaft end play. Camshaft end play Standard 0.03 - 0.06 mm (0.0012 - 0.0024 in) 3. If itis out of the specified range, select thickness of camshaft locate plate to obtain standard specified end play. Example: When camshaft end play is 0.08 mm (0.0031 in) with camshaft locate plate @), replace camshaft locate plate @) with camshaft locate plate @) to set the end play at 0.05 mm (0.0020 in) CAMSHAFT SPROCKET RUNOUT 1. Install sprocket on camshaft, 2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.1 mm (0.004 in) 3, If it exceeds the limit, replace camshaft sprocket, EM-27semaooa| Top canter sew7sia| CYLINDER HEAD VG30E Inspection (Cont'd) VALVE GUIDE CLEARANCE 1. Measure vaNe deflection in a right-angled direction with cam- shaft. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (Dial gauge reading): 0.20 mm (0.0079 in) 2. If it exceeds the limit, check valve to valve guide clearance. ‘a. Measure valve stem diameter and valve guide inner diameter. b. Check that clearance is within specification. Valve to valve guide clearance: Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust 10.030 - 0.053 mm (0.0012 - 0.0021 in) Limit ‘0.10 mm (0.0039 in) ©. If it exceeds the limit, replace valve or valve guide. VALVE GUIDE REPLACEMENT 1. To remove valve guide, heat cylinder head to 180 te 160°C (302 to 320°F} 2. Drive out valve guide with a press [under a 20 KN (2 t, 22 US ton, 2.0 Imp ton) pressure] or hammer and suitable tool EM-28CYLINDER HEAD VG30E semonsc a gy Inspection (Cont'd) 3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake 11.175 - 11.196 mm (0.4400 - 0.4408 in) Exhaust 12.175 - 12.196 mm (0.4798 - 0.4802 in) 4, Heat cylinder head to 150 to 160°C (302 to 320°F) and press service valve guide onto cylinder head. Projection “L”: 13.2 - 13.4 mm (0.520 - 0.528 in) 5, Ream valve guide. Finished size: Intake 7.000 - 7.018 mm (0.2756 - 0.2763 in) Exhaust 8,000 - 8.018 mm (0.3150 - 0.3157 in) VALVE SEATS Check valve seats for any evidence of pitting at valve contact surface, and reseat or replace if it has worn out excessively. © Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve set © Cut with both hands to maintain a uniform cutting surface. REPLACING VALVE SEAT FOR SERVICE PARTS 1, Bore out old seat until it collapses. The machine depth stop should be set so that boring cannot continue beyond the bottom face of the seat recess in cylinder head. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Intake 44.500 - 44.516 mm (1.7520 - 1.7526 in) Exhaust 87.500 - 37.516 mm (1.4764 - 1.4770 in) EM-29CYLINDER HEAD VG30E. Inspection (Cont'd) Reaming should be done in circles concentric to the valve guide center so that valve seat will have the correct fit. 3. Heat cylinder head to 150 to 160°C (302 to 320°F) 4. Press fit valve seat until it seats on the bottom. 5. Cut or grind valve seat using suitable tool at the specified dimensions as shown in S.DS. 6. After cutting, lap valve seat with abrasive compound. 7. Check valve seating condition. T_tntake Exnaurt Saat face angle “a” degree 45 5 Contacting wath “W" mm in) | 1.75 (0.0880) | 1.7 (0.067) semsszs| {T(Margin thickness) U 7 _ a 7 — VALVE DIMENSIONS Check dimensions in each valve. For dimensions, refer to S.DS. When valve head has been worn down to 0.5 mm (0,020 in) in margin thickness, replace valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less. VALVE SPRING Squareness 1. Measure “'S” dimension. Out-of-square: Outer Less than 2.2 mm (0.087 in) Inner Less than 1.9 mm (0.075 in) 2. If it exceeds the limit, replace spring. EM-30CYLINDER HEAD WGHE sew7eza Inspection (Cont'd) Pressure Check valve spring pressure Pressure: N (kg, Ib) at height mm (in) ‘Standard Outer 250.1 (25.5, 56.2) at 40.0 (1.575) Inner 1255.0 (26.0, 57.3) at 25.0 (0.984) Limit Outer More than 228.5 (23.3, 51.4) at 25.0 (0.984) Inner More than 225.6 (23.0, 50.7) at 25.0 (0.984) It it exceeds the limit, replace spring. ROCKER SHAFT AND ROCKER ARM 1. Check rocker shafts for scratches, seizure and wear. 2. Check outer diameter of rocker shaft, Diameter: 17.979 - 18.000 mm (0.7078 - 0.7087 in) 3. Check inner diameter of rocker arm. Diameter: 18,007 - 18.028 mm (0.7089 - 0.7098 in) Rocker arm to shaft clearanct 0.007 - 0.049 mm (0.0003 - 0.0019 in) © Keep rocker arm with hydraulic valve lifter standing to prevent air from entering hydraulic valve lifter when checking. HYDRAULIC VALVE LIFTER 1. Check contact and sliding surfaces for wear or scratches, EM-31SEM?608 = Cylinder head side Wide pitch Narrow piteh| semeseo Knock pin—> / CYLINDER HEAD wexe Inspection (Cont'd) 2. Check diameter of valve liter. ‘Outer diameter: 15.967 - 15,957 mm (0.5278 - 0.6282 in) 3. Check valve lifter guide inner diameter. Inner diamet 16.000 - 16.013 mm (0.6299 - 0.6304 in) Standard clearance between valve lifter and lifter guide: (0.043 - 0.066 mm (0.0017 - 0.0026 in) Assembly 1. Install valve component parts © Always use new valve oil seal, Refer to OIL SEAL RE- PLACEMENT. © Before installing valve oil seal, install inner valve spring seat @ Install outer valve spring (uneven pitch type) with its narrow pitch side toward cylinder heed side. © After installing valve component parts, use plastic hammer to lightly tap valve stem tip to assure a proper fit. Install camshafts, locate plates and cylinder head rear covers. ‘© Set knock pin of camshaft at the top. 3. Install valve lifters into valve lifter guide. © Assemble valve lifters to their original position and hold all valve lifters with wire to prevent lifters from falling off. © After installing them, remove the wire. EM-32Rocker shaft dieation qa aD essa ara GUish i tena a) PNY) | A | SO Sep® Tighten in numerical order. seme2sc| CYLINDER HEAD wen Assembly (Cont'd) 4, Install rocker shafts with rocker arms, @ Tighten bolts gradually in two or three stages. © Before tightening, be sure to set camshaft the lobe at the position where lobe Is not lifted. a. Set No. 1 piston at T.D.C. on its compression stroke and tighten rocker shaft bolts for No. 2, No. 4 and No. 6 cylinders. b. Set No. 4 piston at T.D.C. on its compression stroke and tighten rocker shaft bolts for No. 1, No. 3 and No. § cylinders. 5. Install exhaust manifold to cylinder head in reverse order of removal, Installation 1. Set No. 1 piston at T.D.C. on its compression stroke as follows: a. Align crankshaft sprocket aligning mark with mark on oil pump body. 'b. Confirm that knock pin on camshaft is set at the top, 2. Install both drain plugs. ‘© Apply sealant to drain plug threads. 3. Install exhuast manifolds to cylinder head. EM-33Cylinder heed bole wather Cylinder hes sie seme77a| pS stuease CYLINDER HEAD VGN Installation (Cont'd) 4, Install cylinder head with new gasket. Be aure to install washers between bolts and cylinder head. Do not rotate crankshaft and cemshatt separately, or valves will hit piston heads. 5. Tighten cylinder head bolts in numerical order using ST10120000 (J24239-01). © Tightening procedure: (1) Tighten ell bolts to 29 N-m (8.0 kg-m, 22 fb). {@) Tighten ell bolts to 59 N-m (6.0 kg-m, 43 ftp). {@) Loosen all botts completely. (4) Tighten all bolts to 29 N-m (8.0 kg-m, 22 fb). {(8) Tur all botts 60 to 65 degrees clockwise, Hf an angle wrench is not available, tighten all bolts to 54 to 64 Nem (85 to 8.5 kg-m, 40 to 47 fib). © Bolts for ©, ©, @ and @ are longer than the others. Li: 127 mm (6.00 in) for ©, ©, @ and @ Li: 106 mm (4.17 In) for others 6. Install both rocker covers. 7. Install compressor and alternator bracket. 8. Install alternator. 9. Install compressor. [Snes ROTRUCKPRTTENDER [ang OO EOD A. 34VG30E CYLINDER HEAD Installation (Cont'd) 410. Install exhaust front tube to exhaust manifold 11. Install rear belt cover and camshaft sprocket. © RH. camshaft sprocket and LH. camshaft sprocket are different parts. Be sure to install them in the correct location. Aligning ~ Identification mark a R.H. camshaft sprocket RS. 0°53" LH. camshaft sprocket LB 327" semaoaa 12. Install timing belt and adjust belt tension. Refer to “TIMING BELT — installation”. 18. Install distributor. ee (1) Align mark on shaft with protruding mark on housing. Mark on shaft Mark on housing {protrosing) eN os SJ mark on housing EN incon 8 = (2) After installing, confirm that distributor rotor head is set as Rotor heed positon shown in figure. (Wo. tevlinger at 7.0.0.) semssoa| EM-35Tighten bots in numerical ord. semersc, ee Foal terinor <7 seabed Bette CYLINDER HEAD GE Installation (Cont'd) 14, Install intake manifold. Install all parts which were removed in step 9 under “CYLIN- DER HEAD — Removal”. (See page EM-23.) @ Tightening procedure (1) Tighten all bolts to 3 to 5 Nem (0.3 to 0.5 kg-m, 2.2 to 3.6 ft-Ib). Tighten all nuts to 3 to 5 Nem (0.3 to 0.5 kg-m, 2.2 to 3.6 ft-lb). (2) Tighten all bolts to 16 to 20 Nem (1.6 to 2.0 kg-m, 12 to 14 ft-lb). Tighten all nuts to 24 to 27 N-m (2.4 to 2.8 kg-m, 17 to 20 ft-Ib). (8) Tighten all bolts to 16 to 20 Nem (1.6 to 2.0 kg-m, 12 to 14 ft-lb). Tighten all nuts to 24 to 27 N-m (2.4 to 2.8 kg-m, 17 to 20 ft-Ib). 15. Install injector fuel tube assembly. 16. Connect all injector harness connectors. 17. Install fuel feed and fuel return hoses to injector fuel tube assembly. 418, Install intake manifold collector. Install all parts which were removed in step 5 under “CYLIN- DER HEAD — Removal". (See page EM-23.) 19, Install A'S.C.D. and accelerator control wie. 20. Check hydraulic valve lifter. a. Push plunger forcefully with your finger. © Be sure to check it with rocker arm in its free position (not on the lobe). . If valve lifter moves more than 1mm (0.04 in), air may be inside it. ¢. Bleed air off by running engine at 1,000 rpm under no load for about 10 minutes. d. If hydraulic valve lifters are stil noisy, replace them and bleed air off again in the same manner as in step 20 (c). EM-36ENGINE REMOVAL VG30E —M-37ENGINE REMOVAL VG30E senaiz WARNING: a. Situate vehicle on a flat and solid surface. b. Place chocks at front and back of rear wheels. ¢. Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself and/or fire may break out in fuel line. d. For safety during subsequent steps, the tension of wires should be slackened against the engine. Before disconnecting fuel hose, release fuel pressure from fuel line Refer to “Releasing Fuel Pressure” in section EF & EC. 1. Before removing front axle from transmission, place safety stands under designated front supporting points. Refer to Gl section for lifting points and towing. g. Be sure to hoist engine and transmission in a safe manner. h. For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: ‘© When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake lines, and brake master cylinder. © In hoisting the engine, always use engine slingers in a safe manner. © Do not loosen front engine mounting insulator cover securing nuts. ‘When cover is removed, damper oll flows out and mounting Insulator will not function. For tightening torque, refer to sections AT, MT and PD. For 4WD model, sealant should be applied between engine and transmission. Refer to section MT. EM-38ENGINE REMOVAL —_ Removal 1. Remove engine undercover and hood. 2. Drain engine coolant. 3, Remove vacuum hoses, fuel tubes, wires, harnesses and connectors and so on. 4, Remove radiator with shroud and cooling fan. 5. Remove drive belts. 6. Remove power steering oil pump and air conditioner com- pressor. 7. Remove front exhaust tube. 8, Remove transmission from vehicle. Refer to MT and AT sections. 9. Install engine slingers. 10. Hoist engine with engine slingers and remove engine mounting bolts from both sides. 11, Remove engine from vehicle. EM-39For 4D model ney 0 les (Berne anaes ‘rlinder block — ea so 9 5 6 \ ‘Rear oll seal retainer oe, 108 Cit pump assembly (For 2W0 mode) Seen section) Select suitable thickness of ‘main bearing ‘Connecting rod —~ — canker 9 Refer to SRaeore Maia besring 2p—~ / ©) 90-100 (9.2 -10.2, 67-74) “Tighten or loosen in cesta Gately AG? ows. 4h) For | Lorton [ig Pe neo — 8) 20.29 30-40,22-20) 29-20 7.9 Bo:40,22-20) ‘or. 0.8, rary fe: Apply satan. TE: Nim team, re) EM-40CYLINDER BLOCK VG30E CAUTION: ‘© When installing sliding parts such as bearings and pistons, be sure to apply engine oil on the sliding surfaces © Place removed parts such as bearings and bearing caps in their proper order and direction. © When tightening connecting rod bolts and main bearing cap bolts, apply engine oil to thread portion of bolts and seating surface of nuts. Disassembly PISTON AND CRANKSHAFT Place engine on a work stand. Drain coolant and oil, Remove oil pan and oil pump. Remove timing belt. Remove water pump. Remove cylinder head, Remove pistons with connecting rods. © When disassembling piston and connecting rod, remove snap ring first, then heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature. 8. Remove bearing cap and crankshaft. © Before removing bearing cap, measure crankshaft end play. ‘© Bolts should be loosened in two or three steps. Inspection PISTON AND PISTON PIN CLEARANCE 1 piston pin hole “sp” 20.969 - 20.981 mm (0.8255 - 0.8260 in) EM-41SeMozsA Piston Prost Measuring point seme229| sem1soa| VG30E CYLINDER BLOCK Inspection (Cont'd) 2. Measure outer diameter of piston pin “Dp” Standard diameter “Dp”: 20.971 - 20.983 mm (0.8256 - 0.8261 in) 3. Calculate piston pin clearance dp - Dp = -0.008 to 0.004 mm (-0.0003 to 0.0002 in) If it exceeds the above value, replace piston assembly with pin PISTON RING SIDE CLEARANCE Side clearance: Top ring 0.040 - 0.073 mm (0.0016 - 0.0029 in) 2nd ring (0.030 - 0.063 mm (0.0012 - 0.0025 in) Max. limit of side clearance (0.4. mm (0.004 in) If out of specification, replace piston and/or piston ring assembly. PISTON RING END GAP End gap: Top ring 0.21 - 0.44 mm (0.0089 - 0.0173 in) 2nd ring 0.18 - 0.44 mm (0.0071 - 0.0173 in) il ring 0.20 - 0.76 mm (0.0079 - 0.0299 in) Max. limit of ring gap: 1.0 mm (0.039 in) If out of specification, replace piston ring. if gap still exceeds the limit even with a new ring, rebore cylinder and use oversized piston and piston rings, Refer to S.D.S. CONNECTING ROD BEND AND TORSION Bend: Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit 0.30 mm (0.0118 in) er 100 mm (3.94 in) length It it exceeds the limit, replace connecting rod assembly. EM-42CYLINDER BLOCK VG30E Inspection (Cont'd) CYLINDER BLOCK DISTORTION AND WEAR 4. Clean upper face of cylinder block and measure the distortion Limit: (Messuring points 0.10 mm (0.0039 in) QoS e| 2 tout of specication, resurtace it Se Re Le) 3 ee in engine. ‘Amount of cylinder head resurtacing is “A” ‘Amount of cylinder block resurfacing is “B”. The maximum limit is as follo A+ B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshatt center 227.60 - 227.70 mm (8.9606 - 8.9645 in) 3. If necessary, replace cylinder block The resurfacing limit is determined by cylinder head resurfacing sewai99 PISTON-TO-BORE CLEARANCE 1. Using @ bore gauge, measure cylinder bore for wear, out-of- round and taper. Standard inner diameter: 87.000 - 87.030 mm (3.4252 - 3.4264 in) Wear limit: 0.20 mm (0.0079 in) Out-of-round (X — ¥) limit: 0.015 mm (0.0006 in) Taper (A - B) limit: (0.015 mm (0.0006 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. 2. Check for scratches and seizure. If seizure is found, hone it. Units mn (int ‘© It both cylinder block and piston are replaced with new ones, re eee) select piston of the same grade number punched on cylinder rs area) | mrersn: bSssatexee avert etn a é pe (ass EM-43CYLINDER BLOCK VG30E Inspection (Cont'd) 3. Measure piston skirt diameter. Piston diameter “A” Refer to S.D.S. Measuring point ‘‘a” (Distance from the bottom): 18 mm (0.71 in) 4. Check that piston-to-bore clearance is within specification, Piston-to-bore clearance “B”: (0.025 - 0.045 mm (0.0010 - 0.0018 in) 5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to $.0.S. 6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”. Rebored size calculation: D=A+B-C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance : Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps, and tighten to the specified torque to prevent distortion of cylinder bores in final assembly. 8 Cut cylinder bores. ‘© When any cylinder needs boring, all other cylinders must also be bored. '® Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance, 10. Measure finished cylinder bore for out-of-round and taper. © Measurement should be done after cylinder bore cools down. CRANKSHAFT 1. Check crankshaft main and pin journals for score, wear or 4 cracks, >< | 2. With'a micrometer, measure journals for taper and out-of-round. Out-of-round (X= ¥): Less than 0.005 mm (0.0002 in) y Taper (A ~ B): Less than 0.005 mm (0.0002 in) Teper: A-B Ourofround: X-¥ 3, Measure crankshaft runout. Runout (Total indicator reading): Less than 0.10 mm (0.0039 in) EM-44No.3 [Dosa im Bang yay 7 WOT RE] SO hove we ANY Ge No.2" CYLINDER BLOCK VG30E Inspection (Cont'd) BEARING CLEARANCE Either of the folowing two methods may be used, however, method A gives more reliable results and is preferable. Method A (Using bore gauge & micrometer) Main bearing 1. Set main bearings in their proper positions on cylinder block and main bearing cap. 2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. 3. Measure inner diameter “A” of each main bearing, 4, Measure outer diameter “'Dm" of each crankshaft main journal. 5. Calculate main bearing clearance. Main bearing clearance (A - Dm): Standard 0.028 - 0.055 mm (0.0011 - 0.0022 in) Limit 0.090 mm (0.0035 in) 6. If it exceeds the limit, replace bearing. 7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. a. When grinding crankshaft journal, confirm that "L” dimension in filet roll is more than the specified limit. “L": 0.1mm (0,004 in) b. Refer to S.DS. for grinding crankshaft and available service parts, 8. If crankshaft is reused, measure main bearing clearances and select thickness of main bearings. If crankshaft is replaced with a new one, it is necessary to select thickness of main bearings as follows: @. Grade number of each cylinder block main journal is punched ‘on the respective cylinder block. EM-45CYLINDER BLOCK VG30E Inspection (Cont'd) b. Grade number of each crankshaft main journal is punched on the respective crankshat ‘No. 4 journal 1.3 grade number sewer: cc. Select main bearing with suitable thickness according to the following table, Main bearing grade number: Wain our! Crankshaft ae u iv 2 journal grade number 3 8 1 2 1 1 2 3 2 2 a 4 For example: Main journal grace number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 +2 — Connecting rod bearing (Big end) 1. Install connecting rod bearing to connecting rod and cap, 2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Measure inner diameter "C” of each bearing, 4. Measure outer diameter “Dp” of each crankshaft pin journal. 5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance (C - Dp): Standard 0.014 - 0.054 mm (0.0006 - 0.0021 in) Limit 10.090 mm (0.0035 in) 6. If it exceeds the limit, replace bearing. 7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearin; Refer to step 7 of "BEARING CLEARANCE — Main bearin« EM-46Micrometer CYLINDER BLOCK VG30E Inspection (Cont'd) Method B (Using plastigauge) ‘CAUTION: © Do not turn crankshaft or connecting rod while plastigage is being inserted. ‘© When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then if excessive bearing clearance exists, use @ thicker main bearing or undersized bearing so that the specified bearing clearance is obtained. CONNECTING ROD BUSHING CLEARANCE (Small end) 1, Measure inner diameter “C” of bushing. 2. Measure outer diameter “‘Dp" of piston pin. 3. Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C - Dp ‘Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.023 mm (0.0009 in) If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin. REPLACEMENT OF CONNECTING ROD BUSHING (Small end) 41. Drive in small end bushing unti itis flush with end surface of rod. Be sure to align the oil hol 2. After driving in small end bushing, ream the bushing so that clearance between connecting rod bushing and piston pin is the specified value. Clearance between connecting rod bushing and piston pin: (0.005 - 0.017 mm (0.0002 - 0.0007 in) FLYWHEEL/DRIVE PLATE RUNOUT Runout (Total indicator reading): Flywheel (M/T model) Less than 0.15 mm (0.0059 in) Drive plate (A/T model) Less than 0.15 mm (0.0058 in) EM-47Front mark Engin front Oithole ytinder J number sewao7e aoe « non 7g, or mana a No.2" No. ay No. AY ayy With oil groove rox oer No.3 | vs et ‘SEMSI7A a aE) | CYLINDER BLOCK VG30E Assembly PISTON 4. Install new snap ring on one side of piston pin hole. 2. Heat piston to 60 to 70°C (140 to 158°) and assemble piston, piston pin, connecting rod and new snap ring. © Align the direction of piston and connecting rod. @ Numbers stamped on connecting rod and cap correspond to each cylinder. @ After assembly, make sure connecting rod swings smoothly. 3. Set piston rings as shown. (CRANKSHAFT 1. Set main bearings in their proper positions on cylinder block ‘and main bearing cap. ‘© Confirm that correct main bearings are used. Refer to “Inspection” in this section. 2. Install crankshaft and main bearing caps and tighten bolts to the specified torque. ‘© Prior to tightening bearing cap bolts, place bearing cap in its proper position by shitting crankshaft in the axial direction. ‘© Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially. '@ Alter securing bearing cap bolts, make sure crankshaft turns smoothly by hand, EM-48EMOTETOOOD. (43037) ‘or sutabie 10! VG30E, CYLINDER BLOCK Assembly (Cont'd) 3. Measure crankshaft end play. Crankshaft end play: Standard (0.050 - 0.170 mm (0.0020 - 0.0067 in) Limit 0.30 mm (0.0118 in) If beyond the limit, replace bearing with a new one. 4. Install connecting rod bearings in connecting rods and con- necting rod caps. ‘© Confirm that correct bearings are used. Refer to “Inspection”. © Install bearings so that oil hole in conrecting rod aligns with oil hole of bearing, Install pistons with connecting rods. Install them into corresponding cylinders with Tool. Be careful not to scratch cylinder well by connecting rod. ‘Arrange so that front mark on piston head faces toward front of engine. b. Install connecting rod bearing caps. Tighten connecting rod bearing cap nuts to the specified torque. ): Connecting rod bearing nut (1) Tighten to 14 to 16 Nem (1.4 to 1.6 kg-m, 10 to 12 ftb). (2) Turn nuts 60 to 65 degrees clockwise. Hf an angle wrench is not available, tighten nuts to 38 to 44 Nem (3.9 to 4.5 kg-m, 28 to 33 ftb). 6. Measure connecting rod side clearance, Connecting rod side clearance: Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit 0.40 mm (0.0187 in) If beyond the limit, replace connecting rod and/or crankshatt EM-49CYLINDER BLOCK VG30E ‘sT16610001 ‘Assembly (Cont'd) REPLACING PILOT BUSHING 1, Remove pilot bushing (M/T) or pilot convertor (A/T). 2. Install pilot bushing (M/T) or pilot convertor (A/T) EM-50SERVICE DATA AND SPECIFICATIONS (S.D.S.) VG30E General Specifications COMPRESSION PRESSURE jement ve Unit: Displacement __em* (cu in) 2,960 (180.62) ‘Compression presure Bore and stroke mm in) 87 x83 (3.43 x3.27) Standard 4,196 (12.2, 173) Valve arangement one. saree as tan sza) Fring onder 129.456 911.0, 14) ‘Number of piston rings ‘Compression 2 oi 1 ‘Number of main beorngs 4 Ccompresion ratio 20 FRONT seM7i30 —EM-51SERVICE DATA AND SPECIFICATIONS (S.D.S. VG30E Inspection and Adjustment CYLINDER HEAD Valve spring Unit: mm in Ouw~e12 @0re) Sanded tim Freeheght mind Toner aa (796) oe tan Hand surfs ciation ontee, 0.1 (0000 Omer S87 ea, TT prose eerie Tit. he te) Saanenersl inner ‘at 25.0 (0.984) Owe 22 (0087) outotagues mm in) van inner 1910078) Height (nina foes so72 (eps 4220) Unit: mm in 16907-15957 VALVE (ore 06282) Unit: mn in e000. 16013 Liter guide inside ameter scars rea} 7 (Margin hekne ‘arance betwee iter and 013-0068 I ‘iter ide (0.017 .0026) Valve head diameter intake 4200-422 (1.654. 1.861) Exhaust 36,0-362 (1.378- 1.386) Valve enath Take 126.3 125.9 (4933-4967) Exhaust 1242-1248 (4890-4913) ‘Valve stom diameter “a” Take 6.965 - 6.980 (02742-02748) Exhourt 7.968 - 7.970 (0.3136 -0.3138) ‘Valve seat angle “a” Take 45°15" 45°46" Exhaust Vatve mars Tncake’ 1.18 1.45 0.0483 0.0571) Exhaust 1.38 - 1.65 (0.0531 - 0.0680) Vavve margin °T™ iit ‘More than 0 (0.020) ‘Vate stem ond surface Lon then 02 (01 singing limit ‘Vat ciesrance Teak ro) Exhaust oo EM-52SERVICE DATA AND SPECIFICATIONS (S.D.S.) VG30E Inspection and Adjustment (Cont'd) Valve guide Intake valve seat nits nm tnd en Banded Standort Senvice is YW Vane aude (6.0680) tr23- 14.034 | 11229-11.204 fe ower (o.4340-0.4344) | (0.4418 0.4823) iometer aun | 12029-12008 | 12229-12204 (014733-0.4738) | (0.4812-0.4817 416-418 Vane aide 11638-1646) a tower Invoke 7000-7018 cn (02756-02763) Oversize (05 (0.0201) (Finishes teal Exhaust emo;orel F030 oy | _ 44500-4516 (17520-17526), a, ~ Oylinderheas | 10975-10996 | 11.178. 11.106 ne (0.0880) Cxtinder need 8K | (g.4321 0.4328) | (0.4400 0.408) bere valve aude ole dome gynguy | 1-978- 11.996 | 12.175- 12.106 (0.4718-0.4723) | (04793 -0.4802) . a 0.027 0.059 Interference ft 416-418 ofviwe aude Caron (0.0011 -0.0023) 11938-1646) in. nits_mm in semrssa standard | Max. tolerance aaa Tate | 0020-0053 Stem 10 ide too00e 0.0021) | 9.19 Exhaust valve seat clnarance oosa (0.0008) Exnaust| 0090-0053 | (0:0098) ‘Standard (0.0012 0.0021) e w 020 ave datetion lit ae (0.0078) Rocker shaft and rocker arm 17 (0067) nit: mm fn m5-327 Rocker shaft 7 a 1287) da Outer diameter 17.979 - 18.000 (9.280 1.287) ai s (0.7078 -0.7087) 344-346 (1.9541 362) dla, Rocker arm “en 18007 - 18.008 Oversize [0.5 (0.0201), (0.7069 0.7088) Fo3-05 (0.012 -0.920) , 37.800 -97.516 (1.4764 - 1.4770) dia, ‘Clearance between rocker arm 0.007 - 0.049 2 and rocker shaft (0.0003 - 0.0019) a eee (0.087) as Wa 46 1.364 1.382) de Unit: em Gin EM-53.CAMSHAFT AND CAMSHAFT BEARING SERVICE DATA AND SPECIFICATIONS (S.D.S.) VG30E Inspection and Adjustment (Cont‘d) Unit: mm tiny Yate Sing g é e120 onl Unit: ogre semaooe Max tolerance Comat journal to 0.060-0.105 ~ bearing clearance (0.0024 00040 Inner dameterot @)=47,000-47.025 ~ camehat beeing (has04- 18816) @: 42500-42525 _ (18792-16742) ©: 48000-48025 _ (1808 1.8007) ‘Ouerdiameterot @: 46920-46900 camanat journal (iae72- 18800) - @: 12420-42400 _ (19701-18700) ©: 47920-47940 _ (868 1874) Comat runout as than : ITAL. 0.04 (0.0016) CX) emer (Cam height "A ntake 99,537 - 30.727 (1.8666 -1.5641) Exheurt 0.18 (0.0088) ‘Wear iit of am height Tota indicator reading 2 ® < ‘ . 1 CYLINDER BLOCK Unit: em find Les than 0.03 0.0012) 0.10 (0.0039) 87.000 87.010 (3.4252 3.4256) 87,010 - 87.020 (3.4256. 3.4260) £87,020 - 87,030 (3.4260- 3.4264) (0.20 (0.0079) ‘Les than 0.015 (0.0006) Teor (AC) ‘Less than 0.015 (0.0006) Main journal inner siameter (Grade No.0 (66.645 - 66.654 (2.6238 - 2.6242) Grade No.1 (66.654 - 66.669 (2.6242 2.6245) Grade No.2 66.663 68.672 (2.46245 2.6249) Difference in inner diameter between evlindrs Standard Less than 0.05 10.0020) —EM-54SERVICE DATA AND SPECIFICATIONS (S.D.S.) NG30E Inspection and Adjustment (Cont'd) PISTON, PISTON RING AND PISTON PIN Piston ring ‘ Unit: mm in Available piston eit: in Senders ni See cewance * 0040-0073, or (0.0016 - 0.0029) 03 (0.008) 0080-0068 2ed (0.0012 - 0.0025) Fira ow " 021-04 op (0.0083 - 0.01731 018-048 ea (0.0071 - 0.0173) 1.0 (0.020) ai ina) oe seme Piston pin (86.965 - 86.975 (3.4238 - 3.4242) Unie:_men (int 26976. 8.08 (24242 3.424) ; Coen Peon pin outer dionewr | 20071-2098 (08286-08260 025 wocett : ‘omtownce tot =" | 999 ono co;oed we oanum) 025 00000) gy 215.07.268 (4397 3.4956) a 0008 10 0.004 Oy) 87.465 -87 515 (3.4435 3.4485) Piston pin to connecting overtiz (Service) rod bushing clearance wom Piston pin bok diameter "20.969 - 20.981 (0.8256 -0.8260) Piston clearance to cylinder block (0028 - 0.046 (0.0010 -0.0018), CONNECTING ROD ‘Center distance Bend, orion (per 100 Goan nit Piston pin bushing ‘Connecting rod bia end inner diameter ‘Side clearance Standard Len EM-55 (0.006 - 0.017 (0.0002 - 0.00071 Values measured at ambient temperature of 20°C (68°F) nit: mm ind 164.1 1542 (6.067 -6.071) Bend: 0.15 (0.0059) Torsion: 0:30 (0.0118) 20.982 - 20.996 (0.8261 - 0.8265) 153,000 53.013 (2.0866 2.0871) 0.20 -0.36 (0.0079 -0.0138) (040 (0.0187) After installing in connecting rodSERVICE DATA AND SPECIFICATIONS (S.D.S.) VG30E Inspection and Adjustment (Cont'd) CRANKSHAFT AVAILABLE MAIN BEARING rie: me in| Main journal ia "Dm" Grade No.0 62967-62975 2.4790-2.4799) ppm main bearing EN je TWN oN Grade No.1 62.959 62.967 (2.4787 2.4790) * a Grate No.2 62951-62959 (2.4764-2.4787) Pin journal dia. “Dp” 49,985. 49.974 (19667 - 1.9675) (Center distance "7" 415 (1.638) ‘Outotsound (X=) ‘Standerd Less than 0.00 (0.0002 Teper (A— 8) ‘Standard Lee than 0.006 (0.0002 Funout (FF EM Standard Les than 0.10 (0.0039) SS Mo.4 Lower main besring Free nd pley {wianout oi groove) Standard 0.080 -0.170 (0.0020 - 0.0067) 7 Limit 030100118) No, 1 main bearing ' ‘Grose Thickness "TWh TWentiiton a umber mm in) ‘mm tn} color J r 1817-1821 ack ; © (oars: 00717 c Dm 1 1821-1825 . iS semees (00717-00719) ae 2 1825-1829 224-228 Gagn Qurotround X—Y (00719-00720) (0882-0800) eer ane 3 1929-1833 Yellow (0.0720 -0.0722) a8 ‘ 1933-1837 ave (00722 -0.0723) No. 2 and 3 main bearing Grode Thickness "T™ Wath "W"—_—dertifiction ewris umber mm in) ‘mm tn) ‘olor 1817-1821 © (00718-07171 U3 1 1821-1825 (00747-00719 a 2 1825-1829 189-191, (00719-00720) (0:744-0.752) 1929-1833, 3 (00720-00722) Mood ‘ 1833-1897 ue (00722-00723) -56SERVICE DATA AND SPECIFICATIONS (S.D.S.) GRE! Inspection and Adjustment (Cont'd) No. 4 main bearing Grade Thickness Identification umber rn Cin) color yan -1821 kL o (00718-00717) Ca : 121-1825 own (00717-00719) 1.825 - 1.829 2 (00719-00720) Co 1.829 1.893, 1 3 (00720-00722) od 4 1.993 -1.897 oa (00722-00723) ‘Main bearing 0.25 mm (0.0098 in) undersize Unit: me ind ‘Thickness 1.988 - 1.966 (0.0767 -0.0770) AVAILABLE CONNECTING ROD BEARING Connecting rod bearing undersize Unit: mm ind Tickets (rank pin journal dlameter “Dp” Stondord 1.502 - 1.606 (0.0591 - 0.0593) 49,955 - 49,974 (1.9667 - 1.9675) Undersize ‘0.08 (0.0031), 1.542 - 1.546 (0.0607 - 0.0600) 0.12 (0.0087), 1862 - 1566 (0.0618 0.0617) Grind to that bearing clearance is the specified vale, (0.25 (0.0098), 11.627 - 1631 (0.0641 0.0642) MISCELLANEOUS COMPONENTS. nit: mm (ind Flywheel Runout (T-LR1 Les then 0.15 (0.0050) Bearing clearance Unit: me fn) ‘Main bearing clearance ‘Standard 0.028 - 0.055 (0.0011 -0.0022) Limit 0.090 (0.0036) ‘Connecting rod beering clesrance ‘Standerd 0.014 0.086 (0.0008 -0.0021) Limit 0.090 (0.0035) EM-57OUTER COMPONENT PARTS KA24E ie. (16-24, 12-18) ~~ piseibutor 10.13 10-13,7-9) Fw. 12100-12,7-9) DP) ra2 so (1455-155, 105-1121 Bl: Nm (kgm, feb) Ba: Aon asi sane, semeaac EM-58COMPRESSION PRESSURE [KAZ4E ‘Compresion terter > Measurement of Compression Pressure osene 10. Warm up engine. Turn ignition switch off. Disconnect fusible link for injectors. 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: kPa (kg/cm’, psi)/epm Standard 1,824 (13.5, 192)/300 Minimum 981 (10, 142)/300 Difference limit between cylinders 98 (1.0, 14)/300 It 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. If adding oil helps compression, piston rings may be worn ‘or damaged. If so, replace piston rings after checking piston. It pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to $.D.S.) If valve or valve seat is damaged excessively, replace them. i 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. EM-59OIL PAN KA24E Removal 1. Raise vehicle and support it with safety stands. 2. Drain engine oil 3. Remove front stabilizer bar securing bolts and nuts from ‘side member. 4. Lift engine, 5. Remove oil pan bolts. os o 2 ® Laoten bolts in reverts ord. semaa7c 6. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. © Do not drive seal cutter into oll pump or rear oil seal retainer portion, or aluminum mating face will be damaged. © Do not insert screwdriver, or oll pan flange will be deformed. (2) Slide Too! by tapping its side with a hammer, and remove oll an, 7. Pull out oil pan from front side. EM-60cuthere Liquid gasket Groove ort hole OIL PAN [KA24E Installation 1 ore 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. Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent. Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. Install oil pan. Wait at least 30 minutes before refilling engine oil. EM-61TIMING CHAIN KAZE CAUTION: © After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. EM-62semz0r¢] TIMING CHAIN KA24E Removal erene Disconnect battery tert Drain coolant from Remove radiator shroud and cooling fan. Remove the following belts. Power steering drive belt Compressor drive belt Alternator drive belt Remove all spark plugs. ‘Set No. 1 piston at T.D.C. on its compression stroke. Remove the following parts. Power steering pump, idler pulley and power steering pump brackets ‘Compressor idler pulley Crankshaft pulley il pump with pump drive spindle Rocker cover EM-63KA24E TIMING CHAIN Removal (Cont'd) 8, Remove oil pan, (Refer to OlL PAN.) 9. Remove front cover. Remove the following parts. Chain tensioner Chain guides Timing chain and sprocket il thrower, oil pump drive gear and crankshaft sprocket sprocket Inspection Check for cracks and excessive wear at roller links. Replace if necessary. Wear semzoec| EM-64TIMING CHAIN KA24E| Crankshaft Crankshat sorocket it pump crive gear \ it thrower er? \ = (ory \O (Com sprocket ‘Crank sprocket ‘=: Punchmark Installation 1. Install crankshaft sprocket, oil pump drive gear and oil thrower. Make sure that mating marks of crankshaft sprocket face engine front. Install camshaft sprocket. Confirm that No. 1 piston is set at T.D.C. on its compression stroh Install timing chain. Set timing chain by aligning its mating marks with those of crankshaft sprocket and camshaft sprocket. oe 5. Tighten camshaft sprocket bolt, 6. Install chain guide and chain tensioner. EM-65