Maintenance

MAINTENANCE
SECTION MA
CONTENTS
PRECAUTIONS AND PREPARATION............................2 Checking Positive Crankcase Ventilation (PCV)
Supplemental Restraint System (SRS) ″AIR System .......................................................................27
BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Changing Positive Crankcase Ventilation (PCV)
Special Service Tools ..................................................2 Filter (TB42S) ............................................................27
PRE-DELIVERY INSPECTION ITEMS............................3 Checking Vacuum Hoses and Connections ..............28
GENERAL MAINTENANCE ............................................4 Checking Vapor Lines................................................28
PERIODIC MAINTENANCE (Except for Europe) .........5
Engine and Emission Control Maintenance ................5 RD
Chassis and Body Maintenance..................................7
Maintenance Under Severe Driving Conditions ..........8 ENGINE MAINTENANCE ..............................................29
PERIODIC MAINTENANCE (For Europe) .....................9 Checking Tightening Torque ......................................29
Engine Oil & Minor Service .........................................9 Checking Drive Belt ...................................................29
Engine and Emission Control Service.......................10 Changing Engine Oil..................................................30
Chassis and Body Services.......................................11 Changing Engine Oil Filter ........................................31
Maintenance Under Severe Driving Conditions ........13 Changing Engine Coolant..........................................31
RECOMMENDED FLUIDS AND LUBRICANTS...........14 Checking Cooling System .........................................33
Fluids and Lubricants ................................................14 Checking and Replacing Fuel Filter and Draining
SAE Viscosity Number ..............................................15 Water .........................................................................33
Anti-freeze Coolant Mixture Ratio .............................16 Checking Fuel Lines ..................................................34
Cleaning and Replacing Air Cleaner Filter ................35
Checking Injection Nozzle .........................................35
TB
Checking Idle Speed .................................................36
ENGINE MAINTENANCE ..............................................17 Timing Belt Replacement...........................................36
Checking Tightening Torque ......................................17
Adjusting Intake and Exhaust Valve Clearance ........17 TD
Checking Drive Belts .................................................18
Changing Engine Coolant..........................................18 ENGINE MAINTENANCE ..............................................37
Checking Cooling System .........................................20 Checking Tightening Torque ......................................37
Checking Fuel Lines ..................................................20 Adjusting Intake and Exhaust Valve Clearance ........37
Changing Fuel Filter (TB42S)....................................21 Checking Drive Belt ...................................................37
Changing Fuel Filter (TB45E)....................................21 Changing Engine Oil..................................................38
Cleaning and Changing Air Cleaner Filter Changing Engine Oil Filter ........................................38
(TB42S)......................................................................22 Changing Engine Coolant..........................................39
Cleaning and Changing Air Cleaner Filter Checking Cooling System .........................................40
(TB45E)......................................................................22 Checking and Replacing Fuel Filter and Draining
Checking Cyclone Pre-air Cleaner ............................23 Water .........................................................................41
Changing Engine Oil..................................................24 Checking Fuel Lines ..................................................42
Changing Oil Filter.....................................................25 Cleaning and Replacing Air Cleaner Filter ................43
Checking and Changing Spark Plugs .......................25 Checking Cyclone Pre-air Cleaner ............................44
Checking Ignition Wires.............................................26 Checking Injection Nozzle .........................................44
Checking Choke Mechanism (TB42S) ......................26 Checking Idle Speed .................................................45
CONTENTS (Cont’d) GI
CHASSIS AND BODY MAINTENANCE .......................47 Checking Brake System ............................................52
Checking Exhaust System.........................................47 Changing Brake Fluid ................................................52
Checking Clutch Fluid Level and Leaks....................47 Checking Brake Booster, Vacuum Hoses,
Checking Clutch System ...........................................47 Connections and Check Valve ..................................52
Checking M/T Oil Level and Leaks ...........................47 Checking Disc Brake .................................................53
EM
Changing M/T Oil.......................................................47 Checking Drum Brake ...............................................53
Checking Water Entry................................................48 Balancing Wheels ......................................................54 LC
Checking A/T Fluid ....................................................48 Tire Rotation ..............................................................54
Changing A/T Fluid ....................................................49 Checking Power Steering Fluid and Lines ................55
Checking Transfer Fluid Level...................................49 Checking Steering Damper .......................................55 EC
Changing Transfer Fluid ............................................49 Checking Steering Gear Box and Linkage................55
Checking Propeller Shaft...........................................49 Lubricating Locks, Hinges and Hood Latches...........56
Greasing Nipples of Propeller Shafts ........................50 Checking Seat Belts, Buckles, Retractors, FE
Checking Differential Gear Oil...................................50 Anchors and Adjusters...............................................56
Changing Differential Gear Oil ..................................50 Checking Body Corrosion..........................................57
CL
Checking Front Wheel Bearing Grease ....................51 SERVICE DATA AND SPECIFICATIONS (SDS) ..........58
Repacking Front Wheel Bearing and Axle Joint Engine Maintenance (TB45E & TB42S)....................58
Grease .......................................................................51 Engine Maintenance (RD) .........................................58 MT
Checking Free-running Hub Grease .........................51 Engine Maintenance (TD42)......................................59
Checking Water Entry in Knuckle Flange..................51 Chassis and Body Maintenance................................59
Checking Brake Fluid Level and Leaks.....................52 AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) “AIR

BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS composition which is available to NISSAN MODEL Y61 is as follows (The composition varies
according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.
Special Service Tools
Tool number Engine application

Description
Tool name TB42S TB45E TD42 RD28ETi
EG17650301 Adapting radiator
Radiator cap cap tester to radiator
tester adapter filler neck
X X X X
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
NT564 Unit: mm (in)
KV10106001 Removing oil filter
Oil filter wrench
X — X —
NT690
KV10115801 Removing oil filter

Oil filter wrench
— X — —
NT362
KV10113600 Removing fuel filter

Fuel filter wrench Removing oil filter
Oil filter wrench
— — X X
a: Max. 100 mm
NT553 (3.94 in) dia.
MA-2
PRE-DELIVERY INSPECTION ITEMS
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that GI
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD — engine off UNDER BODY EM

l Radiator coolant level and coolant hose connec- l Manual transmission/transaxle gear oil, transfer
tions for leaks fluid and differential gear oil level
l Battery fluid level, specific gravity and condi- l Brake and fuel lines and oil/fluid reservoirs for LC
tions of battery terminals leaks
l Drive belts tension l Tighten bolts and nuts of steering linkage and
l Fuel filter for water or dusts, and fuel lines and gear box, suspension, propeller shafts and drive EC
connections for leaks shafts
l Engine oil level and oil leaks l Tighten rear body bolts and nuts (Models with
X
l Clutch and brake reservoir fluid level and fluid wooden bed only) FE
lines for leaks
l Windshield and rear window washer and head- ROAD TEST
lamp cleaner reservoir fluid level CL
l Clutch operation
l Power steering reservoir fluid level and hose
l Parking brake operation
connections for leaks
l Service brake operation MT
l Automatic transmission/transaxle shift timing
ON INSIDE AND OUTSIDE and kickdown
l
X Remove front spring/strut spacer (If applicable) l Steering control and returnability AT
l Operation of all instruments, gauges, lights and l Engine performance
accessories l Squeaks and rattles
l Operation of horn(s), wiper and washer TF
l Steering lock for operation ENGINE OPERATING AND HOT
l Check air conditioner for gas leaks
l Adjust idle mixture and speed (and ignition tim-
l Front and rear seats, and seat belts for opera- PD
ing*1)
tion
l Automatic transmission/transaxle fluid level
l All moldings, trims and fittings for fit and align-
l Engine idling and stop knob operation (Diesel
ment
only) FA
l All windows for operation and alignment
l Hood, trunk lid, door panels for fit and alignment
l Latches, keys and locks for operation FINAL INSPECTION RA
l Weatherstrips for adhesion and fit l Install necessary parts (outside mirror, wheel
l Headlamp aiming covers, seat belts, mat, carpet or mud flaps)
l Tighten wheel nuts (Inc. inner nuts if applicable) l Inspect for interior and exterior metal and paint BR
l Tire pressure (Inc. spare tire) damage
l Check front wheels for toe-in l Check for spare tire, jack, tools (wheel chock),
l Install clock/voltmeter/room lamp fuse (If appli- and literature ST
cable) l Wash, clean interior and exterior
l
X Install deodorizing filter to air purifier (If appli-
cable) *1: Not required on models with a direct ignition system RS
l
X Remove wiper blade protectors (If applicable) l : Not applicable to this model.
X
BT
HA
EL
SE
IDX
MA-3
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.
Item Reference pages

OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise
specified.
Tires Check the pressure with a gauge periodically when at a service station, including the
spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or —
excessive wear.
Windshield wiper blades Check for cracks or wear if they do not wipe properly. —
Doors and engine hood Check that all doors, the engine hood, the trunk lid and back door
operate properly. Also ensure that all latches lock securely. Lubricate hinges, latches, rollers and
links if necessary. Make sure that the secondary latch keeps the hood from opening when the
MA-56
primary latch is released.
When driving in areas using road salt or other corrosive materials, check for lubrication fre-
quently.
Tire rotation Tires should be rotated every 5,000 km (3,000 miles) for 4WD models. MA-54
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when per-
forming periodic maintenance, cleaning the vehicle, etc.
Lights Make sure that the headlights, stop lights, tail lights, turn signal lights, and other lights
—
are all operating properly and installed securely. Also check headlight aim.
Warning lights and chimes Make sure that all warning lights and chimes are operating prop-
—
erly.
Steering wheel Check for change in the steering conditions, such as excessive free play, hard
steering or strange noises. —
Free play: Less than 35 mm (1.38 in)
Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for MA-56
cuts, fraying, wear or damage.
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the
engine oil or refuel.
Windshield washer fluid Check that there is adequate fluid in the tank. —
Engine coolant level Check the coolant level when the engine is cold. MA-18, 31, 39
Engine oil level Check the level after parking the vehicle on a level spot and turning off the
MA-24, 30, 38
engine.
Brake and clutch fluid level Make sure that the brake and clutch fluid levels are between the
MA-47, 52
“MAX” and “MIN” lines on the reservoir.
Battery Check the fluid level in each cell. It should be between the “MAX” and “MIN” lines. —
MA-4
PERIODIC MAINTENANCE (Except for Europe)
The following tables show the normal maintenance schedule. Depending upon weather and atmospheric GI
conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent
maintenance may be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.
Engine and Emission Control Maintenance EM

DIESEL ENGINE
Abbreviations: I = Inspect and correct or replace as necessary, R= Replace, A = Adjust, C = Clean, D = Drain water and inspect.
MAINTENANCE OPERATION MAINTENANCE INTERVAL
LC
Perform at the specified months Months — 6 12 18 24 30 36 42 48 Reference
or mileage whichever comes km x 1,000 1 10 20 30 40 50 60 70 80 page
first. (Miles x 1,000) (0.6) (6) (12) (18) (24) (30) (36) (42) (48)
EC
Engine compartment and under vehicle TD RD
Torque of manifolds & exhaust tube nuts I MA-37 MA-29
FE
Drive belts I I I I I MA-37 MA-29
Intake & exhaust valve clearance A A A A A MA-37 *4
Timing belt for camshaft & injection pump (RD28ETi engine) Replace every 100,000 km (60,000 miles) — *5
CL
Engine oil (Use API CC or CD oil)★ Replace every 5,000 km (3,000 miles) or 3 months MA-38 MA-30
Engine oil filter★*1 R R R R R R R R MA-38 MA-31
Engine anti-freeze coolant (Ethylene glycol base) R R MA-39 MA-31
MT
Engine coolant (Soft water)*2 R R R R R R R R MA-39 MA-31
Cooling system I I I I MA-40 MA-33
Air cleaner filter (Dry paper type)★ C C C R C C C R MA-43 MA-35
AT
Air cleaner filter (Viscous paper type)★ R R MA-43 MA-35
Cyclone pre-air cleaner★ (TD42 engine) I I I I I I I I MA-44 —
Fuel filter D D D R D D D R MA-41 MA-33
TF
Fuel lines I I MA-42 MA-34
Injection nozzles*3 MA-44 MA-35
Idling speed I I I I I MA-45 MA-36
PD
NOTE: Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
*1: Use two filters of part No. 15208 43G00 or equivalent for TD42 engine models. FA
Use part No. 15208 40L02 or equivalent for RD28ETi engine models.
*2: Models bound for non-emission regulation area
*3: If engine power decreases, black exhaust smoke is emitted or engine noise increases, check and, if necessary, adjust the fuel
injection nozzle’s starting pressure and the fuel spray pattern. RA
*4: “VALVE CLEARANCE” RD in EM section
*5: “TIMING BELT”, RD in EM section
BR
ST
RS
BT
HA
EL
SE
IDX
MA-5
Engine and Emission Control Maintenance
(Cont’d)
GASOLINE ENGINE
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust, C = Clean.
Months — 6 12 18 24 30 36 42 48 Reference
Perform at the specified months or mile- page
km x 1,000 1 10 20 30 40 50 60 70 80
age whichever comes first.
(Miles x 1,000) (0.6) (6) (12) (18) (24) (30) (36) (42) (48)
Engine compartment and under vehicle
Torque of manifolds & exhaust tube nuts & carburetor fixing nuts*1 I MA-17
Intake & exhaust valve clearance A A A A MA-17
Drive belts I*1 I*1 I I*1 I MA-18
Engine oil (Use API SE, SF, SG or SH oil)★ R R R R R R R R MA-24
Engine oil filter★*2 R R R R R R R R MA-25
Engine anti-freeze coolant (Ethylene glycol base) R R MA-18
Engine coolant (Soft water) R R R R R R R R MA-18
Cooling system I I I I MA-20
Fuel filter★ R R MA-21
Fuel lines I I MA-20
Air cleaner filter (Dry paper type)★ C C C R C C C R MA-22
Air cleaner filter (Viscous paper type)★ R R MA-22
Cyclone pre-air cleaner★ I I I I I I I I MA-23
Positive crankcase ventilation (PCV) system (TB42S engine) I I I I MA-27
PCV filter★ (TB42S engine) R R MA-27
Spark plugs (TB42S engine) I R I R I R I R MA-25
Spark plugs (TB45E engine) I*1 I*1 I*1 R I*1 I*1 I*1 R MA-25
Ignition wires I I MA-26
Carburetor idle rpm & mixture ratio (TB42S engine) I I I I I I I I I *3
Ignition timing (TB42S engine) A A A A A A A A *3
Vacuum hoses & connections*1 I I I I MA-28
Heated oxygen sensor (TB45E engine) I I —
EVAP vapor lines I I MA-28
Conditions”.
*1: Models without three way catalyst
*2: Use part No. 15208 31U01 or equivalent for TB45E engine models.
Use part No. 15208 W1106 or equivalent for TB42S engine models.
*3: “Checking and Adjusting Idle-rpm, Ignition Timing and Mixture Ratio”, “CARBURETOR”, TB42S in EC section.
MA-6
Chassis and Body Maintenance GI

Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, T = Tighten, L = Lubricate.
Perform at the specified Months — 6 12 18 24 30 36 42 48 Reference

months or mileage km x 1,000 1 10 20 30 40 50 60 70 80 page
whichever comes first. (Miles x 1,000) (0.6) (6) (12) (18) (24) (30) (36) (42) (48) EM
Underhood and under vehicle
Brake, clutch, automatic transmission & steering gear fluid or oil (For level &
I I I I I I I I MA-47, 48, 52, 52
leaks)★
LC
Brake fluid★ R R MA-52
Brake booster vacuum hoses, connections & check valve I I MA-52
Power steering fluid & lines (For level & leaks) I*1 I I*1 I I*1 I I*1 I MA-55
EC
Brake, clutch & exhaust systems I I I I I I I I MA-47, 52
Manual transmission (For level & leaks) I I I I I I I I MA-47
Manual transmission oil Replace every 100,000 km (60,000 miles). MA-47
FE
Transfer fluid & differential gear oil (For level & leaks) I I I R I I I R MA-49, 50
Steering gear box & linkage, axle & suspension parts, propeller shafts & front
I I I I I I I I I MA-55, 49
drive shafts★
Steering damper I I I I MA-55
CL
Greasing points of propeller shafts★ See Note (2) L L L L MA-50
Body mountings T T T T T *2
Outside and inside
MT
MA-54
Wheel alignment (if necessary, rotate & balance wheels) I I I I
*3
Brake pads, discs & other brake components★ I I I I I I I I MA-53 AT
Brake linings, drums & other brake components★ I I I I MA-53
Front wheel bearing grease★ I★ R I★ R *4
Axle joint in knuckle flange L L MA-51 TF
Free-running hub grease★ I I I I MA-51
Locks, hinges & hood latch★ L L L L L L L L MA-56
Seat belts, buckles, retractors, anchors & adjuster I I I I MA-56 PD
Foot brake, parking brake & clutch (for free play stroke & operation) I I I I I I I I *5
Air bag system See NOTE (3)
NOTE: (1) Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driv- FA
ing Conditions”.
(2) The propeller shaft should be re-greased daily if it is immersed in water.
(3) Inspect at the first 10 years, and then every 2 years. RA
*1: Models without three way catalyst
*2: “CAB BODY” in BT section
*3: “Front Wheel Alignment” in FA section BR
*4: “Front Wheel Bearing” in FA section
*5: “Brake Pedal and Bracket” in BR section, “Adjusting Clutch Pedal” in CL section
ST
RS
BT
HA
EL
SE
IDX
MA-7
Maintenance Under Severe Driving Conditions

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions

A —
Driving under dusty conditions G — Driving in areas using salt or other corrosive
B —
Driving repeatedly short distances materials
C —
Towing a trailer or caravan H — Driving on rough and/or muddy roads or in
D —
Extensive idling the desert
E —
Driving in extremely adverse weather condi- I — Driving with frequent use of braking or in
tions or in areas where ambient temperatures mountainous areas
are either extremely low or extremely high J — Frequent driving in water
F — Driving in high humidity areas or in mountain-
ous areas
Maintenance operation: Check = Check and correct or replace as necessary.
Reference
Driving Maintenance Maintenance Maintenance page
condition item operation interval
TB TD RD
A B C D . . . . . . Engine oil & oil filter
Gasoline engine Every 3 months or MA-24 — —
Replace
5,000 km (3,000 miles)
Diesel engine Replace More frequently — MA-38 MA-31
A . . . . . . . . . Air cleaner filter
Dry paper type Clean More frequently MA-22 MA-43 MA-35
Viscous paper type Replace MA-22 MA-43 MA-35
Cyclone pre-air cleaner Check MA-23 MA-44 —
Positive crankcase ven- Replace MA-27 — —
tilation filter
A . . . E . . . . . Fuel filter Replace Every 20,000 km MA-21 MA-41 MA-33
(12,000 miles) or 12
. . . . . F . . . . Brake fluid Replace months MA-52
. . . . . . G H . . Steering gear & linkage, axle & suspension parts Check Every 5,000 km (3,000 MA-55, 49, 51
& propeller shaft & front drive shafts miles) or 3 months *1
A . C . . . G H I . Brake pads, discs & other brake components Check MA-53
. . . . . . G . . . Lock, hinges & hood latch Lubricate MA-56
. . . . . . . . . J Front wheel bearing grease & free-running hub *2, MA-51
Check
grease
A . C . . . G H I . Brake linings, drums & other brake components Check Every 6 months or MA-53
10,000 km (6,000 miles)
. . . . . . G H I . Greasing points of propeller shafts Lubricate MA-50
*1: “FRONT AXLE AND FRONT SUSPENSION” in FA section, “REAR AXLE AND REAR SUSPENSION” in RA section
*2: “Front Wheel Bearing”, “FRONT AXLE — Drive Flange and Free-running Hub” in FA section
Maintenance for off-road driving
Whenever you drive off-road through sand, mud or water as deep as the wheel hub, more frequent mainte-
nance may be required of the following items:
G Brake pads and discs
G Brake lining and drums
G Brake lines and hoses
G Wheel bearing grease and free-running hub grease
G Differential, transmission and transfer oil
G Steering linkage
G Propeller shafts and front drive shafts
G Air cleaner filter
G Clutch housing (Check water entry. Refer to MA-48.)
MA-8
PERIODIC MAINTENANCE (For Europe)
The following tables show the normal maintenance schedule. Depending upon weather and atmospheric GI
conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent
maintenance may be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.
Engine Oil & Minor Service EM

Annual driving distance below 30,000 km (18,000 miles)
Abbreviations: R = Replace, I = Inspect and correct or replace as necessary. LC
MAINTENANCE OPERATION
Perform either at number of kilometers (miles) or km x 1,000 10 20 30 40 50 60 70 80 90 Reference
months, whichever comes first.
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54) page EC
Months 6 12 18 24 30 36 42 48 (54)
Underhood and under vehicle FE
Engine oil (Use CCMC PD1 or PD2 oil)★ R R R R R R R R R MA-31
Engine oil filter★ R R R R R R R R R MA-31
Drive belts I I I I I I I I I MA-29 CL
Conditions”. MT
Annual driving distance over 30,000 km (18,000 miles) AT

Abbreviations: R = Replace, I = Inspect and correct or replace as necessary.
MAINTENANCE OPERATION TF
Reference
km x 1,000 10 20 30 40 50 60 70 80 90 page
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)
PD
Engine oil (Use CCMC PD1 or PD2 oil)★ R R R R R R R R R MA-31
Engine oil filter★ R R R R R R R R R MA-31 FA
Drive belts I I I I I I I I I MA-29
NOTE: Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving RA
Conditions”.
BR
ST
RS
BT
HA
EL
SE
IDX
MA-9
Engine and Emission Control Service

Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust. [ ]: At the specified mileage only
Perform either at number of kilometers (miles) km x 1,000 10 20 30 40 50 60 70 80 90 Reference
or months, whichever comes first. page
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)
Months 6 12 18 24 30 36 42 48 54

Engine anti-freeze coolant (Ethylene glycol base) See NOTE (2) R MA-31
Cooling system I I I MA-31
Fuel lines I I MA-34
Fuel filter R R MA-33
Air cleaner filter (Viscous paper type)★ R R MA-35
Intake & exhaust valve clearance A A A A *1
Injection nozzles See NOTE (3) MA-35
Timing belts for camshaft and injection pump [R] *2
NOTE: (1) Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe
Driving Conditions”.
(2) First replace at 80,000 km (48,000 miles) or 48 months, then every 60,000 km (36,000 miles) or 36 months.
(3) If engine power decreases, black smoke is emitted or engine noise increases, check and, if necessary, adjust
the fuel injection nozzle’s starting pressure and the fuel spray pattern.
*1: “VALVE CLEARANCE”, RD in EM section
*2: “TIMING BELT” RD in EM section
Annual driving distance over 30,000 km (18,000 miles)

Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust.
Reference
km x 1,000 10 20 30 40 50 60 70 80 90
page
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)

Engine anti-freeze coolant (Ethylene glycol base) See NOTE (2) R MA-31
Cooling system I I MA-31
Fuel lines I MA-34
Fuel filter R MA-33
Air cleaner filter (Viscous paper type)★ R MA-35
Intake & exhaust valve clearance A A A *1
Injection nozzles See NOTE (3) MA-35
Timing belts for camshaft and injection pump R *2
NOTE: (1) Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe
Driving Conditions”.
(2) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles).
(3) If engine power decreases, black smoke is emitted or engine noise increases, check and, if necessary, adjust
the fuel injection nozzle’s starting pressure and the fuel spray pattern.
*1: “VALVE CLEARANCE”, RD in EM section
*2: “TIMING BELT”, RD in EM section
MA-10
Chassis and Body Services GI

Abbreviations: R = Replace, I = Inspect, and correct or replace as necessary, L = Lubricate, T = Tighten.
[ ]: At the specified mileage only
MAINTENANCE OPERATION MAINTENANCE INTERVAL EM
Perform either at number of kilometers (miles) or months, km x 1,000 10 20 30 40 50 60 70 80 90 Reference
whichever comes first. page
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)
Months 6 12 18 24 30 36 42 48 54 LC
CHASSIS AND BODY Underhood and under vehicle
Brake & clutch fluid (For level & leaks)★ I I I I MA-52, 47
Automatic transmission fluid (For level & leaks)★ I I I I MA-48
EC
Brake fluid★ R R MA-52
Brake booster vacuum hoses, connections & check valve I I MA-52 FE
Power steering fluid & lines (For level & leaks) I I I I MA-55
Brake & clutch systems I I I I MA-52, 47
Manual transmission oil (For leaks) I I I I MA-47 CL
Manual transmission oil [R] MA-47
Transfer fluid I I R I MA-49
Limited slip differential (LSD) gear oil (For level & leaks)★*1 I I R I MA-50
MT
Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system★ I I I I MA-55, 47 *2
Greasing points of propeller shaft See NOTE (1) L L L L MA-50 AT
Drive shafts & steering damper★ I I I I *3
Body mounting bolts & nuts T T T T *4
Outside and Inside TF
Wheel alignment (If necessary, rotate & balance wheels) I I I I MA-54, *5
Brake pads, discs & other brake components★ I I I I MA-53
PD
Front wheel bearing grease I R I R MA-51
Axle joint in knuckle flange L L MA-51
Free running hub grease I I I I MA-51 FA
Headlamp aiming I I I I *6
Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I *7
Ventilation air filter R R R *8 RA
Body corrosion Annually MA-57
Air bag system See NOTE (2) *9
BR
NOTE: (1) The propeller shaft should be re-greased daily if it is immersed in water.
(2) Inspect after 10 years, then every 2 years.
(3) Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driv- ST
ing Conditions”.
*1: Including differential gear with differential lock
*2: “Front Axle and Front Suspension Parts” in FA section, “Rear Axle and Rear Suspension Parts” in RA section RS
*3: “FRONT AXLE — Drive Shaft” in FA section
*5: “Front Wheel Alignment” in FA section
*6: “Aiming Adjustment” in EL section BT
*8: “Ventilation air filter” in HA section
*9: “Maintenance Items” in RS section
HA
EL
SE
IDX
MA-11
Chassis and Body Services (Cont’d)
Annual driving distance over 30,000 km (18,000 miles)
Abbreviations: R = Replace. I = Inspect, and correct or replace as necessary, L = Lubricate, T = Tighten.
Reference
km x 1,000 10 20 30 40 50 60 70 80 90 page
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)
CHASSIS AND BODY Underhood and under vehicle
Brake & clutch fluid (For level & leaks)★ I I I MA-52, 47
Automatic transmission fluid (For level & leaks)★ I I I MA-48
Brake fluid★ R MA-52
Brake booster vacuum hoses, connections & check valve I MA-52
Power steering fluid & lines (For level & leaks) I I I MA-55
Brake & clutch systems I I I MA-52, 47
Manual transmission oil (For leaks) I I I MA-47
Manual transmission oil R MA-47
Transfer fluid I R I MA-49
Limited slip differential (LSD) gear oil (For level & leaks)★*1 I R I MA-50
Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system★ I I I MA-55, 47 *2
Geasing points of propeller shaft L L L MA-50
Drive shafts & steering damper★ I I I *3
Body mounting bolts & nuts T T T *4
Outside and Inside
Wheel alignment (If necessary, rotate & balance wheels) I I I MA-54, *5
Brake pads, discs & other brake components★ I I I MA-53
Front wheel bearing grease I R I MA-51
Axle joint in knuckle flange L MA-51
Free running hub grease I I I MA-51
Headlamp aiming I I I *6
Foot brake, parking brake & clutch (For free play, stroke & operation) I I I *7
Ventilation air filter R R R *8
Body corrosion Annually MA-57
Air bag system See NOTE (1) *9
NOTE: (1) Inspect after 10 years, then every 2 years.

(2) Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driv-
ing Conditions”.
*2: “Front Axle and Front Suspension Parts” in FA section, “Rear Axle and Rear Suspension Parts” in RA section
*3: “FRONT AXLE — Drive Shaft” in FA section
*6: “Aiming Adjustment” in EL section
*8: “Ventilation air filter” in HA section
*9: “Maintenance Items” in RS section
MA-12
Maintenance Under Severe Driving Conditions GI

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions EM

A —
Driving under dusty conditions G — Driving in areas using salt or other corrosive
B —
Driving repeatedly short distances materials
C —
Towing a trailer or caravan H — Driving on rough and/or muddy roads or in LC
D —
Extensive idling the desert
E —
Driving in extremely adverse weather condi- I — Driving with frequent use of braking or in
tions or in areas where ambient temperatures mountainous areas EC
are either extremely low or extremely high J — Frequent driving in water
F — Driving in high humidity areas or in mountain-
ous areas FE
Maintenance operation: Check = Check and correct or replace as necessary.
Maintenance CL
interval
Driving Maintenance Maintenance Reference
condition item operation Annual driving distance page
below 30,000 km
(18,000 miles)
over 30,000 km
(18,000 miles) MT
A B C D . . . . . . Engine oil & oil filter Every 3 months or Every 5,000 km MA-30, 31
Replace 5,000 km (3,000 (3,000 miles)
miles)
AT
A . . . . . . . . . Air cleaner filter Viscous paper type Every 30,000 km Every 30,000 km MA-35
Replace (18,000 miles) or (18,000 miles)
18 months
A . . . E . . . . . Fuel filter Replace Every 20,000 km Every 30,000 km MA-33 TF
(12,000 miles) or (18,000 miles)
. . . . . F . . . . Brake fluid Replace 12 months MA-52
. . C . . . . H . . Automatic transmission fluid Every 60,000 km Every 60,000 km
(36,000 miles) or 24 (36,000 miles) PD
months
Replace
Limited slip differential (LSD) gear oil*3 Every 30,000 km Every 30,000 km MA-50
(18,000 miles) or (18,000 miles)
18 months FA
. . . . . . G H . . Steering gear & linkage, axle & suspension parts & Every 10,000 km Every 15,000 km MA-55, 49,
propeller shaft & exhaust system Check (6,000 miles) or 6 (9,000 miles) 51
months *1
RA
. . . . . . G H . J Greasing points of propeller shafts Lubricate MA-50
. . C . . . . H . . Drive shafts & steering damper Check *1
A . C . . . G H I . Brake pads, discs & other brake components Check MA-53 BR
. . . . . . . . . J Front wheel bearing grease & free-running hub grease Check *2, MA-51
*1: “Front Axle and Front Suspension Parts” in FA section, “Rear Axle and Rear Suspension” in RA section ST
Maintenance for off-road driving

RS
Whenever you drive off-road through sand, mud or water as deep as the wheel hub, more frequent mainte-
nance may be required of the following items: BT
G Brake pads and discs
G Brake lining and drums
G Brake lines and hoses HA
G Wheel bearing grease and free-running hub grease
G Differential, transmission and transfer oil
G Steering linkage EL
G Propeller shafts and front drive shafts
G Air cleaner filter
G Clutch housing (Check water entry. Refer to MA-48.) SE
IDX
MA-13
RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants

Capacity (Approximate)
Recommended Fluids/Lubricants
Liter Imp measure
Engine oil (Refill)
With oil filter TB45E 7.6 6-3/4 qt
TB42S 7.5 6-5/8 qt Gasoline engine: API SG or SH*1 for
Europe
TD42 10.5 9-1/4 qt API SE, SF, SG or SH*1
RD28ETi 6.4 5-5/8 qt except for Europe
Without oil filter TB45E 7.3 6-3/8 qt Diesel engine: API CC or CD*1 for TD42
CCMC PD1 or PD2*4 for
TB42S 7.0 6-1/8 qt RD28ETi
TD42 9.3 8-1/8 qt
RD28ETi 5.8 5-1/8 qt
Cooling system (with reservoir tank)
With front heater M/T
TB45E 12.0 10-5/8 qt
A/T
TB42S M/T 13.0 11-1/2 qt
TD42 M/T 15.1 13-1/4 qt
RHD 11.8 10-3/8 qt
RD28ETi MT
LHD 11.6 10-1/4 qt
Anti-freeze coolant (Ethylene glycol base)
Without front M/T
TB45E or soft water
heater A/T 11.3 10 qt
TB42S M/T 12.3 10-7/8 qt
TD42 M/T 14.4 12-5/8 qt
RHD 11.1 9-3/4 qt
RD28ETi MT
LHD 10.9 9-5/8 qt
With rear heater RHD 12.9 11-3/8 qt
RD28ETi MT
LHD 12.7 11-1/8 qt
Manual transmission
FS5R50B 3.8 6-3/4 pt API GL-4, Viscosity SAE 75W-90 only
FS5R30A 5.1 9 pt
Differential carrier gear oil (without limited slip differential) — — API GL-5*1
Differential carrier gear oil (with limited slip differential)
Except Europe Gear Oil Hypoid LSD (Part No.: KLD31-
— —
14002) or equivalent*2
Transfer fluid Genuine Nissan ATF or equivalent*3 or
TX12A 1.9 1-5/8 qt API GL-4*1
Automatic transmission fluid 11.8 10-3/8 qt Genuine Nissan ATF or equivalent*3
Power steering fluid Type DEXRONTMIII or equivalent
Refill to the proper oil level
Brake and clutch fluid according to the instructions in DOT3 or DOT4*5 (US FMVSS No. 116)
the “Do-it-yourself operations” for Europe
section DOT 3 (US FMVSS No. 116) except for
Europe
Multi-purpose grease — — NLGI No. 2 (Lithium soap base)
Propeller shaft grease NLGI No. 2 (Molybdenum disulphide
lithium soap base)
Air conditioning system refrigerant — — HFC-134a (R-134a)
Air conditioning system lubricants Nissan A/C System Oil Type S or
— —
exact equivalent
*1: For further details, see “SAE viscosity number”.

*2: API GL-5, SAE 140 and 10% volume of LSD Friction Modifier (Part No.: 38469-C6000) is an equivalent.
*3: For more information regarding suitable fluids, contact a Nissan dealer for correct brands of DEXRONTMIII ATF.
*4: If CCMC oils are not available, API CD may be used. However, CCMC oils are strongly recommended if at all possible.
*5: Never mix different types of fluids (DOT3 and DOT4).
MA-14
SAE Viscosity Number GI
EM
LC
EC
FE
CL
MT
TI0005 TI0003 AT
I For cold and warm areas: I For cold and warm areas:
10W-30 is preferable for ambient tempera- 75W-90 for transfer and 80W-90 for differen-
tures above −20°C (−4°F). tial are preferable. TF
I For hot areas: I For hot areas:
20W-40 and 20W-50 are suitable. 90 is suitable for ambient temperatures
below 40°C (104°F). PD
FA
RA
BR
ST
RS
BT
HA
TI0006
I For cold areas: EL
10W-30 is preferable for ambient tempera-
ture above −20°C (−4°F).
On turbocharger models, 5W-20 is not rec- SE
ommended. Use 5W-30 only below 0°C
(32°F).
I For hot and warm areas: IDX
20W-40 and 20W-50 are suitable.
MA-15
Anti-freeze Coolant Mixture Ratio

The engine cooling system is filled at the factory with a high-quality,
year-round, anti-freeze coolant solution. The anti-freeze solution
contains rust and corrosion inhibitors. Therefore, additional cooling
system additives are not necessary.
CAUTION:
When adding or replacing coolant, be sure to use only an eth-
ylene glycol anti-freeze with the proper mixture ratio. See the
following examples:
Outside temperature
down to Anti- Soft
freeze water
°C °F
−15 5 30% 70%
−35 −30 50% 50%
The use of other types of coolant solutions may damage your

cooling system.
MA-16
ENGINE MAINTENANCE TB
Checking Tightening Torque GI

I Checking should be performed while engine is cold.
MANIFOLD BOLTS AND NUTS

Intake manifold:
TB42S EM
: 16 - 19 N⋅m (1.6 - 1.9 kg-m, 12 - 14 ft-lb)
TB45E
: 21 - 26 N⋅m (2.1 - 2.7 kg-m, 15 - 20 ft-lb) LC
Exhaust manifold:
: 27 - 31 N⋅m (2.8 - 3.2 kg-m, 20 - 23 ft-lb)
EC
EXHAUST TUBE NUTS
: 43 - 50 N⋅m (4.4 - 5.1 kg-m, 32 - 37 ft-lb)
FE
CARBURETOR NUTS
: 16 - 19 N⋅m (1.6 - 1.9 kg-m, 12 - 14 ft-lb)
CL
MT
AT
Adjusting Intake and Exhaust Valve Clearance
Adjustment should be made while engine is warm but not
running. TF
1. Set No. 1 cylinder at top dead center on its compression stroke,
and adjust valve clearances q 1 ,q2 ,q3 ,q 6 ,q7 and q10 .
2. Set No. 6 cylinder at top dead center on its compression stroke, PD
and adjust valve clearances q 4 ,q5 ,q8 ,q 9 ,q11 and q
12 .
Valve clearance:
Intake q1 ,q 3 ,q 5 ,q7 ,q9 and q 11
FA
TB42S: 0.38 mm (0.015 in)
TB45E: 0.35 mm (0.014 in) RA
Exhaust q 2 ,q 4 ,q6 ,q8 ,q10 and q 12
TB42S: 0.38 mm (0.015 in)
TB45E: 0.35 mm (0.014 in) BR
Adjusting screw lock nuts:
: 16 - 22 N⋅m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
ST
RS
SMA874B BT
I Tighten rocker cover bolts in numerical order.
: 1 - 3 N⋅m (0.1 - 0.3 kg-m, 9 - 26 in-lb) HA
EL
SE
SMA891B
IDX
MA-17
Checking Drive Belts
SMA875BA
1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,

replace with a new one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
Adjust if belt deflections exceed the limit.
Belt deflection:
Unit: mm (in)
Used belt deflection
Deflection of
Deflection after new belt
Limit
adjustment
13 - 15 10 - 12
Alternator 16 (0.63)
(0.51 - 0.59) (0.39 - 0.47)
Air conditioner 8 - 10 6-8
11 (0.43)
compressor (0.31 - 0.39) (0.24 - 0.31)
Power steering oil 15 - 17 14 - 16
19 (0.75)
pump (0.59 - 0.67) (0.55 - 0.63)
Applied pushing
98 N (10 kg, 22 lb)
force
Inspect drive belt deflections when engine is cold.
Changing Engine Coolant

WARNING:
To avoid being scalded, never change the coolant when the
engine is hot.
—DRAINING ENGINE COOLANT—
1. Turn the ignition switch from “OFF” to “ON” and make sure that
the A/C display indicates “32”. Then turn ignition switch to
“OFF”.
SMA972C
MA-18
Changing Engine Coolant (Cont’d)
2. Open radiator drain cock at the bottom of radiator, and remove GI
radiator filler cap.
I Be careful not to allow coolant to contact drive belts.
EM
LC
SMA973C
3. Remove cylinder block drain plug. EC

4. Close drain cock and tighten drain plug securely.
FE
CL
MT
SMA974C
AT
5. Fill radiator with water and close radiator cap.
6. Run engine and warm it up sufficiently.
7. Race engine 2 or 3 times under no-load. TF
8. Stop engine and wait until it cools down.
9. Repeat step 2 through step 8 until clear water begins to drain
from radiator. PD
10. Drain water.
—REFILLING ENGINE COOLANT—
11. Close drain cock and tighten drain plug securely. FA
I Apply sealant to the thread of drain plug.
Cylinder block drain plug
: 34 - 44 N⋅m (3.5 - 4.5 kg-m, 25 - 33 ft-lb) RA
12. Open radiator cap.
13. Fill radiator with coolant up to specified level.
Follow instructions attached to anti-freeze container for mixing BR
ratio of anti-freeze to water.
For coolant mixture ratio, refer to MA-16.
Coolant capacity (With reservoir tank): liter (lmp qt) ST
With heater
TB45E (A/T & M/T) 12.0 (10-5/8)
TB42S (M/T) 13.0 (11-1/2) RS
Without heater
TB45E (A/T & M/T) 11.3 (10)
SMA878B TB42S (M/T) 12.3 (10-7/8) BT
Pour coolant through coolant filler neck slowly to allow air in
system to escape.
14. Remove reservoir tank, drain coolant, then clean reservoir tank. HA
15. Install reservoir tank and fill it with coolant up to “MAX” level and
then install radiator cap.
16. Run engine and warm it up sufficiently. EL
17. Race engine 2 or 3 times under no-load.
18. Stop engine and cool it down, then add coolant if necessary.
19. Start the engine. Increase engine speed from idle to approxi- SE
mately 2,000 rpm. Check that there is no heater core flowing
water noise coming from the heater unit under the instrument
panel.
SMA412B 20. If there is flowing water noise, repeat steps 16, 17 and 18 above IDX
until the noise stops.
MA-19
Checking Cooling System

CHECKING HOSES
Check hoses for proper attachment and for leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR CAP

Apply pressure to radiator cap with cap tester to see if it is satis-
factory.
Radiator cap relief pressure:
108 - 127 kPa
(1.08 - 1.27 bar, 1.1 - 1.3 kg/cm2, 16 - 18 psi)
SLC613
Pull the negative-pressure valve to open it. Check that it closes

completely when released.
SMA871B
CHECKING COOLING SYSTEM FOR LEAKS

Apply pressure to the cooling system with cap tester to check for
leakage.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
CAUTION:
Higher pressure than the specified value may cause damage
to radiator.
SMA975C
Checking Fuel Lines

Inspect fuel lines and tank for proper attachment and for leaks,
cracks, damage, loose connections, chafing and deterioration. If
necessary, repair or replace faulty parts.
MA-20
Checking Fuel Lines (Cont’d)
CAUTION: GI
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
EM
LC
SMA804AC
Changing Fuel Filter (TB42S) EC

Be careful not to spill fuel over engine compartment. Place a
shop towel to absorb fuel. FE
CL
MT
SMA976C
AT
Changing Fuel Filter (TB45E)
WARNING:
Before removing fuel filter, release fuel pressure from fuel line TF
to eliminate danger.
PD
FA
RA
1. Remove fuse for fuel pump.
2. Start engine.
3. After engine stalls, crank engine two or three times to make BR
sure that fuel pressure is released.
4. Turn ignition switch OFF and install fuse for fuel pump.
ST
RS
SMA977C BT
5. Loosen fuel hose clamps.
6. Replace fuel filter. HA
I Be careful not to spill fuel over engine compartment. Place
a shop towel to absorb fuel.
I Use a high-pressure type fuel filter. Do not use a synthetic EL
resinous fuel filter.
I When tightening fuel hose clamps, refer to “Checking Fuel
Lines”. SE
SMA978C
IDX
MA-21
Cleaning and Changing Air Cleaner Filter

(TB42S)
Viscous paper type
The viscous paper type filter does not need cleaning between
renewals.
SMA881B
Dry paper type

It is necessary to clean the element or replace it at the recom-
mended intervals, more often under dusty driving conditions.
SMA882B
To properly tighten wing nuts, and tighten wing nuts until they
touch air cleaner. Then tighten them three more turns.
SMA919B

(TB45E)
Viscous paper type
The viscous paper type filter does not need cleaning between
renewals.
SMA979C
Dry paper type

It is necessary to clean the element or replace it at the recom-
mended intervals, more often under dusty driving conditions.
SMA980C
MA-22
(TB45E) (Cont’d) GI
To properly tighten wing nuts, position clamps at four places
and tighten wing nuts until they touch air cleaner. Then tighten
them three more turns.
EM
LC
SMA981C
Checking Cyclone Pre-air Cleaner EC

Remove dust cover and check duct for dust clogging. Clean away
any dust. FE
CL
MT
AT
TF
PD
FA
SMA883BA
RA
BR
ST
RS
BT
HA
EL
SE
SMA996C
IDX
MA-23
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 com-
ponents.
2. Remove drain plug and oil filler cap.
3. Drain oil and refill with new engine oil.
Oil grade: API SG or SH for Europe
API SE, SF, SG or SH except for Europe
Viscosity:
SMA884BA See “RECOMMENDED FLUIDS AND LUBRI-
CANTS”.
SMA983C
Refill oil capacity (Approximately):

Unit: liter (lmp qt)
TB42S TB45E
With oil filter change 7.5 (6-5/8) 7.6 (6-3/4)
Without oil filter change 7.0 (6-1/8) 7.3 (6-3/8)
CAUTION:
I Be sure to clean drain plug and install with new washer.
Drain plug:
: 29 - 39 N⋅m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
I Use recommended engine oil.
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.
SMA885B
MA-24
Changing Oil Filter GI

1. Remove oil filter with a suitable tool.
WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.
EM
LC
SMA984C
EC
FE
CL
MT
SMA985C
AT
2. Before installing new oil filter, clean the oil filter mounting sur-
face on cylinder block, and coat the rubber seal of oil filter with
a little engine oil. TF
PD
FA
SMA010
RA
3. Screw in the oil filter until a slight resistance is felt, then tighten
additionally more than 2/3 turn.
4. Add engine oil. BR
Refer to Changing Engine Oil.
ST
RS
SMA886B BT
Checking and Changing Spark Plugs
1. Disconnect ignition wires from spark plugs at boot. Do not pull HA
on the wire.
2. Remove spark plugs with spark plug wrench.
3. Clean plugs in sand blast cleaner. EL
4. Check insulator for cracks or chips, gasket for damage or dete-
rioration and electrode for wear and burning. If they are exces-
sively worn away, replace with new spark plugs. SE
SMA481B
IDX
MA-25
Checking and Changing Spark Plugs (Cont’d)
Spark plug: (TB42S)
Standard type BP5ES
Hot type BP4ES
Cold type BP6ES, BP7ES
Spark plug: (TB45E)

Standard type BPR5E-11
Hot type BPR4E-11
Cold type BPR6E-11
5. Check spark plug gap.

Gap:
TB42S
0.8 - 0.9 mm (0.031 - 0.035 in)
TB45E
1.0 - 1.1 mm (0.039 - 0.043 in)
6. Install spark plugs. Reconnect ignition wires according to Nos.
indicated on them.
Spark plug:
: 20 - 29 N⋅m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)
SMA476
Checking Ignition Wires

1. Inspect wires for cracks, damage, burned terminals and for
improper fit.
2. Measure the resistance of wires and check for intermittent
breaks by shaking them.
Resistance: Less than 30 kΩ
If it exceeds the limit, replace the ignition wire with a new one.
SMA015AA
Checking Choke Mechanism (TB42S)

1. When engine is shut off and cold, check choke valve and
mechanism to make sure that they operate freely.
(1) Fully open throttle valve and insure that choke valve closes
properly.
(2) Push choke valve and, check it for binding or unsmooth move-
ment.
2. Check that bimetal cover index mark is set at the choke hous-
ing index mark.
3. Start engine and run it at idle. Check to see if choke valve
SMA855A gradually opens approaching full open as engine warms up.
MA-26
Checking Positive Crankcase Ventilation (PCV) GI

System
CHECKING PCV VALVE
With engine running at idle, remove ventilation hose from rocker
cover; if valve is working properly, a hissing noise will be heard as
air passes through it and a strong vacuum should be felt immedi-
EM
ately when a finger is placed over valve inlet.
LC
SMA887BA
EC
FE
CL
MT
SMA988C
AT
CHECKING VENTILATION HOSES
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
TF
hose cannot be freed of obstructions, replace.
PD
FA
SMA888BA
RA
BR
ST
RS
SMA989C BT
Changing Positive Crankcase Ventilation (PCV)
Filter (TB42S) HA
Remove air cleaner cover and replace PCV filter.
EL
SE
SMA889BA
IDX
MA-27
Checking Vacuum Hoses and Connections

Check vacuum hoses for improper attachment and for leaks,
cracks, damage, loose connections, chafing and deterioration.
Checking Vapor Lines

1. Visually inspect vapor lines for proper attachment and for
cracks, damage, loose connections, chafing and deterioration.
2. Inspect vacuum relief valve of fuel tank filler cap for clogging,
sticking, etc.
Refer to EVAPORATIVE EMISSION CONTROL SYSTEM
INSPECTION in EC section.
SMA990C
MA-28
ENGINE MAINTENANCE RD

Checking should be performed while engine is cold.
MANIFOLD BOLTS AND NUTS

Intake and exhaust manifolds:
M10 EM
: 25 - 29 N⋅m (2.6 - 3.0 kg-m, 19 - 22 ft-lb)
M8
: 16 - 20 N⋅m (1.6 - 2.0 kg-m, 12 - 14 ft-lb) LC
Nut
: 16 - 20 N⋅m (1.6 - 2.0 kg-m, 12 - 14 ft-lb)
EC
Checking Drive Belt
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
SMA997C
HA
EL
SE
IDX
MA-29
Checking Drive Belt (Cont’d)
1. Inspect for cracks, fraying, wear or oil adhesion. Replace if
necessary.
The belts should not touch the bottom of the pulley groove.
2. Check drive belt deflection by pushing on the belt midway
between pulleys.
Unit: mm (in)
Deflection after Deflection of new belt
Limit
adjustment
Alternator 17 (0.67) 12 - 14 (0.47 - 0.55) 9 - 11 (0.35 - 0.43)
Air conditioner
11 (0.43) 7 - 9 (0.28 - 0.35) 6 - 8 (0.24 - 0.31)
compressor
Power steering oil
14 (0.55) 10 - 12 (0.39 - 0.47) 9 - 11 (0.35 - 0.43)
pump
Applied pushing
98 N (10 kg, 22 lb)
force
Check drive belt deflections when engine is cold.
Changing Engine Oil

WARNING:
I Be careful not to burn yourself, as engine oil is hot.
I Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
ponents.
2. Remove oil filler cap and drain plug.
SMA998C 3. Drain oil and fill with new engine oil.
Oil grade: CCMC PD1 or PD2
Viscosity:
See “RECOMMENDED FLUIDS AND
LUBRICANTS”, MA-14.
Refill oil capacity (approximate):
Without oil filter change
6.4 (5-5/8 Imp qt)
With oil filter change
5.8 (5-1/8 Imp qt)
CAUTION:
I Be sure to clean and install oil pan drain plug with washer.
Drain plug:
: 29 - 39 N⋅m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
I The refill capacity changes depending on the oil tempera-
ture and drain time; use these valves as a reference and be
certain to check with the dipstick when changing the oil.
MA-30
Changing Engine Oil (Cont’d)
4. Check oil level. GI
5. Start engine. Check area around drain plug and oil filter for any
sign of oil leakage.
minutes check oil level.
EM
LC
SMA999C
Changing Engine Oil Filter EC

1. Remove oil filter with Tool.
WARNING: FE
Be careful not to burn yourself, as the engine and engine oil
are hot.
CL
MT
SMA001D
AT
2. Clean oil filter mounting surface on cylinder block. Coat rubber
seal of new oil filter with engine oil.
3. Screw in the oil filter until a slight resistance is felt, then tighten TF
an additional 2/3 of a turn.
4. Add engine oil.
Refer to Changing Engine Oil. PD
I Clean excess oil from engine.
FA
SMA010
RA
WARNING: BR
To avoid the danger of being scalded, never change the cool-
ant when the engine is hot.
—DRAINING ENGINE COOLANT— ST
1. Move heater TEMP control knob all the way to HOT.
2. Open radiator drain plug at the bottom of radiator.
RS
SMA972C BT
3. Remove radiator filler cap.
Remove reservoir tank, drain coolant, then clean reservoir tank. HA
Install it temporarily.
EL
SE
SMA002D
IDX
MA-31
4. Remove cylinder block drain plug located at left rear of cylin-
der block.
5. Drain coolant and install reservoir tank, cylinder block drain
plug and radiator drain plug.
6. Fill radiator with water and warm up engine.
7. Stop engine and wait until it cools down.
8. Repeat step 2 through step 7 two or three times.
9. Drain water.
SMA003D

10. Install reservoir tank, radiator drain plug, and cylinder block
drain plugs.
I Apply sealant to the thread of cylinder block drain plug.
Cylinder block drain plug:
: 34 - 44 N⋅m (3.5 - 4.5 kg-m, 25 - 33 ft-lb)
11. Fill radiator and reservoir tank with coolant up to the MAX level
and install radiator cap.
SMA182B
Coolant capacity (With reservoir tank): (Imp qt)

RHD models
Without rear heater 11.8 (10-3/8)
With rear heater 12.9 (11-3/8)
LHD models
Without rear heater 11.6 (10-1/4)
With rear heater 12.7 (11-1/8)
Reservoir tank capacity (for MAX level):
1.2 (1-1/8 Imp qt)
system to escape.
SMA412B
12. Warm up engine to normal operating temperature.
13. Run engine at 2,000 rpm for 10 seconds and return to idle
speed.
I Repeat 2 or 3 times.
Watch coolant temperature gauge so as not to overheat the
engine.
14. Stop engine and cool it down.
I Cool down using a fan to reduce the time.
15. Remove the radiator filler cap and check coolant level.
I If necessary, refill radiator up to filler neck with coolant.
16. Refill reservoir tank to Max line with coolant.
17. Repeat step 12 through step 16 two or more times.
SMA004D 18. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 2,000 rpm with heater tempera-
ture control set at several positions between COOL and HOT.
I Sound may be noticeable at heater water cock.
19. If sound is heard, bleed air from cooling system by repeating
steps 12 through 16 until coolant level no longer drops.
I Clean excess coolant from engine.
MA-32
Checking Cooling System GI

CHECKING HOSES AND CLAMPS
Check hoses and clamps for proper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.
EM
LC
CHECKING RADIATOR CAP EC

factory. FE
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) CL
MT
SLC613
AT
Pull the negative-pressure valve to open it. Check that it closes
TF
PD
FA
SMA871B
RA
CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system with cap tester to check for BR
leakage.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi) ST
CAUTION:
Use of higher pressure than the specified value may cause
damage to radiator. RS
SMA007D BT
Checking and Replacing Fuel Filter and
Draining Water HA
Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.
EL
CHECKING FUEL FILTER
Check fuel filter for fuel leakage, damage and other abnormal
signs. SE
REPLACING FUEL FILTER
SMA757B 1. Disconnect harness connector and drain fuel. IDX
MA-33
Draining Water (Cont’d)
2. Remove fuel filter using band-type filter wrench.
Remove fuel filter and fuel filter sensor.
CAUTION:
Remove fuel filter without spilling fuel. If spilt, wipe off imme-
diately. Be specially careful not to spill fuel on engine mount
insulator.
SMA005D
3. Wipe clean fuel filter mounting surface on fuel filter bracket and
smear a little fuel on rubber seal of fuel filter.
4. Screw fuel filter on until a slight resistance is felt, then tighten
an additional more than 2/3 of a turn.
5. Install fuel filter sensor to new fuel filter.
6. Bleed air from fuel line.
Refer to Bleeding Fuel System in EC section.
7. Start engine and check for leaks.
SMA010
DRAINING WATER
1. Drain water as follows.
Loosen drain cock and drain water.
Loosening drain cock 4 to 5 turns causes water to start drain-
ing. Do not remove drain cock by loosening it excessively.
If water does not drain properly, move the priming pump up and
down.
SMA825B
2. Bleed air.
Checking Fuel Lines

Check fuel lines and tank for proper attachment, leaks, cracks,
CAUTION:
Keep clean parts with compressed air when assembling.
SMA803A
MA-34
Cleaning and Replacing Air Cleaner Filter GI
EM
LC
SMA006D
DRY PAPER TYPE EC

Clean or replace element more often under dusty driving condi-
tions. FE
CL
MT
SMA485B
AT
VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any clean-
ing operation between renewal. TF
PD
FA
RA
Checking Injection Nozzle
WARNING: BR
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to come into contact with your hand or
body, and make sure that your eyes are properly protected. ST
1. Install nozzle to injection nozzle tester and bleed air from flare
nut.
2. Check initial injection pressure by pumping tester handle one RS
full stroke per second.
Initial injection pressure:
EF791A Used nozzle BT
More than 14,220 kPa
(142.2 bar, 145 kg/cm2, 2,062 psi)
New nozzle HA
14,711 - 15,495 kPa
(147.1 - 155.0 bar, 150 - 158 kg/cm2,
2,133 - 2,247 psi) EL
I Always check initial injection pressure before installing
new nozzle.
SE
SEF672A
IDX
MA-35
Checking Injection Nozzle (Cont’d)
3. Check spray pattern by pumping tester handle one full stroke
per second.
a. If main spray angle is within 30 degrees as shown, injec-
tion nozzle is good.
b. It is still normal even if a thin stream of spray deviates from
main spray (pattern B).
4. If initial injection pressure or injection nozzle is not normal,
adjust or clean injection nozzle.
5. Test again. If it is not corrected, replace nozzle.
Refer to EC section for injection pressure adjustment, clean-
ing and replacement.
SEF079S
6. Install all injection nozzles with Tool and securely connect fuel
spill tube and delivery tubes.
7. Bleed air from fuel system and check for fuel leakage with
engine running.
Injection nozzle to cylinder head:
: 59 - 69 N⋅m (6.0 - 7.0 kg-m, 43 - 51 ft-lb)
Spill tube nut:
: 39 - 49 N⋅m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Injection tube:
: 20 - 25 N⋅m (2.2 - 2.5 kg-m, 16 - 18 ft-lb)
Checking Idle Speed

Inspection should be carried out with gears in “Neutral” and
with air conditioner and other electrical loads off.
1. Warm up engine until engine coolant temperature indicator
points to the middle of gauge.
2. Attach a diesel tachotester’s pick-up to No. 1 fuel injection tube.
3. Race engine two or three times and check idle speed.
Idle speed:
Unit: rpm
MT 750−+50
0
AT 750−+50
0
Timing Belt Replacement

Refer to EM section.
MA-36
ENGINE MAINTENANCE TD

Checking should be performed while engine is cold [approxi-
mately 20°C (68°F)].
Manifold bolts and nuts:
Intake
: 15 - 20 N⋅m (1.5 - 2.0 kg-m, 11 - 14 ft-lb) EM
Exhaust
: 25 - 29 N⋅m (2.5 - 3.0 kg-m, 18 - 22 ft-lb)
Exhaust tube nuts: LC
: 43 - 50 N⋅m (4.4 - 5.1 kg-m, 32 - 37 ft-lb)
Adjusting Intake and Exhaust Valve Clearance EC

Adjustment should be made while engine is warm but not
running. FE
1. Set No. 1 cylinder in top dead center on its compression stroke,
and adjust valve clearance q 1 ,q2 ,q4 ,q5 ,q 8 and q 9 .
2. Set No. 6 cylinder at top dead center on its compression stroke, CL
and adjust valve clearance q 3 ,q6 ,q7 ,q10 , q11 and q
12 .
Valve clearance:
Intake q1 ,q 3 ,q5 ,q7 ,q9 and q 11 MT
0.30 - 0.40 mm (0.012 - 0.016 in)
SMA906BA Exhaust q 2 ,q4 ,q6 ,q8 ,q10 and q 12
0.30 - 0.40 mm (0.012 - 0.016 in) AT
Adjusting screw lock nuts:
: 15 - 20 N⋅m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
I Tighten lock nuts, by fixing the adjusting screws using a minus TF
driver.
PD
FA
RA
Checking Drive Belt
1. Inspect for cracks, fraying, wear or oil adhesion. Replace if BR
necessary.
The belts should not touch the bottom of the pulley groove.
2. Check drive belt deflection by pushing on the belt midway ST
between pulleys.
Unit: mm (in) RS
Deflection after Deflection of new belt
Limit BT
adjustment
Alternator 20 (0.79) 11 - 13 (0.43 - 0.51) 9 - 11 (0.35 - 0.43)
Air conditioner 10.5 HA
6 - 7 (0.24 - 0.28) 5 - 6 (0.20 - 0.24)
compressor (0.413)
Power steering oil 11.5 - 13.0 10.5 - 11.5
20 (0.79)
pump (0.453 - 0.512) (0.413 - 0.453) EL
Applied pushing
98 N (10 kg, 22 lb)
force
SE
Check drive belt deflections when engine is cold.
SMA613CA
IDX
MA-37
Changing Engine Oil

WARNING:
I Be careful not to burn yourself, as engine oil is hot.
I Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
ponents.
2. Remove oil filler cap and drain plug.
DMA012 3. Drain oil and fill with new engine oil.
Oil grade: API CC or CD
Viscosity:
See “RECOMMENDED FLUIDS AND
Refill oil capacity (approximate):
Without oil filter change
9.3 (8-1/8 Imp qt)
With oil filter change
10.5 (9-1/4 Imp qt)
CAUTION:
I Be sure to clean and install oil pan drain plug with washer.
Drain plug:
: 29 - 39 N⋅m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
I The refill capacity changes depending on the oil tempera-
ture and drain time; use these valves as a reference and be
certain to check with the dipstick when changing the oil.
4. Check oil level.

5. Start engine. Check area around drain plug and oil filter for any
sign of oil leakage.
minutes check oil level.
SMA908B
Changing Engine Oil Filter

1. Remove oil filter with Tool.
WARNING:
Be careful not to burn yourself, as the engine and engine oil
are hot.
SMA909B
MA-38
Changing Engine Oil Filter (Cont’d)
2. Clean oil filter mounting surface on cylinder block. Coat rubber GI
seal of new oil filter with engine oil.
3. Screw in the oil filter until a slight resistance is felt, then tighten
an additional 2/3 of a turn.
4. Add engine oil.
Refer to Changing Engine Oil.
I Clean excess oil from engine. EM
LC
SMA010
EC
WARNING:
To avoid the danger of being scalded, never change the cool-
FE
ant when the engine is hot.
CL
—DRAINING ENGINE COOLANT—
1. Move heater TEMP control knob all the way to HOT.
2. Open radiator drain plug at the bottom of radiator. MT
AT
3. Remove radiator filler cap.
Remove reservoir tank, drain coolant, then clean reservoir tank.
Install it temporarily. TF
PD
FA
DMA013
RA
4. Remove cylinder block drain plug located at left rear of cylin-
der block.
5. Drain coolant and install cylinder block drain plug and radiator BR
drain plug.
6. Fill radiator with water and warm up engine.
7. Stop engine and wait until it cools down. ST
8. Repeat step 2 through step 7 two or three times.
9. Drain water.
RS
SMA910B BT
10. Install reservoir tank, radiator drain plug, and cylinder block HA
drain plugs.
I Apply sealant to the thread of cylinder block drain plug.
Cylinder block drain plug: EL
: 54 - 64 N⋅m (5.5 - 6.5 kg-m, 40 - 47 ft-lb)
11. Fill radiator and reservoir tank with coolant up to the MAX level
and install radiator cap. SE
SMA182B
IDX
MA-39
Coolant capacity (With reservoir tank):
With heater
15.1 (13-1/4 Imp qt)
Without heater
14.4 (12-5/8 Imp qt)
Reservoir tank capacity (for MAX level):
0.6 (1/2 Imp qt)
system to escape.
12. Warm up engine to normal operating temperature.
13. Run engine at 2,000 rpm for 10 seconds and return to idle
SMA412B
speed.
I Repeat 2 or 3 times.
Watch coolant temperature gauge so as not to overheat the
engine.
14. Stop engine and cool it down.
I Cool down using a fan to reduce the time.
15. Remove the radiator filler cap and check coolant level.
I If necessary, refill radiator up to filler neck with coolant.
16. Refill reservoir tank to Max line with coolant.
17. Repeat step 12 through step 16 two or more times.
18. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 2,000 rpm with heater tempera-
ture control set at several positions between COOL and HOT.
I Sound may be noticeable at heater water cock.
19. If sound is heard, bleed air from cooling system by repeating
steps 12 through 16 until coolant level no longer drops.
I Clean excess coolant from engine.
Checking Cooling System

CHECKING HOSES AND CLAMPS
Check hoses and clamps for proper attachment, leaks, cracks,
CHECKING RADIATOR CAP

factory.
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
SLC613
MA-40
Checking Cooling System (Cont’d)
Pull the negative-pressure valve to open it. Check that it closes GI
EM
LC
SMA871B
CHECKING COOLING SYSTEM FOR LEAKS EC

Apply pressure to the cooling system with cap tester to check for
leakage. FE
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION: CL
Use of higher pressure than the specified value may cause
damage to radiator.
MT
SMA990A
AT
Draining Water
TF
Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.
CHECKING FUEL FILTER
PD
Check fuel filter for fuel leakage, damage and other abnormal
signs. FA
REPLACING FUEL FILTER
DMA011
1. Disconnect harness connector and drain fuel. RA
2. Remove fuel filter using band-type filter wrench.
3. Remove fuel filter and fuel filter sensor.
CAUTION: BR
Remove fuel filter without spilling fuel. If spilt, wipe off imme-
diately. Be specially careful not to spill fuel on engine mount
insulator. ST
RS
DMA014 BT
4. Wipe clean fuel filter mounting surface on fuel filter bracket and
smear a little fuel on rubber seal of fuel filter. HA
5. Screw fuel filter on until a slight resistance is felt, then tighten
an additional more than 2/3 of a turn.
6. Install fuel filter sensor to new fuel filter. (Type A) EL
7. Bleed air from fuel line.
8. Start engine and check for leaks. SE
SMA010
IDX
MA-41
Draining Water (Cont’d)
DRAINING WATER
1. Drain water as follows.
Type A
Loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it exces-
sively.
If water does not drain properly, move the priming pump up and
down.
SMA825B
Type B
Loosen air bleeder screw from the sedimentor cover and then
loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it exces-
sively.
SMA281C
2. Bleed air.
Checking Fuel Lines

Check fuel lines and tank for proper attachment, leaks, cracks,
CAUTION:
Keep clean parts with compressed air when assembling.
SMA803A
MA-42
Cleaning and Replacing Air Cleaner Filter GI
EM
LC
EC
FE
CL
MT
DMA015
AT
To properly tighten wing nuts, clamp air cleaner housing cover
and tighten wing nuts until they touch the cover. Then tighten TF
them three more turns.
PD
FA
RA
DRY PAPER TYPE
Clean or replace element more often under dusty driving condi-
BR
tions.
ST
RS
BT
SMA882B
VISCOUS PAPER TYPE HA

The viscous paper type air cleaner filter does not require any clean-
ing operation between renewal.
EL
SE
IDX
MA-43
Checking Cyclone Pre-air Cleaner

Remove duct cover and check duct for dust clogging. Clean away
dust.
DMA016
Checking Injection Nozzle

WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to come into contact with your hand or
body, and make sure that your eyes are properly protected.
1. Install nozzle to injection nozzle tester and bleed air from flare
nut.
2. Check initial injection pressure by pumping tester handle one
full stroke per second.
Initial injection pressure:
EF791A Used nozzle
9,807 - 10,297 kPa
(98.1 - 103.0 bar, 100 - 105 kg/cm2,
1,422 - 1,493 psi)
New nozzle
10,297 - 11,278 kPa
(103.0 - 112.8 bar, 105 - 115 kg/cm2,
1,493 - 1,635 psi)
I Always check initial injection pressure before installing
new nozzle.
SEF672A
3. Check spray pattern by pumping tester handle one full stroke

per second.
a. If main spray angle is within 30 degrees as shown, injec-
tion nozzle is good.
b. It is still normal even if a thin stream of spray deviates from
main spray (pattern B).
4. If initial injection pressure or injection nozzle is not normal,
adjust or clean injection nozzle.
5. Test again. If it is not corrected, replace nozzle.
Refer to EC section for injection pressure adjustment, clean-
ing and replacement.
SEF079S
6. Install all injection nozzles with Tool and securely connect fuel
spill tube and delivery tubes.
7. Bleed air from fuel system and check for fuel leakage with
engine running.
Injection nozzle to cylinder head:
: 54 - 64 N⋅m (5.5 - 6.5 kg-m, 40 - 47 ft-lb)
Spill tube nut:
: 29 - 39 N⋅m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
Injection tube:
: 20 - 25 N⋅m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
MA-44
Checking Idle Speed GI

Preparation
1. Make sure that injection timing is correct.
2. Make sure that injection nozzles are in good condition.
3. Make sure that the following parts are in good condition.
I Air cleaner clogging EM
I Glow system
I Engine oil and coolant levels
I Valve clearance LC
I Air intake system (Oil filler cap, oil level gauge, etc.)
4. Set shift lever in “Neutral” position. Engage parking brake and
lock both front and rear wheels with wheel chocks. EC
5. Turn off air conditioner, lights and accessories.
6. Make sure that idle control knob is fully released and idle adjust-
ing screw contacts accelerator control lever. FE
CL
MT
AT
I Warm up engine until engine coolant

temperature indicator points to middle TF
of gauge.
I Attach tachometer’s pick-up to No. 1
fuel injection tube. PD
In order to take accurate reading of
engine rpm, remove clamps that secure
No. 1 fuel injection tube.
FA
H
Start engine.
SMA021A
RA
H
BR
Run engine at about 2,000 rpm for about
F
2 minutes under no-load.
ST
H
Run engine for one minute at idle speed.
RS
H
NG
SMA406B
Check idle speed.
--------------------------------------------------------------------------------------------------------------------------------------------------------
E Adjust idle speed by turn-
ing idle speed adjusting
BT
Idle speed: screw.
700+50 0 rpm
HA
OK
H
END
EL
I Rev engine two or three times and allow engine to return
to idle speed. If idle speed is not within the specified range, SE
check acceleration linkage for binding and correct it if nec-
essary.
SMA792B
IDX
MA-45
Checking Idle Speed (Cont’d)
AIR CONDITIONER EQUIPPED MODEL
1. Make certain that the clearance between the actuator idle con-
trol lever pin and the injection pump control lever is within the
specified limits.
Clearance: 1 - 2 mm (0.04 - 0.08 in)
2. Adjust idle speed to specified rpm without the air conditioner
operating.
3. Then check the idle speed when the air conditioner is operat-
ing and make sure it is correct.
Unit: rpm
DMA017
Idle speed 0
850 −50
(Air conditioner “ON”)
If not, adjust it by turning FICD actuator stroke adjusting screw.
MA-46
CHASSIS AND BODY MAINTENANCE
Checking Exhaust System GI

Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, loose connections, chafing and
deterioration.
EM
LC
SMA211A
Checking Clutch Fluid Level and Leaks EC

If fluid level is extremely low, check clutch system for leaks.
FE
CL
MT
SMA991C
AT
Checking Clutch System
Check fluid lines and operating cylinder for improper attachment,
cracks, damage, loose connections, chafing and deterioration. TF
PD
FA
SMA992C
RA
Checking M/T Oil Level and Leaks
Never start engine while checking oil level. BR
1. Check manual transmission for leakage.
2. Check oil level.
Filler plug: ST
: 25 - 34 N⋅m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
RS
SMA103 BT
Changing M/T Oil
Oil grade: HA
API GL-4. Refer to “RECOMMENDED FLUIDS AND
Oil capacity: EL
FS5R50B 3.8 liters (6-3/4 Imp pt)
Refill 2.9 liters (5-1/8 Imp pt)
FS5R30A 5.1 liters (9 Imp pt) SE
Drain plug:
: 25 - 34 N⋅m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
SMA255A
IDX
MA-47
Checking Water Entry

Check water entry in the clutch housing by removing the seal-
ing grommet, whenever driving in deep water or mud.
SMA369B
Checking A/T Fluid

1. Warm up engine.
2. Check for fluid leakage.
3. Before driving, fluid level can be checked at fluid temperatures
of 30 to 50°C (86 to 122°F) using “COLD” range on dipstick.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear posi-
tion. Leave selector lever in “P” position.
c. Check fluid level with engine idling.
d. Remove dipstick and note reading. If level is at low side of
SMA501CA either range, and fluid to the charging pipe.
e. Re-insert dipstick into charging pipe as far as it will go.
f. Remove dipstick and note reading. If reading is at low side of
range, add fluid to the charging pipe.
Do not overfill.
4. Drive vehicle for approximately 5 minutes in urban areas.
5. Re-check fluid level at fluid temperatures of 50 to 80°C (122 to
176°F) using “HOT” range on dipstick.
6. Check fluid condition.

I If fluid is very dark or smells burned, refer to AT section for
checking operation of A/T. Flush cooling system after repair of
A/T.
I If A/T fluid contains frictional material (clutches, bands, etc.),
replace radiator and flush cooler line using cleaning solvent and
compressed air after repair of A/T. Refer to LC section
(“Radiator”, “ENGINE COOLING SYSTEM”).
SMA107
MA-48
Changing A/T Fluid GI

1. Warm up A/T fluid.
2. Stop engine.
3. Drain A/T fluid from drain plug and refill with new A/T fluid.
Always refill same volume with drained fluid.
Fluid grade: EM
Genuine Nissan ATF or equivalent. Refer to “REC-
OMMENDED FLUIDS AND LUBRICANTS”, MA-14.
Fluid capacity (With torque converter): LC
11.8 (10-3/8 Imp qt)
SMA515C Drain plug:
: 29 - 39 N⋅m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) EC
4. Run engine at idle speed for five minutes.
5. Check fluid level and condition. Refer to “Checking A/T Fluid”.
If fluid is still dirty, repeat steps 2 through 5. FE
CL
MT
AT
Checking Transfer Fluid Level
Never start engine while checking fluid level.
1. Check transfer for leakage. TF
2. Check fluid level.
Filler plug:
: 25 - 34 N⋅m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) PD
FA
SMA936B
RA
Changing Transfer Fluid
Fluid grade:
Genuine Nissan ATF or equivalent or API GL-4.
BR
Refer to “RECOMMENDED FLUIDS AND
LUBRICANTS”, MA-14. ST
Fluid capacity:
1.9 liters (1-5/8 Imp qt)
Drain plug: RS
: 25 - 34 N⋅m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
SMA993C BT
Checking Propeller Shaft
Check propeller shaft for damage, looseness or grease leakage. HA
Tightening torque: Refer to PD section.
EL
SE
SMA945B
IDX
MA-49
Greasing Nipples of Propeller Shafts

Apply multi-purpose grease to nipples of propeller shafts.
SMA043C
SMA944B
Checking Differential Gear Oil

1. Check differential carrier for oil leakage.
2. Check oil level.
Filler plug:
: 59 - 98 N⋅m (6 - 10 kg-m, 43 - 72 ft-lb)
SMA108-A
Changing Differential Gear Oil

Oil capacity:
Front
5.4 liters (9-1/2 Imp pt)
Rear
H233B (Without diff. lock)
H233B (With diff. lock)
H260 (Without diff. lock)
SMA109-A
H260 (With diff. lock)
Drain plug:
: 59 - 98 N⋅m (6 - 10 kg-m, 43 - 72 ft-lb)
Limited-slip differential gear

I Use only approved or recommended limited-slip differential
gear oil.
I Limited-slip differential identification.
(1) Lift both rear wheels off the ground.
(2) Turn one rear wheel by hand.
(3) If both rear wheels turn in the same direction simultaneously,
vehicle is equipped with limited-slip differential.
MA-50
Checking Front Wheel Bearing Grease GI

I Check that wheel bearings operate smoothly.
I Check front wheel bearings for grease leakage and water or
dust entry.
I Replace front wheel bearings or front wheel bearing grease if
wheel bearings do not turn smoothly. EM
LC
Repacking Front Wheel Bearing and Axle Joint EC

Grease
FRONT WHEEL BEARING GREASE
FE
Apply multi-purpose grease sparingly to the following parts:
I Threaded portion of spindle CL
I Contact surface between wheel bearing washer and outer
wheel bearing
I Grease seal lip MT
I Wheel hub (as shown at the left)
SFA469A
AT
AXLE JOINT GREASE
I Drain approximately 2 liters (1-3/4 Imp qt) of differential oil.
I Remove knuckle spindle. TF
I Slightly pull out axle and repack axle joint with recommended
grease.
Refer to FA section. PD
FA
SFA869B
RA
Checking Free-running Hub Grease
Check free-running hub grease for leakage and water or dust entry. BR
ST
RS
SMA946B BT
Checking Water Entry in Knuckle Flange
I Check for water entry in knuckle flange by removing one bolt HA
of lower knuckle flange bearing cap and probing with a suitable
thin bar.
I After checking, be sure to reinstall the bolt to a tightening torque EL
of 30 to 40 N⋅m (3.1 to 4.1 kg-m, 22 to 30 ft-lb).
SE
SMA949B
IDX
MA-51
Checking Brake Fluid Level and Leaks

If fluid level is extremely low, check brake system for leaks.
SBR451D
Checking Brake System

Check brake fluid lines and parking brake cables for improper
attachment, leaks, chafing, abrasion, deterioration, etc.
SBR389C
Changing Brake Fluid

1. Drain brake fluid from each air bleeder valve.
2. Refill until new brake fluid comes out from each air bleeder
valve. Use same procedure as in bleeding hydraulic system to
refill brake fluid. Refer to BR section.
I Refill with recommended brake fluid.
I Never reuse drained brake fluid.
I Be careful not to splash brake fluid on painted areas.
SBR419C
Checking Brake Booster, Vacuum Hoses,

Connections and Check Valve
Check vacuum lines, connections and check valve for improper
attachment, air tightness, chafing and deterioration.
SBR419A
MA-52
Checking Disc Brake GI

ROTOR
Check condition and thickness.
Standard thickness:
CL36VE
32.0 mm (1.260 in) EM
CL18VF
18.0 mm (0.709 in)
Minimum thickness: LC
CL36VE
SMA260A
30.0 mm (1.181 in)
CL18VF EC
16.0 mm (0.630 in)
FE
CL
MT
AT
CALIPER
Check for leakage.
TF
PD
FA
SMA922A
RA
PAD
Check for wear or damage. BR
Standard thickness:
Front 12.0 mm (0.472 in)
Rear 10.0 mm (0.394 in) ST
Minimum thickness:
2.0 mm (0.079 in)
RS
SMA847B BT
Checking Drum Brake
WHEEL CYLINDER
HA
Check for leakage.
EL
SE
SBR205A
IDX
MA-53
Checking Drum Brake (Cont’d)
DRUM
Check condition of inner surface.
Standard inner diameter:
295 mm (11.61 in)
Drum repair limit (Inner diameter):
296.5 mm (11.67 in)
SMA848B
LINING
Check for wear or damage.
Standard thickness:
6.1 mm (0.240 in)
Lining wear limit (Minimum thickness):
1.5 mm (0.059 in)
SMA849B
Balancing Wheels
Adjust wheel balance using the road wheel center.
Wheel balance (Maximum allowable unbalance):
Refer to SDS, MA-59.
Tire Rotation
Wheel nuts:
: 118 - 147 N⋅m (12 - 15 kg-m, 87 - 108 ft-lb)
SMA800BB
MA-54
Checking Power Steering Fluid and Lines GI

I Check fluid level with engine off.
I Check fluid level with dipstick on reservoir cap. Use “HOT”
range at fluid temperatures of 50 to 80°C (122 to 176°F). Use
“COLD” range at fluid temperatures of 0 to 30°C (32 to 86°F).
CAUTION: EM
I Do not overfill.
I Recommended fluid is Automatic Transmission Fluid type
“DEXRONTMIII” or equivalent. LC
SST280B
I Check lines for improper attachment, leaks, cracks, damage, EC

loose connections, chafing or deterioration.
I Check rack boots for accumulation of power steering fluid.
FE
CL
MT
SST757C
AT
Checking Steering Damper
Check steering damper for damage and oil leakage.
TF
PD
FA
SMA938A
RA
Checking Steering Gear Box and Linkage
STEERING GEAR BR
I Check gear housing and boots for looseness, damage or
grease leakage.
I Check connection with steering column for looseness.
ST
STEERING LINKAGE RS
I Check ball joint, dust cover and other component parts for
looseness, wear, damage or grease leakage.
BT
HA
EL
SE
IDX
MA-55
Lubricating Locks, Hinges and Hood Latches
SMA994C
Checking Seat Belts, Buckles, Retractors,

Anchors and Adjusters
SMA995C
MA-56
Checking Body Corrosion GI

Visually check the body sheet metal panel for corrosion, paint damage (scratches, chipping, rubbing, etc.) or
damage to the anti-corrosion materials. In particular, check the following locations.
Hemmed portion
Hood front end, door lower end, trunk lid rear end, etc.
Panel joint EM
Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut tower in engine
compartment, etc. LC
Panel edge
Trunk lid opening, sunroof opening, fender wheelarch flange, fuel filler lid flange, around holes in panel, etc.
Parts contact EC
Waist molding, windshield molding, bumper, etc.
Protectors FE
Damage or condition of mudguard, fender protector, chipping protector, etc.
Anti-corrosion materials
Damage or separation of anti-corrosion materials under the body. CL
Drain holes
Condition of drain holes at door and side sill. MT
When repairing corroded areas, refer to the Corrosion Repair Manual.
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
MA-57
SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Maintenance (TB45E & TB42S)

INSPECTION AND ADJUSTMENT Spark plug type (TB42S)
Drive belt deflection Standard type BP5ES
Unit: mm (in) Hot type BP4ES
Used belt deflection Cold type BP6ES, BP7ES
Deflection of
Deflection after new belt Plug gap 0.8 - 0.9 mm (0.031 - 0.035 in)
Limit
adjustment
13 - 15 10 - 12
Alternator 16 (0.63)
(0.51 - 0.59) (0.39 - 0.47)
Air conditioner 8 - 10 6-8

Spark plug type (TB45E)
11 (0.43)
compressor (0.31 - 0.39) (0.24 - 0.31) Standard type BPR5E-11
Power steering 15 - 17 14 - 16 Hot type BPR4E-11
19 (0.75)
oil pump (0.59 - 0.67) (0.55 - 0.63)
Cold type BPR6E-11
Applied pushing
98 N (10 kg, 22 lb)
force Plug gap 1.0 - 1.1 mm (0.039 - 0.043 in)
Oil capacity (Refill capacity) Valve clearance (Hot)

Unit: (lmp qt) Unit: mm (in)
TB42S TB45E TB42S TB45E
With oil filter change 7.5 (6-5/8) 7.6 (6-3/4) Intake 0.38 (0.015) 0.35 (0.014)
Without oil filter Exhaust 0.38 (0.015) 0.35 (0.014)

7.0 (6-1/8) 7.3 (6-3/8)
change
Cooling system check

Unit: kPa (bar, kg/cm2, psi)
Cooling system testing pressure 98 (0.98, 1.0, 14)
108 - 127
Radiator cap relief pressure
(1.08 - 1.27, 1.1 - 1.3, 16 - 18)
Engine Maintenance (RD)

INSPECTION AND ADJUSTMENT Engine oil capacity (Refill capacity)
Unit: (Imp qt)
Drive belt deflection
Unit: mm (in) With oil filter change 6.4 (5-5/8)
Without oil filter change 5.8 (5-1/8)
Deflection Deflection of
Drive belts
Limit after adjust- new belt
ment
Coolant capacity (Refill capacity)
Alternator
With air condi- 12 - 14 9 - 11
With reservoir tank
17 (0.67) Unit: (Imp qt)
tioner compressor (0.47 - 0.55) (0.35 - 0.43)
Without air condi- 7-9 6-8 With heater Without heater
11 (0.43)
tioner compressor (0.28 - 0.35) (0.24 - 0.31) RHD 12.9 (11-3/8) 11.8 (10-3/8)
Power steering oil 10 - 12 9 - 11 LHD 12.7 (11-1/8) 11.6 (10-1/4)
14 (0.55)
pump (0.39 - 0.47) (0.35 - 0.43)
Reservoir tank 2.4 (2-1/8)
Applied pushing force 98 N (10 kg, 22 lb)
MA-58
SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Maintenance (TD42) GI

INSPECTION AND ADJUSTMENT Injection nozzle
Drive belt deflection Injection pressure
Unit: mm (in) kPa (bar, kg/cm2, psi)
9,807 - 10,297
Used nozzle (98.1 - 103.0, 100 - 105,
EM
Deflection of
Deflection after new belt 1,422 - 1,493)
Limit
adjustment
10,297 - 11,278
20 11 - 13 9 - 11 New nozzle (103.0 - 112.8, 105 - 115,
LC
Alternator
(0.79) (0.43 - 0.51) (0.35 - 0.43) 1,493 - 1,635)
Air conditioner
compressor
10.5
(0.413)
6-7
(0.24 - 0.28)
5-6
(0.20 - 0.24)
EC
Idle speed
Power steering 20 11.5 - 13 10.5 - 11.5
FICD OFF FICD ON
oil pump (0.79) (0.453 - 0.512) (0.413 - 0.453)
+50 0
FE
Applied pushing Idle speed rpm 700 0 850 −50
98 N (10 kg, 22 lb)
force
Inspect drive belt deflections when engine is cold. CL
Valve clearance (Hot)

MT
Intake and exhaust mm (in) 0.30 - 0.40 (0.012 - 0.016)
AT
Chassis and Body Maintenance
INSPECTION AND ADJUSTMENT TF
Wheel balance
Dynamic PD
Maximum allowable (At rim flange) 10 (0.35) (one side)
unbalance g (oz)
Static g (oz) 20 (0.71) FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
MA-59

Maintenance

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Maintenance

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MAINTENANCE

Supplemental Restraint System (SRS) “AIR

Special Service Tools

Tool number Engine application

KV10115801 Removing oil filter

KV10113600 Removing fuel filter

UNDER HOOD — engine off UNDER BODY EM

Item Reference pages

Engine and Emission Control Maintenance EM

Chassis and Body Maintenance GI

Perform at the specified Months — 6 12 18 24 30 36 42 48 Reference

Maintenance Under Severe Driving Conditions

Severe driving conditions

Engine Oil & Minor Service EM

Annual driving distance over 30,000 km (18,000 miles) AT

Engine and Emission Control Service

Underhood and under vehicle

Annual driving distance over 30,000 km (18,000 miles)

Underhood and under vehicle

Chassis and Body Services GI

NOTE: (1) Inspect after 10 years, then every 2 years.

Maintenance Under Severe Driving Conditions GI

Severe driving conditions EM

Maintenance for off-road driving

Fluids and Lubricants

*1: For further details, see “SAE viscosity number”.

SAE Viscosity Number GI

Anti-freeze Coolant Mixture Ratio

The use of other types of coolant solutions may damage your

Checking Tightening Torque GI

MANIFOLD BOLTS AND NUTS

Checking Drive Belts

1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,

Changing Engine Coolant

3. Remove cylinder block drain plug. EC

Checking Cooling System

CHECKING RADIATOR CAP

Pull the negative-pressure valve to open it. Check that it closes

CHECKING COOLING SYSTEM FOR LEAKS

Checking Fuel Lines

Changing Fuel Filter (TB42S) EC

Cleaning and Changing Air Cleaner Filter

Dry paper type

Cleaning and Changing Air Cleaner Filter

Dry paper type

Checking Cyclone Pre-air Cleaner EC

Changing Engine Oil

Refill oil capacity (Approximately):

Changing Oil Filter GI

Spark plug: (TB45E)

5. Check spark plug gap.

Checking Ignition Wires

Checking Choke Mechanism (TB42S)

Checking Positive Crankcase Ventilation (PCV) GI

Checking Vacuum Hoses and Connections

Checking Vapor Lines

Checking Tightening Torque GI

MANIFOLD BOLTS AND NUTS

Check drive belt deflections when engine is cold.

Changing Engine Oil

Changing Engine Oil Filter EC

—REFILLING ENGINE COOLANT—

Coolant capacity (With reservoir tank): (Imp qt)