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SERVICE< MANUAL " "

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QUICK REFERENCE INDEX


GENERAL INFORMATION

GI

MAINTENANCE ENGINE MECHANICAL ENGINE LUBRICATIONCOOLING & SYSTEMSENGINE FUEL EMISSION & CONTROLYSTEMS ENGINE CONTROL, FUEL EXHAUST YSTEM& S CLUTCH

MA

EM LC
EF

&EC

FE CL MT AT PD FA RA SR ST SF HA EL

NISSAN
j

MANUAL TRANSMISSION AUTOMATICRANSMISSION T


.

24DSX
-

MODEL

S13

SERIES

PROPELLER SHAFT DIFFERENTIAL & CARRIERFRONT AXLE& FRONT SUSPENSION REAR AXLE& REAR SUSPENSION BRAKE SYSTEM STEERING SYSTEM
BODY

HEATER AIRCONDITIONER & ELECTRICAL SYSTEM

,
cg NISSAN MOTOR CO., LTD.
..

Printed in U.S.A.
Motor Company Ltd., Tokyo, Japan.

Not to be reproduced in who~e or in part without the prior written permission of Ni~n < ""

FOREWORD
This manual contains maintenance and repair procedures for the Nissan SX. In order to assure your safety and the efficient functioning of the vehicle, this manusl should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at a~y time without notice.

IMPORTANT AFETY S NOTICE


The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, 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 jeopardiz~d by the service method selected.

NISSAN MOTORCo.,LTD.
Overseas Service Department Tokyo, Japan

GENERAL INFORMATION I SECTION

GI
GI- 2 GI- 5
~

CONTENTS
PRECAUTIONS HOW TO USE THIS MANUAL

HOW TO READ WIRING DIAGRAMS


HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES IDENTIFICATION INFORMATION
"""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

GI- 7
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LIFTING POINTS AND TOW TRUCK TOWING TIGHTENING TORQUE OF STANDARD BOLTS

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PRECAUTIONS
Observe the following precautions ~o ensure safe and proper servicing. 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 inflammable 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.
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2. Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.
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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.

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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.

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PRECAUTIONS
6. Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint.

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7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set. Arrange the disassembled parts in accordance with their assembled locations and sequence. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. Use only the lubricants specified in MA section. Use approved bonding agent, sealants or their equivalents when required. Use tools and recommended special tools where specified for safe and efficient service repairs. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.

Precautions for E.F.I. or E.C.C.S. Engine


1. Before connecting or disconnecting E.F.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 eliminate danger. 3. Be careful not to jar components such as control unit and air flow meter.

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PRECAUTIONS Precautions for 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 compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on inflammable material. Keep inflammable material off the exhaust pipe.

Clean floor SG

Precautions for Fuel


Unleaded gasoline of at least 87 AKI number (RON 91)

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HOW TO USE THIS MANUAL


1. A QUICK REFERENCE INDEX, a black tab (arenaqq.us18) 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. 2. THE CONTENTS are listed on the first page of each section. 3. THE TITLE is indicated on the upper portion of each page and shows the part or system. 4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. "BR-5"). 5. THE lARGE IllUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG.
"Example"
Pad retainer

r;~'~
Torque
member

~
~
,/I

J~
~
~.

::;:;

~
.

5~

/
/

r-


Main pin

IE!

to sliding portion

Pin boot

Outer shim

SBRA

6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary. 7. The followings SYMBOLS AND ABBREVIATIONS are used:

~
E1I

~ rJ ~ ~
EaI~

@>
"f:l

:
:

S.O.S. L.H., R.H. .

Tightening torque Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. Should be lubricated with oil. Sealing point Checking point Always replace after every disassembly. Apply petroleum jelly. Apply A.T.F. Select with proper thickness. Adjustment is required. Service Data and Specifications Left-Hand, Right-Hand

M/T A/T Tool L.H.D. R.H.D. A.T.F. 0,


02 03 D. 22 2, 12 1,

Manual Transaxle/Transmission Automatic Transaxle/Transmission Special Service Tools Left-Hand Drive Right-Hand Drive Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear

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HOW TO USE THIS MANUAL


8. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. "Example" Tightening torque: 59 - 78 Nom ( - kg-m, 43 - 58 ft-Ib) 9. TROUBLE DIAGNOSES are included in sections dealing with complicated components. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed.

. . .

BOLD TYPED STATEMENTS except WARNING and CAUTIONgive you helpfulinformation.

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HOW TO READ WIRING DIAGRAMS


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WIRING DIAGRAM Symbols used in WIRING DIAGRAM are shown below:


Example
CONNECTOR Th is shows that these con nectors white 6 terminal connectors. POWER SUPPLY are -This shows the ignition switch position in which the system can be ope rated. - See POWER SUPPLY ROUTING in EL section for the detai led wiring diagram.

BRANCH M/T model

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~B~

'-LAMP -!

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I

lG~

A/T model

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~ CLG~ ~B-S
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@
: MfT model : AfT model

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~~

SWITCH This shows that continuity exists between terminals CD and CID, when the switch is turned to ON position.

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G

.rn '""".~
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SWITCH

ABBREVIATIONS

LOCATION NUMBER This number shows where the connector is located. See HARNESS LAYOUT in EL section. The number is identical with the one in HARNESS LAYOUT. I

-b
BODY D GROUN

'WIRE

COLOR CODING

BR

Brown Orange Pink Purple Gray Sky Blue

B -BI,,'
W R G Y L LG ~ ~ ~ ~ ~ White Red Green Blue Yellow
. ht Green

OR
P PU GY SB I

~@!
I: Instrument harness

M: Main harness S G

. d the base is stripe, . When. the iven first, or wire co followe d by the stripe color as g IS shown below: Example: L/W
~

~ Llg

Blue with Whtte Stripe

SWITCH POSITIONS
Normally open

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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.

. . .

Normally closed

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SELE

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HOW TO READ WIRING DIAGRAMS


Example

CONNECTOR SYMBOLS All connector symbols in wiring diagrams are shown from the terminal side.


Example

Connector SG

EE

.
Efj

M.~ te,m;nal

Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

Connector symbol

G";d'-[~ Connector

Female terminal

Guide

Connector Connector symbol


SG

MULTIPLESWITCH The continuity of the multiple switch is identified in the switch chart in wiring diagrams.

Example

WIPER SWITCH

Continuity circuit of wiper switch


SWITCH POSITION -B/Y OFF INT CONTINUITY CIRCUIT 3 - 4,5 - 6 1 -6

-W/B -L/Y

-B.
-yo

-R.

B E C (f)

1 5 @ 2

LO HI WASH

Example: Wiper switch in LO position

Continuity circuit:

Red wire - @ terminal -

CID terminal

- Wiperswitch (@ - @:

LO) - @ terminal - CD terminal - Black wire

SG

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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 Wiring Diagram

STARTING

SYSTEM

SUPER MULTIPLE JUNCTION (S.M.J.)


arenaqq.us A"angament

w
'"

rnIJ ~

],
liJ

[ ,=fd:0CI~ crhKk 0
,~
r

Dm3

g
FF

0 0 0

Check

:=

y--R

Super Multiple Junction (S.M.J.)

.S.M.J.

L--S

't

( (Foldout
r-R~
~B
(Main harness)

Refer to last page


page).

DO

L
BR~ (Instrument harness)

+-+

r-B

(Main harness)

(Instrument

harness)

BRl.

SELF

GI-9

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

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(
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INSPECTION START)

rill
I

-=-

SG I

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_MECT

iii

CHECK POWER SUPPLY. Check the following items. 1) Turn ignition switch "ON" .~ [ IN.G. 1) Harness continuity betWeen 2) Check voltage between crank angle sensor and battery. terminal @ and ground. 2) E.C.C.S. relay-1 (See page EF & T~Battery voltage should exist. EC) 3) "BR" fusible link O.K. 2 4) Power source for E.C.U. (See page EF & EC) 5) Ignition switch Check the following items. 1) Harness continu ity betWeen crank angle sensor and I N.G~ grou nd 2) Ground circuit for E.C.U. (See page EF & EC)

CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF".

[ill

~ ~ 00
SG

2) Disconnect crank angle sensor harness connector. 3) Check resistance betWeen terminal @ and ground. Resistance: Approximately
I

on

O.K.

NOTICE The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check" or the "Symptom Chart". 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pin Point Check. If you must perform circuit continuity between harness connectors more detail, such as in case of sub harness is used, refer to Wiring Diagram and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be "OFF" . 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as it was.

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HOW TO FOllOW

FLOW CHART IN TROUBLE DIAGNOSES


HOW TO FOllOW
ITJ

THIS FLOW CHART

Work and diagnostic procedure


Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. I

CHECK POWER SUPPLY. 1) Turn ignition switch "ON".


2) Check

Check

item being performed.

voltage between

Procedure,

steps or
results

terminal @ and ground. Battery voltage should exist.

measurement

O.K. I2J Measurement results

Required results are indicated in bold type in the corresponding block, as shown below. These have the following meanings: Battery voltage ~ 11 14V or approximately 12V Voltage: Approximately OV ~ Less than 1V

Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. For example, symbol m indicated in the left upper portion of each illustration corresponds with the symbol in the flowchart for easy identification. More precisely, the procedure under the "CHECK POWER SUPPLY" outlined previously is indicated by an illustration m .

@] Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. 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.

Example View from terminal side

Connector symbol

Direction

mark

~
View from harness side
Connector symbol

.
.

View f,om lermlnel side n' r.s. All connector symbols shown from the terminal side are enclosed by a single line.

~:

~:

View f,omhernessside .n

H.S.

Connector

~ [it
Direction mark

All connector symbols shown from the harness enclosed by a double line.

side are

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HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES


Key to symbols signifying measurements or procedures
Symbol Symbol explanation Check after disconnecting the connector to be measured. Symbol Symbol explanation
AIC switch is "OFF".

IV
) @CONNECT

cT

Check after connecting the connector to be measured. Insert key into ignition switch. Turn ignition switch to "OFF" position.
Turn ignition switch to "ON" position. Turn ignition switch to "START" position.

AIC switch is "ON". REC switch is "ON". REC switch is "OFF".


DEF switch is "ON". VENT switch is "ON".

00 00
OOACC

Turn ignition switch from "OFF" to "ACC" position.


Turn ignition switch from "ACC" to "OFF" position. Turn ignition switch from "OFF" to "ON" position. "cfi

Fan switch is "ON". (At any position except for "OFF" position)
Fan switch is "OFF".

Apply battery voltage directly to components.

OOF

Turn ignition switch from "ON" to "OFF" position.

Drive vehicle.

0
trJ

Do not start engine,or check


with engine stopped.
Start engine.
running.

Disconnect battery negative cable.

or check

with engine

Depress

brake

pedal.

Apply parking brake.

Release brake pedal.

Release parking brake. Check after engine is warmed up sufficiently.

Depress accelerator pedal.

CffH

Release accelerator pedal.

l!V
La)
Le1J

Voltage should be measured with a voltmeter.

II CIUIIT-foi

II

Circuit resistance should be measured with an ohmmeter.

Pin terminal check for S.M.J. type arenaqq.us AIT control unit connectors. For details regarding the terminal arrangement, refer to the foldout page.

'

Currentshould be measuredwith an ammeter.

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IDENTIFICATION INFORMATION

Model Variation
Destination Body Coupe Fastback Non-California Coupe Fastback Coupe Fastback California Coupe Fastback Coupe Fastback Canada Coupe Fastback HLS13AN RE4R01A RHLS13AN HLS13AV RE4R01A RHLS13AV HLS13FN FS5W71 C RHLS13FN HLS13AU RE4R01A RHLS13AU HLS13FV FS5W71C RHLS13FV KA24E R Model HLS13FU FS5W71C RHLS13FU Engine Transmission Differential carrier

Prefix and suffix designations:


R H L S13 A N (R)

(R) : With A.B.S. N : Canada V : California U: Non-California

0: R : H: L:

Coope Fastba~
KA24E engine L.H. drive

A : Automatic transmission F : 5-speed manual transmission

0 : means no indication.

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IDENTIFICATION

INFORMATION

Identification Number
Vehicle identification plate

Vehicle identification

number (Chassis number)

F.M.V certification Vehicle identification number plate

label

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VEHICLE IDENTIFICATION

NUMBER ARRANGEMENT IN 1 H S 3 6 P X K W

Manufacturer IN 1: N issan passenger vehicle Engine type H: KA24E

IT

Vehicle serial number

Manufacture plant W: Kyushu Model year K: year model Check digit (0 to 9 or XI The code for the check digit is determined by mathematical computation. Restraint system S: Standard P: Automatic

. Vehicle line
S: NISSAN SX Model change (0 to 91 Body type 4: Coupe 6: Fastback

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IDENTIFICATION

INFORMATION
PLATE

Identification Number (Cont'd)


IDENTIFICATION
NISSAN MOTORCO.,LTD. JAPAN

~:it
CHASSIS NO NO DE CHASIS MODEL MOOElO

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&"

ill

.&
",-COlOR TRiM f 'Jk COlOR GUMNICION

0
I ;,.0

ffi& &&

0
CC

ENGIN[
MOTOR

'/;,.0

;; ';~: ; ~ElE

& &
I tf; A
MADEINJAPAN

1 2 3 4 5 6 7 8 9
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Type Vehicle identification number (Chassis numbed Model Body color code Trim color code Engine model Engine displacement Transmission model Axle model

S jJt ~ ItJ :if[** :it ~ U

ENGINE SERIAL NUMBER KA24E engine

TL M

MANUAL TRANSMISSION

NUMBER

AUTOMATIC

TRANSMISSION

NUMBER

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IDENTIFICATION INFORMATION

Dimensions
Coupe
Overall length Overall width Overall height Front tread Rear tread Wheelbase 4, () 1, () 1, () 1, () 1, () 2, ()

Unit: mm (in)

Fastback
4, () 1, () 1, () 1, () 1, () 2, ()

Wheels and Tires


Road wheel Steel Aluminum Offset Tire size Conventional Spare *: Option mm (in) 6-JJx 15 6-JJx 15 40 () /60R 15 86H /60R 15 89H * T/70D 15

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LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand
WARNING: Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.

. .

Garage jack points

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LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift


WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines.

Sill

Put the sill in the slit of the lift pad to prevent the sill from deforming. If the pad does not have lift pad

//

the slit, prepare

a suitable

attachment

with slit.

Note: Lift-up points are the same as pantograph jack points.

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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. When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral (UN" position).

~ ~

NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated.

'i::ij,iiii. ii;~1',,,';1tiii:.; 2

-.

SG

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LIFTING

POINTS

AND TOW TRUCK

TOWING

Front

Tow Truck Towing (Cont'd) TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (With rear wheels on ground) Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. TOWING POINT Alwayspull the cable straightout from the arenaqq.us pull on the hook at a sidewaysangle.

Rear

CE1 DD9M

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TIGHTENINGTORQUE OF STANDARD BOLTS


dia-

Grade

Bolt size

Bolt

meter* mm

Pitch mm N.m

Tightening torque (Without lubricant) Hexagon head bolt kg-m ft-Ib 9 9 18 19 31 34 54 15 16 30 32 52 57 94 9 22 23 43 46 72 80 Hexagon flange bolt N.m ft-Ib kg-m 15 16 29 30 51 56 88 10 25 26 48 51 84 92 15 35 37 70 74 11 12 22 22 38 41 65 7 18 20 35 38 62 68 11 26 27 51 54 87

M6 M8 4T M10 M12 M14 M6 M8 7T M10 M12 M14 M6 M8 9T M10 M12 M14

13 13 25 25 42 46 74 21 22 41 43 71 77 12 29 31 59 62 98

1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head.
Grade 4T 7T 9T Mark 4 7 9

*: Nominal diameter M

6
""""L-

Nominal diameter of bolt threads (Unit: mm)


Metric screw threads

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'..~

MAINTENANCE
.J

SECTION

MA

l1li

CONTENTS
PERIODIC MAINTENANCE GENERAL MAINTENANCE. RECOMMENDED LUBRICANTS AND FLUIDS ENGINE MAINTENANCE "'"'''''''''''' CHASSIS AND BODY MAINTENANCE SERVICE DATA AND SPECIFICATIONS (S.D.S.) :" MA- 2 MA- 4 MA- 6 MA- 8 MA MA",

PERIODIC MAINTENANCE
The following charts show the normal maintenance schedule. Under severe driving conditions, additional or more frequent maintenance will be required. Refer to "Maintenance under severe driving conditions". The periodic maintenance schedule is repeated beyond the last mileage and period shown by returning to the first 15, miles (24, km) or 12 months. EMISSION CONTROL SYSTEM MAINTENANCE
MAINTENANCE. OPERATION Perform at number of miles, kilometers or months, whichever comes first. Drive belts
Air cleaner filter Miles x 1, (km x 1,) Months

(12) 6

MAINTENANCE 15 30 (24) 12 (48) 24

INTERVAL 45 60 (72) 36 (96) 48 1* Reference page

See NOTE (1).

MA-8 MA MA MA-9 MA MA-8 MA

Vapor lines Fuel lines Fuel filter Engine coolant Egnine oil
Engine oil filter (Use Nissan PREMIUM type or equivalent.)

Replace every 30, miles (48, km). 1* 1* 1* 1* See NOTE (2)*. R


R

Then replace every 7, . miles (12, km) or 6 months.


Then replace every second oil change.

MA MA MA

Spark plugs Ignition wires

Replace every 30, miles (48, km). Inspect every 3 years. *

CHASSIS AND BODY MAINTENANCE


MAINTENANCE OPERATION Perform at number of miles, kilometers or months, whichever comes first. Break lines & cables Brake pads & discs Manual and automatic transmission & differential gear oil Steering gear & linkage, and axle & suspension parts Exhaust system
Miles x 1, (km x 1,) Months

15 (24) 12 I I I

MAINTENANCE INTERVAL 30 45 (48) 24 I I I I I (72) 36 I I I

60 (96) 48 I I I I I

Reference page

MA MA MA,15,16 MA, FA-4,RA-4 MA

NOTE: (1) After 60, miles (96, km) or 48 months, inspect every 15, miles (24, km). (2) If vehicle is operated under extremely adverse weather conditions or in arees where ambient temperatures are either extremely low or extremely high, the filters might become clogged. In such an event, replace them immediately. (3) Maintenance items and intervals with "." are recommended by NISSANfor reliable vehicle operation. The owner need not perform such maintenance in order to ~aintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.
Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary.

MA-2

PERIODIC MAINTENANCE
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance is required to. be performed on the following items as shown in the table. Severe driving conditions A - Repeated short trips less than 5 miles (8 km) and outside temperatures remain below freezing B - Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use C - Driving in dusty conditions D - Driving on rough, muddy, or salt spread roads E - Towinga trailer, usinga camper or a car-top carrier
Maintenance operation

Driving condition C ABC DE

Maintenance

item

Maintenance interval

Reference

page

Air cleaner filter


Engine oil & oil filter

R R

More frequently'
Every 3, miles (5, km) or 3 months Every 7, miles (12, km) or 6 months

MA MA

A.

C D E

Brake pads & discs

MA

D E

Manual and automatic transmission & differential gear oil Steering gear & linkage, and axle & suspension parts Steering linkage ball joints & front suspension ball joints Exhaust system I = Inspect. Correct or replace if necessary. R

Every 30, miles (48, km) or 24 months

MA, 15, 16

D . . A. . CD. .
D E

MA, FA-4, RA-4 Every 7, miles (12, km) or 6 months

MA,FA-4

MA

Maintenance operations:

= Replace.

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 vehicl~isto continue operating properly. The owners can perform the checks and inspectionsthemselvesor they can have their NISSANdealers do them for a nominal charge.
Item
OUTSIDE THE VEHICLE The ma!ntenance 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 excessivewear. 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, km (7, miles.) Wheel alignment and balance If the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. Windshieldwiper blades Check for cracks or wear if they do not wipe properly. Doors and engine hood Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate 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 frequently. INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Lights Make sure that the headlights, stop lights, taillights, tUrn signal lights, and other lights are all operating properly and installed securely. Also check headlight aim. 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 excessivefree play, hard steering or strange noises. Free play: Lessthan 35 mm ( 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 restrains 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 folding-down rear seatbacks. . Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage. MA MA MA FA-6 RA-6
Reference page

MA

MA-4

GENERAL MAINTENANCE
Item 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. 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. 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. 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. BR-7 Reference page

CL-5

BR

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). Windshieldwasher fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant levelwhen the engine is cold. Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or loose connections. Brake and clutch fluid levels Makesure that the brake and clutch fluid levelsare between the "MAX" and "MIN" lines on the reservoir. Engine drive belts Makesure that no belt is frayed, worn, cracked or oily. Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine. Power steering fluid level and lines Check the level when the fluid is cold and the engine is turned off. Check the lines for proper attachment, leaks, cracks, etc. Automatic transmission fluid level Check the level on the dipstick after putting the selector lever in "P" with the engine idling. Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it. Underbody The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise 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, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. MA,16 MA-8 MA MA MA MA-9

MA

MA-5

RECOMMENDED LUBRICANTS AND FLUIDS Lubricants and Fluids


Capacity (Approximate) US measure
Engine oil (Refill) With oil filter Without oil filter

Imp measure

Recommended lubricants and fluids Liter

/4 qt /8 qt /8 qt 3/4 qt


oil

/8 qt /8 qt /8 qt 5/8 qt /4 pt /4 pt /4 qt 3/4 qt

Genuine Nissan Motor Oil*1 or equivalent (Energy Conserving Oils of API SF or SG)*2, *3

Cooling system (with reservoir tank) Reservoir tank


Manual transmission Differential gear oil

Anti-freeze coolant (Ethylene glycol base)


API GL-4*2 API GL-5*2

/8 pt /4 pt /4 qt 1 qt

Automatic transmission fluid Power steering fluid Brake fluid Multi-purpose grease


Genuine Nissan ATF*1 or equivalent


Type DEXRON Type DEXRON
TM

TM

Genuine Nissan Brake Fluid*1 or equivalent DOT 3 (US FMVSS No. ) NLGI No.2 (Lithium soap base)

*1: Available in mainland U.S.A. through you Nissan dealer. *2: For further details, see "SAE Viscosity Number". *3: Energy Conserving Oils These oils can be identified by such labels as energy conserving, energy saving, improved fuel economy, etc.

MA-6

RECOMMENDED LUBRICANTS AND FLUIDS SAE Viscosity Number


Outside Temperature Anticipated ENGINE OIL

Range

Before Next Oil Change

Outside Temperature Range Anticipated Before Next Oil Change GEAROIL

C",OF

.

++

++"'--++86

+

+50

+32

-5W

T

T

10W is preferable if the ambient temperature is above C (0 F). 20W and 20W are usable if the ambient temperature is above 10C (50 F) for all seasons.

8OW is preferable if the ambient temperature is below 40C (F).

MA-7

ENGINE MAINTENANCE

Power steering oil pump IAJ Water pump

Checking Drive Belts


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: Inspect drive belt deflections when engine is cold.
Unit:
Used belt deflection Limit Adjusted deflection. ( - ) ( - ) ( - ) 98 N (10 kg, 22 Ib)
mm (in)

lAJQ'
Crank pulley T : Tension checking points IAJ: Adjusting bolts

l:~:o,

lAJA;,,ood;,;oo",
compressor
8MAOO2C

Set deflection of new belt ( - )


(

Alternator Air conditioner compressor Power steering oil pump Applied pushing force

11 ()

12 ()

- )

13 ()

( - )

Changing Engine Coolant

~~~
[~O

~ ~

.-

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.

8M AOO3C

2. Open drain cock at the bottom of radiator, and remove radiator cap.

MA-8
"'.

ENGINE MAINTENANCE 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. to;J 44 N.m ( - kg-m, 25 - 33 ft-Ib)

5. Open air relief plug.

6. 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. Repeat step 2 through step 9 until clear water begins to drain from radiator. Drain water.

Open radiator cap and air relief plug. Fill rafdiator with coolant up to specified level. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity. (With reservoir tank) Q (/8 US qt, /8 Imp qt) Pour coolant through coolant filler neck slowly to allow air in system to escape.

MAX. MIN.

Close air relief plug. Remove reservoir tank, drain coolant, then clean reservoir tank. Install reservoir tank and fill it with coolant up to "MAX" level and then install radiator cap. Run engine and warm it up sufficiently. Race engine 2 or 3 times under no-load. Stop engine and cool it down, then add coolant as necesary.

SMAB

Checking Fuel Lines


Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts.

MA-9

ENGINE MAINTENANCE Checking Fuel Lines CAUTION: (Cont'd)

3 mm in)

~--,'-'

--T-+-+--J__J.-_J

Tightenhigh-pressurerubber hose clamp so that clamp end is 3 mm ( in) from hose end. Ensure that screw does not contact adjacent parts.

SMAA

Changing Fuel Filter


WARNING: Before removing fuel filter, release fuel pressure from fuel line.

1. Remove fuse for fuel pump. 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is 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 shop towel to absorb fuel. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter.

. .

. Whentighteningfuel hose clamps, refer to "CheckingFuel Lines".

Changing

Air Cleaner

Filter

The viscous paper type filter does not need cleaning between renewals.

MA

ENGINE MAINTENANCE

Changing Engine Oil


WARNING: Be careful not to burn yourself, as the engine Is hot. 1. Warm up engine, and check for oil leakage from engine components. 2. Remove drain plug and oil filler cap. 3. Drain oil and refill with new engine oil. Refill oil capacity (Approximate):
Unit: liter (US qt, Imp qt) With oil filter change
Without oil filter change

Front SMAOO9C

(/4,/8) (/8,/8)

CAUTION:

Be sure to clean drain plug and Install with new washer. Drain plug:

tOJ: 9 - 39 N.m 2

( - kg-m, 22 - 29 ft-Ib) Use recommended engine

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.

SMAC

Changing

Oil Filter

1. Remove oil filter with a suitable tool. WARNING:

Be careful not to burn yourself, as the engine and the engine oil are hot.

2. Before installing new oil filter, clean the oil filter mounting surface on cylinder block, and coat the rubber seal of oil filter with a little engine oil.

~

SMA

MA

ENGINE MAINTENANCE Changing Oil Filter (Cont'd)


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.
2/3 of a turn

SMAB

O.K.

N.G.

Changing

Spark Plugs

1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire.

SMA

R
16mmV1
'arenaqq.us~
SEMA Side electrode

2. Remove spark plugs with spark plug wrench. Spark plug: Standard type ZFR5D Hot type ZFR4D Cold type ZFR6D

iii
SMA

3. Check plug gap of each new spark plug. Gap: - mm ( - 0~ in) 4. Install spark plugs. Reconnect ignition wires according to nos. indicated on them. Spark plug:
~

- 29

N.m

( - kg-m, 14 - 22 ft-Ib)

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 kil .If it exceeds the limit, replace the ignition wire with a new one.
SMAA

MA

ENGINE MAINTENANCE

Checking Vapor Lines


1. Visually inspect vapor lines for. improper 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 EF & EC section.
/"

"

MA

CHASSIS AND BODY MAINTENANCE

Checking Exhaust System

Check exhaust pipes, muffler and mounting for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.

SMAA

Checking Clutch Fluid Level and Leaks


Max. Min.

If fluid level is extremely low, check clutch system for leaks.

SMAB

Checking

M/T Oil

1. Check for oil leakage.

,
SMAA

2. If leakage is found, check oil level. Never start engine while checking oil level. Filler plug: ~: 25 - 34 N.m ( - kg-m, 18 - 25 ft-Ib)

SMA

Changing

M/T Oil

~~~
~.;. ~"~

.,.

1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: Q (/8 US pt, /4 Imp pt) Drain plug: ~: 25 - 34 N.m ( - kg-m, 18 - 25 ft-Ib)

SMAA

MA

CHASSIS AND BODY MAINTENANCE

Checking

AIT Fluid

1. Check for fluid leakage.

.
SMAA

Front side Hot: 50 - aooc ( - F) Add"

O.K.

2. If leakage is found, check fluid level. Fluid level should be checked using "HOT" range on dipstick at fluid temperatures of 50 to 80C ( to 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 50C (86 to 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 overfill.

3. Check fluid condition. Check fluid for contamination. If fluid is very dark or smells burned, or contains frictional material (clutches, band, etc.), check operation of AlT. Refer to section AT for checking operation of AlT.

Check fluid for contamination. SMAB

Changing

AIT Fluid

1. Drain fluid by removing oil pan. 2. Replace gasket with new one. 3. Refill with fluid and then check fluid level. Oil capacity (With torque converter): Q (/4 US qt, /4 Imp qt)

SMAB

MA

CHASSIS AND BODY MAINTENANCE

Checking Differential Gear Oil


1. Check differential carrier for oil leakage.

SMAC

2. If leakage is found, check oil level. Filler plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib)

SMA A

Changing

Differential Gear Oil

~~
0,,;" PI~

1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: Q (/4 US pt, /4 Imp pt) Drain plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib)

~
SMAA

Checking Brake Fluid Level and Leaks


=

If fluid level is extremely low, check brake system for leaks.

MAX

MIN

Checking Brake Lines and Cables

Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc.

SMAA

MA

CHASSIS AND BaDY MAINTENANCE

. Check condition of disc brake components. ROTOR . Check condition and thickness.
Unit: mm (in) Front
Disc brake type
SMAA

Checking Disc Brake

Rear CL9H () ()

CL22VB () ()

Standard thickness Minimum thickness

CALIPER

. Check operationand for leakage.

SMAA

PAD Check for wear or damage.

Unit: mm (in)

Front Disc brake type


Standard thickness

Rear CL9H

CL22VB ()

()

Minimum thickness
SMAB

()

Balancing

Wheels

Adjust wheel balance using road wheel center.


Wheel balance (Maximum allowable unbalance at rim flange): Refer to S.D.S. Tire balancing weight: Refer to S.D.S.

MA

CHASSIS AND BODY MAINTENANCE Tire Rotation

FRONT

Do not include the T-type spare tire when rotating the tires. Wheel nuts: ~: 98 - N.m ( - kg-m, 72 - 87 ft-Ib)

A!

SMAB

Checking Steering Gear and Linkage


STEERING GEAR Check gear housing and boots for looseness, damage or grease leakage. Check connection with steering column for looseness. STEERING LINKAGE Check ball joint, dust cover and other component parts for looseness, wear, damage or grease leakage.

. . .
.

.
Q

: Check grease leakage


: Check tightening torque SMA B

Checking Power Steering Fluid and Lines


Check fluid level, when the fluid is cold.

SMAB

Check lines for improper attachment, leaks, cracks, damage,

loose connections, chafing and deterioration.

SSTB

MA

CHASSIS AND BODY MAINTENANCE


LUBRICATING LOCKS, HINGES AND HOOD LATCHES
Fastback

lEI

=~~

m.
SMAB

CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS

CAUTION: 1. AUseat bait arenaqq.us, including retractors and attaching hardwares such as guida rail set, etc" should ba inspacted after any collision. Nin recommends that aUseet bait amblies in use during a collision ba replaced unless the collision was minor and the baits show no damage and continue to operete properly. Seat bait assemblies not in use during a collision should allO ba inspacted and replaced if eithar damage or improper operation is noted. 2. If tha condition of any component of a seat bait is questionable, do not have seat bait repaired, but raplaced as a bait mbly. 3. If wabbing is cut, frayed, or damaged, replace bait assembly. 4. Do not spill drinks, oil, etc. on inner lap bait buckle. Never oil tongue and buckle. 5. Use a NISSAN genuine arenaqq.us bait assembly.

~ Anchor boltN.m


( - kg-m, 17 - 23 ft-Ib) For automatic seat bait, refer to BF section.

Rear seat belt


Check function of buckles and tongues when buckled and released.

Front seat belt

SMAOO1 C

MA

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Maintenance


INSPECTION AND ADJUSTMENT Drive belt deflection
Unit: mm (in) Used belt deflection Limit Adjusted deflection Set deflection of new belt

Spark plug
Standard type Hot type Cold type Plug gap

ZFR5D
ZFR4D ZFR6D - mm ( . in)

Alternator

11 ()

( - I ( - ) ( - I ( - )

Ignition wire
Resistance kS1
Less than 30

Air conditioner compressor

12 ()

Power steering oil pump


I

TIGHTENING
Unit Spark plug Drain plug
Engine block

TORQUE
N'm 29
34 44

13 ( 1() ( )


98 N (10 kg, 22 Ib)

kg-m -

ft-Ib 22 25 - 33

Applied pushing force

Oil pan

Oil capacity (Refill)


Unit: 2 (US qt, Imp qt)
With oil filter Without oil filter

(/4,/8) (/8,/8)

Coolant capacity
Unit: 2 (US qt, Imp qt)
With reservoir tank

(,/8)

MA

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance


INSPECTION AND ADJUSTMENT Clutch
Unit: mm (in) Pedal free height "H" Pedal free play" A"

Brake
Unit: mm (in) Disc brake Pad Standard thickness CL22VB CL9H

- ()

- ( )

() ()

Front axle and front suspension(Unladen)*


Camber Caster Toe-in (Total toe-in) Kingpin inclination degree degree mm (in) degree degree ' to 0

Minimum thickness CL22VB CL9H Rotor Standard th ickness CL22VB CL9H

() ()

' . ~30' 0 - 2 (0 - )

() ()

0' - 12' '- '


Minimum thickness CL22VB

Front wheel turning angle Full turn Inside/outside d egree 39

() ()

/33

CL9H
Pedal Free height M/T A/T

*: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position.

- ( - )

- ( - ) 1 - 3 ( - )

Rear axle and rear suspension (Unladen)*


Camber Toe-out (Total arenaqq.us) degree mm (in) degree I ' to '

Free play Depressed hElight [under force of N (50 kg, Ib) with engine running] Parking brake Number of notches [at pulling force N (20 kg, 44 Ib)]

0 - 5 (0 . ) 0' - 28'

() or more

*: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.

Wheel bearing
Front Wheel bearing axle end mm (in) play Wheel bearing lock nut Tightening torque N.m (kg-m, ft-Ib) () or less Rear () or less

Wheel balance
Wheel balance (Maximum allowable unbalance at rim flange) g (OZ) Tire balance weight g (OZ) 10 ()

(15 22,

(,

)

)

( ) Spacing 5 ()

MA

SERVICE DATA AND SPECIFICATI'ONS(S.D.S.) Chassis and Body Maintenance (Cont'd)


TIGHTENING Unit Clutch Pedal stopper lock nut Clutch switch lock nut
Manual transmission

TORQUE
N'm kg-m ft-Ib

16 22 12 25

- 15 - 34

- - - 6 - 10 6 - 10

12 - 16 9 - 11 18 - 25

Drain and filler plugs Final drive Drain plug Filler plug Front axle and front
suspension Tie-rod lock nut Camber adjusting pin Rear axle and rear suspension Toe adjusting pin Camber adjusting pin Brake system Air bleed valve Brake lamp switch lock nut Brake booster input rod lock nut Wheel and tire Wheel nut

59 59

37 - 46

- -

27 - 34 91 -

-

69 69


12 16

-

51 - 65 51 9 - 11 12 - 16

- 15

- -

98 -

-

72

MA

ENGINE MECHANICAL

SECTION

EM
EM- 2 EM- 3 EM- 6 EM- 7 EM- 8 EM EM EM EM EM

EM

CONTENTS
PRECAUTION PREPARATION OUTER COMPONENT PARTS COMPRESSION PRESSURE OIL PAN TIMING CHAIN OIL SEAL REPLACEMENT CYLINDER HEAD ENGINE REMOVAL CYLINDER BLOCK
SERVICE DATA AND SPECIFICATIONS (S.D.S.)

"""'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' EM

PRECAUTION
LIQUID GASKET APPLICATION PROCEDURE

~~
Groove

'

I~r Side

Bolt hole

SEMC

a. Before applying liquid gasket, remove all traces of old liquid gasket from mating surface using a scraper. b. Apply a continuous bead of liquid gasket to mating surface. (Use Genuine Liquid Gasket or equivalent.) c. Be sure liquid gasket is to mm ( to in) wide (for oil pan). Be sure liquid gasket is to mm ( to in) wide (in areas except oil pan). d. Apply liquid gasket to inner sealing surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) e. Wait at least 30 minutes before refilling engine oil and engine coolant.

EM-2

PREPARATION
SPECIAL SERVICE TOOLS
Tool number (arenaqq.us No.) Tool name STS
(

Description

Disassembling and assembling

Engine stand assembly CD ST ( )

Engine stand @ ST


( Base

KV ) ( Engine attachment

KVSO ) ( Valve spring compressor

~
CI<

Disassembling and assembling valve components

CD

KV

( ) Compressor @KV ) ( Adapter

KVB ( ) Valve oil seal drift

~
3

Installing valve oil seal

KV
(

Disassembling and assembling piston with connecting rod

Piston pin press stand assembly CD KV ( ) Cap @ KV ( ) Spacer @ ST ( ) Press stand @ ST ( ) Spring @ KV ( ) Drift @ KV ( ) Center shaft

~
?~~
EM-3

PREPARATION
Tool number (Kent-Moore No.) Tool name EM (J ) Piston ring compressor

Description

Installing piston assembly into cylinder bore

(J) Valveoil seal remover

KV
(

Seal cutter

WS
( ) Tube presser

ST (J) Pilot bushing puller

~ T
~

Displacement valve oil seal

Removing oil pan

Pressing the tube of liquid gasket

EM-4

PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name Spark plug wrench
Description

Q
16mm

( in)

Pulley holder

c:Y
~

Removing and
spark plug

installing

r
Valve seat cutter set

--

Holding camshaft pulley while tightening or loosening camshaft bolt

~
\

Finishing valve seat dimensions


.-

~~.-

Piston ring expander

Valve guide drift

~
A:~

Removing and installing piston ring

Removing and installing valve guide


Diameter:

A B

mm (in) Intake () () Exhaust () ()

Valve guide reamer

Reaming valve guide (CD) or hole for oversize valve guide (@) Diameter:
Intake 01 Os 7 () () mm (in) Exhaust 8 () '()

~D.

EM;.5

OUTER COMPONENT
KA24E ENGINE

PARTS

16

(

.

, )

16 21 (_,12

)

B.P.T. valve . I A A umt

LI-I~~

I.-L ~

rA'..

)

( ,

,r"

Adjusting bar

( , )

~~

(,7 - 9)

rJ : Apply liquid gasket.


SEMC

: N.m (kg-m, ft-Ib)

EM-6

COMPRESSION

PRESSURE

Measurement of Compression
1. 2. 3. 4. 5. Warm up engine. Turn ignition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable.

Pressure

Q)
6. Attach a compression tester to NO.1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution. Compression pressure: kPa (kg/cm2,. psi)/rpm Standard 1, (, )/ Minimum (10, )/ Difference limit between cylinders 98 (, 14)/ If cylinder compression in one or more cylinders is loyi. 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. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat Is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is I,akage past the gasket surface. If so, replace cylinder head gasket.

SEM B

.
.

EM-7

OIL PAN

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.


@ 0
(jJ) 0

Front

0 @

Q

2SEMC

@ @ Loosen bolts in reverse order.

6. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. Do not insert screwdriver, or oil pan flange will be deformed.

. .

(2) Slide Tool by tapping its side with a hammer, and remove oil pan.

SEMA

7. Pull out oil pan from front side.

EM-8

OIL PAN Installation


Scraper

1. Before installing oil pan, remove all traces of liquid gasket

from mating surface using a scraper.


Also remove traces of liquid gasket from mating surface of cylinder block.

SEMC

2. Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent.

SEMC

Be sure liquid gasket is to mm ( to in) wide.

Cut here.

~
Liquid gasket

:J
SLC

7 mm

in)

--Lt-.
Inner side Groove
Bolt hole SEMB

3. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. 4. Install oil pan. Wait at least 30 minutes before refilling engine oil.

. .

EM-9

TIMING CHAIN

r
~
~

,6 -

'

Camshaft sprocket

(1:~ain'tenSioner


(

08 5.'
. ,

rJ

L

Qj

Front cover

.,
.

.~

Crankshaft sprocket

( , 9 .

L.

rJ : ApplV liquid gasket.


CAUTION:

: N.m (kg-m, ft-Ibl

SEMC

After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.

EM

TIMING CHAIN Removal


1. 2. 3. 4. Disconnect battery terminal. Drain coolant from radiator. Remove radiator shroud and cooling fan. Remove the following belts. Power steering drive belt Compressor drive belt Alternator drive belt

. . .

5. Remove all spark plugs. 6. Set NO.1 piston,at T.D.C. on its compression stroke.

Q
Front
SEMC

7. Remove the following parts. Power steering pump, idler pulley and power steering pump brackets Compressor idler pulley Crankshaft pulley Oil pump with pump drive spindle

. . . . .

Rocker

cover

SEMC

SEMC

EM-"

TIMING CHAIN Removal (Cont'd)


8. Remove oil pan. (Refer to OIL PAN.) 9. Remove front cover.

SEMC

Remove the following parts. . Chain tensioner . Chain guides . Timing chain and sprocket

Oil thrower, oil pump drive gear and crankshaft sprocket

Crank~h3ft sprocket

SEMC

Inspection Check for cracks and excessivewear at roller links. Replace if necessary.

Jf) ~

,~

'

SEMC

EM

TIMING CHAIN
crankShaft Crankshaft ~prOCket

~ ~
~

Installation
.

"4~

1. Install crankshaft sprocket, oil pump drive gear and oil thrower. . Make sure that mating marks of crankshaft sprocket face engine front. .

O;I:;:~~~ '\ n 0 ~
Front.

SEMC

~~~
'/0

(O@
\ ~.
'~ " \\
))
"

2. Install camshaft sprocket. 3. Confirm that NO.1 piston is set at T.D.C. on its compression stroke. 4. Install timing chain. Set timing chain by arenaqq.us its mating marks with those of crankshaft sprocket and camshaft sprocket.

~
II ~ Can ,",ocke<
"

ii

~r C"ok .p-"

e: Punchmark
SEMC

5. Tighten camshaft sprocket bolt.

6. Install chain guide and chain tensioner.

EM

TIMING CHAIN Installation (Cont'd)


7. Apply liquid'gasket to front cover.

mm

8. Apply lithium grease to sealing lip of crankshaft oil seal.

( . inl die.

9. Install front cover. Be careful not to damage cylinder head gasket. Do not forget seal.

. .

SEMC

Install rubber plug. (Refer to "Installation" HEAD.) Install oil pan. (Refer to Oil PAN.)

of CYLINDER

Install oil pump and distributor driving spindle with new gasket in front cover. (1) Assemble oil pump and driving spindle, aligning punchmark on driving spindle with oil hole.

Punchmark

SEMC

EM

TIMING CHAIN Installation (Cont'd)


(2) Make sure that driving spindle is set as shown in figure.

Front

SEMC

Install distributor. Make sure that NO.1 piston is set at T.D.C. and that distributor rotor is set at NO.1 cylinder spark position.

Q
Front
SEMC

EM

OIL SEAL REPLACEMENT


VALVE OIL SEAL 1. Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove valve spring and valve oil seal with Tool or suitable tool. Piston concerned should be set at T.D.C. to prevent valve from falling.

(J)

KV
(

4. Apply engine oil to new valve oil seal and install it with Tool. Before installing valve oil seal, install valve spring seat.

Valve spring seat

()

Unit: mm (in)

SEMC

OIL SEAL INSTALLING DIRECTION

Engine inside

Engine outside Dust seal lip

Oil seal lip

SEMA

FRONT OIL SEAL 1. Remove radiator shroud and crankshaft pulley. 2. Remove front oil seal. Be careful not to damage crankshaft.

EM

9i-

SEAL REPLACEMENT
3. Apply engine oil to new oil seal and install it using suitable tool.

SEMB

REAR OIL SEAL 1. Remove flywheel or drive plate. 2. Remove rear oil seal retainer. 3. Remove traces of liquid gasket using scraper.

4. Remove rear oil seal from retainer.

it

.J'I;

5. Apply engine oil to new oil seal and install it using suitable tool.

Diameter of Iiqu id gasket: - mm

6. Apply liquid gasket to rear oil seal retainer.

~ (

in)

EM

CYLINDER HEAD

~~-8
.,' Valve rocker cover-

, ' '

Rocker cover gasket

37 - 41 ( - , 27 - 30)

Valve and spring

Intake Spring retainer Valve

'~w,

Oilseal

springseatA

V"Wg";..~~
Valve seat

,\;~ ~ , \ ~J
@
~~
@

E'M":~
.

\\

\J @<~ 'b@cg

Cylinder head

Head bolt

~:

N'm (kg-m, ft-Ib) SEMC

EM

CYLINDER HEAD
CAUTION: When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. . When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts.

O.K.

Hydraulic valve lifters are installed in each rocker arm. If hydraulic valve lifter is kept on its side, even when installed in rocker arm, there is a possibility of air entering it. After removal, always set rocker arm straight up, or when laying it on its side, have it soak in new engine oil.

Ii
SEMB

N.G.

. .

Do not disassemble hydraulic valve lifter. Attach tags to valve lifters so as not to mix them up.

SEMB

Removal 1. Drain coolant from radiator and drain plug of block. 2. Remove the following parts. Power steering drive belt Power steering pump, idler pulley and power steering brackets Vacuum hoses of S.C.v. and pressure control solenoid valve Accelerator wire bracket 3. Disconnect E.G.R. tube from exhaust manifold. 4. Remove bolts which hold intake manifold collector to intake manifold. 5. Remove bolts which hold intake manifold to cylinder head while raising collector upwards. 6. Remove rocker cover. When removing rocker cover, do not hit rocker cover against rocker arm.

. . . .

EM

CYLINDER HEAD Removal (Cont'd)


7. Set NO.1 piston at T.D.C. on its compression stroke.

-5/0

5 10 15 20

Red painted

~
Front
SEMC

8. Loosen camshaft sprocket bolt. Support timing chain by using Tool as shown in figure.

SEMC

9. Remove camshaft sprocket.

EM

CYLINDER HEAD Removal (Cont'd)


Remove front cover tightening bolts to cylinder head.

SEM

<ID

CID

Remove cylinder head. Head warpage or cracking could result from removing in incorrect order. Cylinder head bolts should be loosened in two or three steps.

. .

- SEMC Disassembly'

0
10

@
0

@
0

@
0

@
01

(Q

~ (])

~ @

~ @

Q) CD
SEMC

1. Remove rocker shaft assembly. a. When loosening bolts, evenly loosen from outside in sequence. b. Bolts should be loosened in two or three steps. 2. Remove camshaft. Before removing camshaft, measure camshaft end play. (Refer to "Inspection".)

KV ( )

3. Remove valve components with Tool. 4. Remove valve oil seals. (Refer to OIL SEAL REPLACEMENT.)

EM

CYLINDER HEAD Inspection


CYLINDER HEAD DISTORTION Head surface flatness: Less than mm ( in) If 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" The maximum limit is as follows: A + B = mm ( in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced. Nominal cylinder head height: - mm ( - 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):
0 - mm (0 - in) 2. If it exceeds the limit, replace camshaft.

CAMSHAFT CAM HEIGHT 1. Measure camshaft cam height. Standard cam height:

Cam wear limit: mm ('in) 2. If wear is beyond the limit, replace camshaft.

- mm ( -

in)

SEMA

CAMSHAFT

JOURNAL

CLEARANCE

1, Install camshaft bracket and rocker shaft and tighten bolts


to the specified torque. 2. Measure inner diameter of camshaft bearing. Standard inner diameter:

"

- mm (

-

in)

EM

CYLINDER HEAD Inspection (Cont'd)


3. Measure outer diameter of camshaft journal. Standard outer diameter: - mm ( - , in) 4. If clearance exceeds the limit, replace camshaft and/or
cylinder head.

Camshaft journal clearance: Standard - mm ( - in) Limit mm ( in) CAMSHAFT END PLAY

1. Install camshaft in cylinder head. 2. Measure camshaft end play. Camshaft end play: Standard - mm ( - in) Limit mm ( in)

SEMC

CAMSHAFT

SPROCKET

RUNOUT

1. Install sprocket on camshaft. 2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit mm ( in) 3. If it exceeds the limit, replace camshaft sprocket.

SEMC

VALVE GUIDE CLEARANCE 1. Measure valve deflection in a right-angled direction with camshaft. (Valve and valve guide mostly wear in this direction.) . Valve deflection limit (Dial gauge reading): mm ( in)

SEMC

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: Standard - mm ( - in) (Intake) - mm ( - in) (Exhaust) Limit mm ( in) c. If it exceeds the limit, replace'valve or valve guide.

EM

\ \ \

CYLINDER HEAD
Inspection (Cont'd)
VALVE GUIDE REPLACEMENT 1. To remove valve guide, heat cylinder head to to C ( to F).

2. Drive out valve guide with a press [under a 20 kN (2 t, US ton, Imp ton) pressure] or hammer and suitable tool.
.'

SEMC

3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake - mm ( - in) Exhaust - mm ( - in)

4. Heat cylinder head to to C ( to F) and press service valve guide onto cylinder head. Projection "L": - mm ( - in)

SEMC

5. Ream valve guide. Finished size: Intake - mm ( - in) Exhaust - mm ( - in)

"

EM

CYLINDER HEAD Inspection (Cont'd) VALVESEATS


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 seat. Cut with both hands to uniform the cutting surface.

REPLACING

VALVE SEAT FOR SERVICE PARTS

I
Recess diameter
I

SEMA

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 [ mm ( in)): Intake - mm ( - in) Exhaust - mm ( - in) Reaming should be done to the concentric circles to valve guide center so that valve seat will have the correct fit.

3. Heat cylinder head to to C ( to F).

SEMOO8A

"::I SEMB

4. Cut or grind valve seat using suitable tool at the specified dimensions as shown in S.o.S. 5. After cutting, lap valve seat with abrasive compound. 6. Check valve seating condition. Seat face angle" a ": 45 deg. Contacting width "W" Intake - mm ( - in) Exhaust - mm ( - in)

EM

CYLINDER HEAD Inspection (Cont'd)


T (Margin thickness)

cr d

VALVE DIMENSIONS Check dimensions in each valve. For dimensions, refer to S.O.S. When valve head has been worn down to mm ( in) in margin thickness, replace\lalve. Grinding allowance for valve stem tip is mm ( in) or less.

L
SEMA

JdiSEMA EM

VALVE SPRING Squareness 1. Measure "s" dimension. Out-of-square: Outer Intake Less than mm ( in) Exhaust Less than mm ( in) Inner Intake Less than mm ( in) Exhaust Less than mm ( in) 2. If it exceeds the limit, replace spring. Pressure Check valve spring pressure. Pressure: N (kg, Ib) at height mm (in) Standard Outer Intake (, ) at () Exhaust (, ) at () Inner Intake (, ) at () Exhaust (, ) at () Limit Outer Intake (, ) at () Exhaust (, ) at () Inner. Intake (, ) at () Exhaust (, ) at () If it exceeds the limit, replace spring.

EM

CYLINDER

HEAD

Inspection (Cont'd) ROCKER SHAFT AND ROCKER ARM 1. Check rocker shafts for scratches, seizure and wear. 2. Check outer diameter of rocker shaft. Diameter mm (in): - mm ( - in)

3. Check inner diameter of rocker arm. Diameter mm (in): - mm ( - in) Rocker arm to shaft clearance mm (in): - mm ( - in) Keep rocker arm with hydraulic valve lifter standing to prevent air from entering hydraulic valve lifter when checking.

SEMC

Assembly 1. Install valve component parts. Always use new valve oil seal. Refer to OIL SEAL REWide pitch

Cylinder head side


Place upside.

Narrow

pitch

. . . .

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 head side. After installing valve component parts, use plastic hammer to lightly tap valve stem tip to assure a proper fit.

SEM

2. Mount camshaft onto cylinder head, placing knock pin at front end to top position. Apply engine oil to camshaft when mounting onto cylinder head.

SE MC

3. Install camshaft brackets. Front mark is punched on the camshaft bracket.

SEMC

EM

'"

CYLINDER HEAD Assembly (Cont'd)


4. Install rocker shaft with rocker arms.

Front

Intake

Exhaust

Exhaust SEMC

Install retainer with cutout facing direction shown in figure at left.

Front

Cutout SEMC

5. Tighten bolts as shown in figure at left.

(j)

@
0

~
[Q: @

CD 0

@ 0

@ Q)

.Q.

.Q.

.Q.

QJ @)
SEMC

EM

CYLINDER HEAD

Installation
1. Set No.1 piston at T.D.C. on its compression stroke as follows: (1) Align mark on crankshaft pulley with "0" position and confirm that distributor rotor head is set as shown in figure.

-5~ 10 15 20

Red painted

Q
Front
SEMC

(2) Confirm that knock pin on camshaft is set at the top.

SEMC

.
2. Install cylinder head with new gasket and tighten cylinder

CD @
I I

. Do not rotate crankshaft and camshaft separately, valves will hit piston heads. . Tightening procedure (1) Tighten all bolts to 29 Nom ( kg-m, 22 ft-Ib).
(2) Tighten all bolts to 78 Nom ( kg-m, 58 ft-Ib). (3) Loosen all bolts completely. (4) Tighten all bolts to 29 Nom ( kg-m, 22 ft-Ib).
(5) Turn all bolts 80 to 85 degrees
SEMC @
I

head bolts in numerical

order.

or

(j)

CID

clockwise

with an angle

wrench, or if an angle wrench is not available, tighten all bolts to 74 to 83 Nom ( to kg-m, 54 to 61 ft-Ib).

EM

CYLINDER HEAD Installation (Cont'd)


3. Set chain on camshaft sprocket by aligning each mating mark. Then install camshaft sprocket to camshaft.

Silver

4. Tighten camshaft sprocket bolt.

5. Install rubber plugs as follows: (1) Apply liquid gasket to rubber plugs.

Rubberplugsshouldbe replacedwithnewones.
Rubber plugs should be installed within 5 minutes of applying liquid gasket.

(2) Install rubber plugs. then move them with your fingers to uniformly spread the gasket on cylinder head surface. Rubber plugs should be installed flush with the surface. Do not start the engine for 30 minutes after installing rocker cover. Wipe clean excessive liquid gasket from cylinder head top surface.

. . .

--N.G.

o/!I!IIJl
Good
SEMB

EM

CYLINDER HEAD Installation (Cont'd)


6. Check hydraulic valve lifter. (1) Push hydraulic valve lifter forcefully with your finger. Be sure to check It with rocker arm In Its free position.

(2) If valve lifter moves more than 1 mm ( in), air may be inside of it. (3) Bleed air off by running engine at 1, rpm under no-load for about 20 minutes. (4) If hydraulic valve lifters are still noisy, replace them and bleed air off again in the same manner as in step (3).

7. Install rocker cover. Be sure to avoid Interference rocker arm.

between

rocker

cover

and

~:J
@
SEMC

8. Tighten bolts as follows: (1) Tighten 2 bolts to 3 N.m ( kg-m, ft-Ib) temporarily in order shown in figure.

@ @\

.g,

@ @
,0,

(2) Then tighten bolts to 7 to 10 N.m ( to kg-m, to ft-Ib) in order shown in figure. 9. Install any parts removed.

-""6'CD @

.-JJ@
SEMC

EM

ENGINE REMOVAL

M/T model

tC!] 3 1

( )

M~ . ( - 32 - 41)

tC!] 4

(4A)

~ j
0 ~ ~

tC!] 4

(

- 41)

~
,

r ~
'-, ~

tC!]2 2
( )
.I?:

L~


(

LtC!] 22

)

( - - 21)

//'

'''"'

~/

lOJ : N.m (kg-m. ft-Ib)


SEMC

EM

..

ENGINE REMOVAL
WARNING: a. Situate vehicle on a flat and solid surface. b. Place chocks at front and back of rear wheels. c. 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. e. Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to "Releasing Fuel Pressure" in section EF & EC. f. Be sure to hoist engine and transmission in a safe manner. g. 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.

. .

"5
:1,; ",.

.,"'"

EM

CYLINDER BLOCK

Main bearing

cg

Drain plug (, ~

~
.

rJ

: N'm (kg-m, ft-Ib) : Apply liquid ga\et. SEMC

EM

CYLINDER BLOCK

Disassembly
PISTON AND CRANKSHAFT 1. 2. 3. 4. 5. 6.
SEM

/;~y

,
I I.~'
~

~\ ~ I~(
II

~~O1
ST

Place engine on a work stand. Remove timing chain. Drain coolant and remove water pump. Drain oil. Remove oil pan and oil pump. Remove cylinder head.

-)

7. Remove pistons. When disassembling piston and connecting. rod, remove snap rings, then heat piston to 60 to 70C ( to F) or use piston pin press stand at room temperature.

SEMB

KV

EM

8. Remove main bearing beam and crankshaft. Before removing main bearing beam, measure crankshaft end play. Bolts should be loosened in two or three steps.

. .

Inspection PISTON AND PISTON PIN CLEARANCE 1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp": - mm ( - in)
;

..
SEMB

EM

CYLINDER BLOCK Inspection (Cont'd)


2. Measure outer diameter of piston pin "Dp". Standard diameter "Dp":

- mm ( - in)


3. Calculate interference fit of piston pin to piston.

dp - Dp = 0 - mm (0 - In)
If it exceeds the above value, replace pi!3ton assembly with pin.

SEM B

PISTON RING SIDE CLEARANCE Side clearance: Top ring


- mm ( - In)

SEMC

2nd ring - mm ( - In) ring - mm ( - in) Max. limit of side clearance: mm ( in) If out of specification, replace piston and/or piston ring assembly.

PISTON RING END GAP


End gap: Top ring - mm ( - in) 2nd ring - mm ( - in) (R or T is punched on- the ring.) - mm ( - in) (N is punched on the ring.) Oil ring - mm ( - in) Max. limit of ring gap: mm ( 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

SEMC

and piston rings.


Refer to S.D.S.

EM

CYLINDER BLOCK Inspection (Cont'd)


CONNECTING ROD BEND AND TORSION Bend: Limit mm ( in) per mm ( in) length Torsion: Limit mm ( in) per mm ( in) length If it exceeds the limit, replace connecting rod assembly.
SEMB

Measuring points

Distortion: Less than mm (

in)

CYLINDER BLOCK DISTORTION AND WEAR 1. Clean upper face of cylinder block and measure the distortion. Limit: mm ( in) 2. If out of specification, arenaqq.us The resurfacing limit is determined by cylinder head resurfacing in engine. Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing is "B" The maximum limit is as follows: A + B = mm ( in) Nominal cylinder block height from crankshaft center: ( - in) mm 3. If necessary, replace cylinder block.

SEMC

-_N O!CD""
MM

ffi
,
I I I

ON '00
I I I

. . ~.

N CD

, ,

Unit: mm (in)

PISTON-TO-BORE CLEARANCE 1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. Standard inner diameter: - mm ( - in) Wear limit: mm ( in) Out-of-round (X-V) limit: mm ( in) Taper (A-B) limit: mm ( 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.

EM

CYLINDER BLOCK

.
Q
Front
SEMC

Inspection

(Cont'd)

If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block upper surface.

3. Measure piston skirt diameter. Piston diameter" A": Refer to S.D.S. Measuring point "a" (Distance from the top): 52 mm ( in) 4. Check that piston-to-bore clearance is within specification.
a

Piston-to-bore clearance "B": . - mm ( - in)

SEMC

5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to S.D.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 C: Honing allowance mm ( 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 mm ( in) or so in diameter at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

A B

CRANKSHAFT cracks. 2. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X-Y): Main journal Less than mm ( in) Crank pin Less than mm ( in) Taper (A-B): Main journal Less than mm ( in) Crank pin Less than mm ( in) EM

1. Check crankshaft main and pin journals for score, wear or

x
y
Taper: Out-of-round: A- B X- Y SEMA

CYLINDER BLOCK Inspection (Cont'd)


3. Measure crankshaft runout. Runout (Total indicator reading): Less than mm ( in)

BEARING

CLEARANCE

Method A (Using bore gauge and micrometer) Main bearing 1. Set main bearings in their proper positions on cylinder block and main bearing cap.

SEMC

2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. Refer to "Assembly". 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: - mm ( - in) Limit: mm ( 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 fillet roll is more than the specified limit. "L": mm ( In) b. Refer to S.D.S. for grinding crankshaft and available service parts.

SEM

EM

CYLINDER BLOCK Inspection (Cont'd)


0 0

,Q

rg
Front

bl

roJ

[5j

rd

8. ;If crankshaft is reused, measure main bearing clearance and select thickness of main bearing. If crankshaft is replaced with a new one, it is necessary to select thickness of main bearings as follows: a. Grade number of each cylinder block main journal is punched on the respective cylinder block.

SEMC

Journal grade number

b. Grade number of each crankshaft main journal is punched on crankshaft.

SEMC

c. Select main bearing with suitable thickness according to the following table. Main bearing grade number:

Crankshaft journal grade number 0

0 1

1 2 3

2 3 4

For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 =3

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.

EM

CYLINDER BLOCK Inspection (Cont'd)


4. Measure outer diameter "Dp" of each crankshaft pin journal. 5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C Dp Standard: ' - mm ( - in) Limit: mm ( 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. Refer to step 7 of "BEARING CLEARANCE - Main bearing".

8.

If crankshaft is replaced with a new one, select connecting bearing according to the following table.

rod

Connecting rod bearing grade number: Crank pin


grade number 0
SEMB

Connecting rod bearing grade number 0

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 a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained.

. .

EM

CONNECTING ROD BUSHING CLEARANCE (Small end) 1. Measure inner diameter "c" of bushing.

SEMB

EM

CYLINDER BLOCK Inspection (Cont'd)


2. Measure outer diameter "Dp" of piston pin. 3. Calculate connecting rod bearing clearance.

C - Dp = - mm ( - in) (Standard)


mm ( in) (Limit) If it exceeds the limit, replace connecting and/or piston set with pin.
Micrometer SEMA

rod assembly

REPLACEMENT

OF CONNECTING

ROD

BUSHING

(Small end) 1. Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes. 2. After driving in small end bushing, ream the bushing so that clearance between small end bushing and piston pin is specified valve. Clearance between small end bushing and piston pin: - mm ( - in)
SEMA

FLYWHEEL/DRIVE

PLATE RUNOUT

Runout (Total indicator reading): Flywheel (M/T model) Less than mm ( in) Drive plate (A/T model) Less than mm ( in)

SEM C

Dial gauge

Assembly PISTON 1. Install new snap ring on one side of piston pin hole.

SEMB

2. Heat piston to 60 to lOoC ( to F) 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.

Cylinder number
SEMC

EM

CYLINDER BLOCK Assembly (Cont'd)

KV (

EM

3. Set piston rings as shown.


p~markSide
1""""-

,'"

g;r

'

rn

SEMC Oil ring

expander

..
Front

*
i?

V-

~ -""'-.) K'

.8

8 Top ring

upper rail

Ojl ring

/"')

!/ "~

Oil ring

lower rail
SEM

CRANKSHAFT

~~
t2
Front

1. Set main bearings in their proper positions on cylinder block and main bearing beam. Confirm that correct main bearings are used. Refer to "Inspection" of this section.

~ ~~:O.5 50 ~ ~
No.3 No.1 No.2
SEM44BC

2. Install crankshaft and main bearing beam and tighten bolts to the specified torque. Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction. '. Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.

. . .

EM

CYLINDER BLOCK Assembly (Cont'd)


3. Measure crankshaft end play.
Crankshaft end play: Standard - mm ( - in) Limit mm ( in) If beyond the limit, replace bearing with a new one.

4. Install connecting rod bearings in connecting rods and

J
SEMB

. connecting rod caps. bearings are used. Confirm that correct Refer to "Inspection". . Install bearings so that oil hole in connecting oil hole of bearing.

rod aligns with

5. Install pistons with connecting rods. a. Install them into corresponding cylinders with Tool. Be careful not to scratch cylinder wall 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 arenaqq.us torqu~. . Connecting rod bearing nut: (1) Tighten to 14 to 16 N.m ( to kg-m, 10 to 12 ft-Ib). (2) Tighten bolts 60 to 65 degrees clockwise with an angle wrench, or if an angle wrench is not available, tighten them to 38 to 44 N.m ( to kg-m, 28 to 33 ft-Ib).
6. Measure connecting rod side clearance. Connecting rod side clearance: Standard

- mm (

-

in)

Limit mm ( in) If beyond the limit, replace connecting rod and/or crankshaft.

EM

CYLINDER

BLOCK

ST (J) or su itable tool

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).

Crankshaft side

..

M/T

A/T
SEMB

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
Engine model Cylinder arrangement Displacement Bore x stroke Valve arrangement Firing order Number of piston rings Compression Oil Number of main bearings Compression ratio cm' (cu in) mm (in) KA24E 4, in-line 2, () 89 x 96 ( x ) O.H.C.

2 1 5

Unit: kPa (kg/cm2 ,psi)/rpm Compression pressure Standard Minimum Differential limit between cylinders

1,

(,

) /

(10,)/

98 (, 14)/

EM

SERVICE DATA AND SPECIFICATIONS

(S.D.S.)

Inspection and Adjustment


CYLINDER BLOCK
10 ()

60 ()

() H

SEMC Unit: mm (in)

Standard Distortion
Grade 1 Inner diameter Cylinder bore Out-of-round (X-V) Taper (A-B) Difference in inner diameter between cylinders Piston-to-cylinder clearance Cylinder block height (From crankshaft cented
* Wear limit ** Total amount of cylinder head resurfacing and cylinder block resurfacing

Limit ()

- ( - ) - ( - ) - ( - ) Less than ) Less than () Less than () - ( - ) - ( - ) Grade 2 Grade 3

()*

()

()**

CYLINDER

HEAD
Unit: mm (in)

Standard Height (H) Surface distortion


* Total amount resurfacing of cylinder

Limit )* ()


and cylinder block

- ( - ) ()


head resurfacing

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.)


VALVE GUIDE

Inspection and Adjustment (Cont'd)

tL

SEM B SEMC Unit: mm (in)

Standard Intake
Length (L) ()

Service Exhaust
()

Limit Exhaust
()

Intake
()

Outer diameter (D) Inner diameter (d) (Finished size) Cylinder head hole diameter Interference fit Stem to guide clearance Tapping length (Q)

- ( - ) - ( - ) - ( - )

- ( - ) - 8.Q18 ( - ) - ( - )

- ( - ) - ( - ) ( - )

- ( - ) - 8.Q18 ( - ) - ( - )

- ( - )


- ( - ) - ( - )

- ( - ) ()

- ( - )

- ( - )

EM

SERVICE DATA AND SPECIFICATIONS (S.O.S.) Inspection and Adjustment (Cont'd)

Standard

Service

I
D1

I
D1

SEM

SEM

Unit:

mm (in)

Standard Intake Cylinder head seat recess diameter Valve seat outer diameter (D1 ) - ( - ) - (1 - ) 45 Exhaust - ( - ) - ( ) 45 Intake - ( - ) - ( - ) 45

Service Exhaust - ( - ) - ( - ) 45 ( - )

Face angle (a) Contacting width (W)

-
( - )

-
( - )

-
( - )

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.)


VALVE

Inspection and Adjustment (Cont'd)

T (Margin thickness)

SEMA

Valvehead diameter (D) Valvelength (LI Valvestem diameter (d)

Standard Limit
Unit: mm (in)

In.
Ex.

( )


- ( - )

In.
Ex. In. Ex. In.
Valve face angle (01) Ex. In. Valve head margi n (T) Ex.

()


- ( - ) - ( - )
-

( - ) '


45 30' - ( - )

() - ( - )

VALVE SPRING
Unit: mm (in)

Standard Intake Outer Free height (H) Inner Pressu re N (kg,lb) at height Outer () (, ) at () (,) at () () (, ) at () (, ) at () (,) at () (,) at () () () () Exhaust () Intake -

Limit Exhaust

(, ) at (,) (,) at () () ()

Inner Outer

Out-of-square Inner

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd)


CAMSHAFT AND CAMSHAFT BEARING

..

;#
. DC
EM Unit: mm (in)

SEMA

Standard Cam height (A) Valve lift (h) Wear limit of cam height Camshaft journal to bearing clearance Inner diameter of camshaft bearing - ( - ) ()

limit

() ()

- ( - ) - ( - )

Outer diameter of camshaft journal (D) Camshaft f1Inout Camshaft end play ) a b c Valvetiming (Degreeon crankshaft! d e
f

- ( - )

0 (0 )
- ( - ) 3 57 12 56

()

ROCKER ARM AND ROCKER SHAFT


Unit: mm (in) Rocker arm to shaft clearance - ( - ) - ( - ) - ( - )

Rocker shaft diameter Rocker arm rocker shaft hole diameter

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd)


PISTON, PISTON RING AND PISTON PIN Piston Pistonring
Unit: mm (in)

==
Top

Standard - ( - ) (

limit ()

d
Side clearance 2nd

-

)
-

()

a
Oil

- ( )

()

Top

-
(

- )

()

SEMC Unit: mm (in)

Ring gap

2nd

- - )*1 )*2

)

Grade No.1 Standard Piston skirt diameter (A) Grade No.2 Grade No.3

- ( - ) - ( - ) ( - ) - ( - ) - ( - )

Oil Irail ring)

- (

- )

()

*1: R or T is punched on the ring. *2: N is punched on the ring.

CONNECTING

ROD


Service (Oversize) () ()

Dimension (a) Piston pin hole diameter (d) Piston-to-c:ylinderbore clearance/'

Approximately 52 () - ( )

- ( - ) S


SEMA Unit: mm (in)

Piston pin
Unit: mm (in) Standard Piston pin outer diameter Interference fit of piston pin to piston pin hole limit

==
Center distance IS)

Standard - - )

limit

)
()

()


0 - (0 - ) ( )

()

Bend [per mm ( in)] Torsion


[per mm ( in)] Piston pin bushing inner diameter (d)*
Connecting rod big end iner diameter (D)* Side clearance

-

Piston pin to connecting rod bearingclearance

- )

- - )

- )

)

* Without

bearing

EM

SERVICE DATA AND SPECIFICATIONS


CRANKSHAFT

(S.D.S.)

Inspection and Adjustment (Cont'd)

Out-of-round

@- Ci)

Taper@ .@

~. Om
Op
SEM Unit: mm (in) No.O Main journal diameter (Dm) Grade No.1 No.2 No.O Pin journal diameter (Op) Grade No.1 No.2 Center distance (r) Standard Journal Taper of journal and pin I@ - @] Pin Journal Pin - ( - ) - ( - ) - ( - ) - ( - ) - ( - ) - ( - ) - ( - ) Limit () () () () () ()

\J57
EM

Out-of-round of journal and pin I@ -Ci)] , Runout IT.I.R.] * Free end play Fillet roil
* Total indicator reading

- ( - ) More than ()

BEAR ING CLEARANCE


Unit: mm (in)

Standard Main bearing clearance Connecting rod bearing clearance - ( - ) - ( - )

limit ()

()

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd)


AVAILABLE MAIN BEARING Standard
Grade number
0 Thickness mm (in) - - ) - 1 - ) Identification color Black Brown Green Yellow Blue 2

AVAILABLE CONNECTING ROD BEARING


Standard
Grade number
0 Thickness mm (in) 1 - ( - ) - ( - ) - - ) Brown Green
Identification color

2 3
4

- 1 - ) - - ) - - )

Undersize (service)
Unit: mm (in) Thickness Crank pin journal diameter "Dp"

Undersize

(service)
Unit: mm (in) Thickness
Mein journal diameter "Dm" ) () - ( - ) - 1 - ) - - )

)

- )

Grind so that bearing clearance is the specified value.

Grind so that bearing clearance is the specified value.

)

MISCELLANEOUS

COMPONENTS
Unit: mm (in)

Camshaft sprocket runout [T.I.R.] * Flywheel runout Drive plate runout


* Total indicator [T.I.R.] [T.I.R.] reading * *

less than () less than ()


less than )

EM

ENGINE LUBRICATION & COOLING SYSTEMS


I

SECTION

LC
; lC- 2
,.. lC- 3
lClC

CONTENTS
PREPARATION


."..
""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''"""''''''''''''''''''''''''''''''''
''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

ENGINElUBRICATION SYSTEM "


ENGINE COOLING SYSTEM CONDENSER FAN MOTOR ELECTRICAL CIRCUIT SERVICE DATA AND SPECIFICATIONS (S.O.S.)

""

lC

PREPARATION
SPECIAL SERVICE TOOLS
Tool number (Kent-Moore No.) Tool name ST (J ) Oil pressure gauge

Description

U!!

ST (J) Hose

EG
(

a
[j

Adapting oil pressure gauge to cylinder block

Radiator cap tester adapter

Adapting radiator cap tester to radiator filler neck

LC-2

+

Oil gallery in cylinder block By-passpassage Intermittently oiling portion


0 iI passage

--

--

<i=

Pump drive gear

r0-

O I
W

Hydraulic valve lifter


I

Cam ;Urlace I

'" r

(') co I\)
:r>

ENGINE LUBRICATION SYSTEM Oil Pressure Check


WARNING: Be careful not to burn yourself, as the engine and may hoL / pressure check should be done in "Neutral" gear position.

. .

1. Check oil level. 2. Remove oil pressure switch.

3. Install pressure gauge. 4. Start engine and warm it up to normal operating temperature. 5. Check oil pressure with engine running under no-load.
ST (J)

Engine rpm

Approximate discharge pressure kPa (kg/cm2, psi) More than 78 (, 11) (,)

Idle speed 3,


SLC

If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.

LC-4

ENGINE LUBRICATION SYSTEM Oil Pump


\
Drive spindle

~tOJ

6. 10 ( - ,)
body Gasket

> /pump

tOJ:

N.m (kg-m, ft-Ib) SLC

.
.

iT.

~~1~
Punchmark
Oil

~AU) ~~"4A

Always replace with new oil seal and gasket. When removing oil pump, turn crankshaft so that No.1 piston is at T.D.C. on its compression stroke. When installing oil pump, align punchmark on drive spindle and oil hole on oil pump.

hole

Front

~
REGULATOR VALVE INSPECTION

1. Visually inspect components for wear and damage. 2. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump assembly.

EL

LC-5

ENGINE LUBRICATION SYSTEM


OIL PRESSURE RELIEF VALVE INSPECTION Inspect oil pressure relief valve for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove valve by prying it out with suitable tool. Install a new valve in place by tapping it.

Oil Pump (Cont'd)

OIL PUMP INSPECTION


CD

Using a feeler gauge, check the following clearance.


Unit: mm (in)

Rotor

tip clearance CD

Less than ()

Outer rotor to body clearance

- ( - ) - ( - )

Side clearance (with gasket) CID

If it exceeds the limit, replace gear set or entire oil pump assembly.

SLC

LC-6

ENGINE COOLING SYSTEM Cooling Circuit

Thermostat: Thermostat:

Open Closed

Radiator

Intake man ifold

Thermostat

SLCA

System Check
WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. CHECKING COOLING SYSTEM HOSES

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

LC-7

ENGINE COOLING SYSTEM


System Check (Cont'd) CHECKING COOLING SYSTEM FOR lEAKS To check for leakage. apply pressure to the cooling system with a tester. Testing pressure: 98 kPa ( kg/cm2, 14 psi)
CAUTION:

Higher than the specified pressure may cause radiator damage.


SMAA

CHECKING RADIATORCAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure:
78

- 98 kPa ( - kg/cm2,11 - 14 psi)

SLC

Water Pump

~
::~~~.~.~.m~

12'~'
\

~',P/

)!!7

.
SLCA

INSPECTION Check for excessive end play and rough operation.

(f

SLC

INSTAllATION Remove liquid gasket from mating surface of pump housing using a scraper.

. . .

Be sure liquid gasket in grooves Is also removed.

Remove liquid gasket from mating surface of cylinder block. Clean all traces of liquid gasket using white gasoline.

SLCA

LC-8

ENGINE COOLING SYSTEM Water Pump (Cont'd)

. .

Cut off tip of nozzle of liquid gasket tube at point shown in figure. Use Genuine Liquid Gasket or equivalent.

Cut here.

~
KP Diameter of liquid gasket: mm in)

]
SLC

of pump housing as shown. a. Be sure diameter of liquid gasket Is within to mm ( to In) dla. range. b. Attach pump housing to cylinder block within five minutes of applying liquid gasket. c. After Installing pump housing, walt at least 30 minutes before starting engine.

Apply a continuous bead of liquid gasket to mating surface

SLCA

Thermostat INSPECTION 1. Check for valve seating condition at ordinary temperatures. It should arenaqq.usly.

Water inlet
SLCA

Upward

A~

~~

2. Check valve opening

temperature and maximum valve lift.


() 8/90 (/)

Jiggle valve

Valve opening temperature c (oF) Max. valve lift mmfC (infF)

--~
SLC

3. Then check if valve closes at 5C (9F) below valve opening

temperature.

After Installation, run engine for a few minutes, and check>., for leaks.

SLC

LC-9

ENGINE COOLING SYSTEM Thermostat


INSTAllATION

(Cont'd)

. .

Remove liquid gasket from mating surface of thermostat using a scraper. Similarly, remove liquid gasket from mating surface of cylinder block. Clean all traces of liquid gasket using white gasoline.

SLC

Cut here.

. .
KP()

Cut off tip of nozzle of liquid gasket tube at point shown in figure. Use Genuine LiqLJidGasket or equivalent. ..~

]
SLC

Apply a continuous bead of liquid gasket to mating surface of water inlet. a. Be sure diameter of liquid gasket is within to mm ( to in). b. Attach water inlet to cylinder block within five minutes after applying liquid gasket. c. After installing water inlet, wait at least 30 minutes before refilling coolant and starting engine.

SLC

'( .~

LC -1 0

ENGINE COOLING SYSTEM

Radiator
A/T model only ~3 2 ,

)

7 ~
@I

Automatic transmission

~
~

'~ ~~ . ,""lIlY , )

LJ

~:

N-mIkg-m,ft-lb)

Radiator shroud SLCA

CAUTION: When filling radiator with coolant, refer to MA section.

Cooling Fan
DISASSEMBLY AND ASSEMBLY

-~

'\"

Fan

<1( L-.J

~:

N'm (lrg-m;ft-Ibl
SLC

\~ ~o.~~ ,)

INSPECTION Check fan coupling for rough operation, oil leakage or bent bimetal.

SLC

LC

I GNITI ON SWITCH ON or- START

I GNI TI ON SWITCH ACC or- ON

BATTERY fus Ib I e

FUSE

@D~
36

AIR RELAY

CONDI TI ON

r(")
I ~

t'1 P P
!fI

11 41 THERMOSWITCH

n a z -I a r c z -I

To ther-mo

contro

I amp.

M
41
-=

CONDENSER FAN MOTOR

36

@4Ib

0
!II r 0 I\,) w m

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT Wiring Diagram


AIR Green) Ie IlnkI GNITI ON SWI TCH ACC or ON

=
(Sub-h arness) CONNECTOR-ll

~ -

CONDENSER F AN MOTOR

@)

lR;l ~ 't1H
~ "
I ~::;CD

Ii [!t

L/OR

~ mIi]
y..>r;;;,

@
S. M. J.

Ii]

~
<ff~
'"
CD

I
IGNITION ON or SWITCH START

UP

[Refer to (Fo Idout


(Eng i ne harness) room L/OR

last page page). J


L/OR

CONNECTOR-I

~13Id
~

~CD

0
>-

G
~

FUSE BLOCK (Refer to pPOWER SUPPL Y ROUTINGp In EL section.)

@)

(Main harness)

[!t

lBIB@
~

[EttBr;;--,
r--

@l@)

(E. F. I. harness)

1i
BODY GROUND

, '" ,

>I

'" '"

,, CD) , ,

To thermo

contro

I amp.

'"

E. ~ ~ S (Refer to

CONTROL UNIT EF&EC sect Ion. )

SLCA

SLCA

LC

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT

Trouble Diagnosis

@i5
'+ L

00
-

Even though air conditioner operates normally under high engine temperature conditions [above 9SoC (20SoF)] the condenser fan motor does not rotate.

m
CHECK CONDENSER FAN MOTOR. 1) Turn ignition and air conditioner switch "OFF". 2) Disconnect condenser fan motor harness connector-I. 3) Check continuity between connector-H terminal @ and connector-I terminal @. Continuity should exist. If N.G. replace condenser fan motor-. O.K. [!] CHECK GROUND CIRCUIT. Check harness continuity between motor harness connector-I terminal @ and ground. Continuity should exist. If N.G., repair harness.


m
_MEeT

-= SLCA

Iu

CHECK POWER SUPPLY (Motor side). 1) Disconnect condenser fan motor harness connector-H. 2) Turn ignition switch, air conditioner switch and blower switch "ON". 3) Check voltage between fan motor harness connector-II terminal @ and ground. Battery voltage should exist.

O.K.

[ill

iJ
SLCA

N.G.

Ii
CHECK POWER SUPPLY (Motor side). 1) Turn ignition switch "OFF" 2) Disconnector fan motor harness connector-I. 3) Turn ignition switch "ON". 4) Check voltage between terminal @ and ground. Battery voltage should exist.

[!]

@i5
[]I]

Ii]

O.K.

SLCA

lo.K.
N.G. Repair or replace harness between terminals @ and @.

Ii]

'

CHECK THERMOSWITCH. Check continuity between thermoswitch terminals @ and CD. Condition ContinuitY Above Yes 92 C ( -2OSF) Below No 92 C ( -2OSF)

lu
Ii

DISCONNECT

iii
CHECK POWER SUPPLY (Relay side). 1) Turn ignition "OFF". 2) Disconnect air conditioner relay. 3) Turn ignition "ON". 4) Check voltage between terminals @, @ and ground. Battery voltage should exist. O.K. CHECK RELAY. Refer to HA section. @is

O.K.
Check sub-harness for thermoswitch continuity. If N.G., repair or replace them.

SLCA

@is N.G. L--to

Check the followings: 8 Harness continuity between

terminal @ and battery


terminal. 8 "G" fusible link If N.G. replace them.
I

EB

i5
.

00

Check the followings: 8 Harness continuity between

terminal @ and battery


l. N.G. terminal 8 Fuse 8 Ignition switch

EB

00

O.K.
-= SLCA

r Replace relay.

LC

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT Trouble Diagnosis (Cont'd)

iii 34
~ lOK

i5l
0
[it
-=

SLCA

CHECK HARNESS CONTINUITY, 1) Turn ignition switch "OFF", 2) Check continuity between relay harness connector terminal @ and fan motor harness connector-I terminal @. Continuity should exist.

N.G.

Repair or replace harness or connectors between terminals @ and (d) .

[R]

~i5@

SLCA

"-

LC

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Lubrication System


Oil pressure check
Engine rpm Idle speed Approximate discharge pressure kPa (kg/em' , psi)
More than 78 (, 11)

Oil pump
Unit: mm (in)

Rotor tip clearance Outer rotor to body clearance Side clearance (with gasket)

Less than ()

- ( - ) - ()

(,60

- 70)

Engine Cooling System


Thermostat
Valve opening temperature
Max. valve lift

Radiator
c (OF) (infF) () 8/90 (/) Cap relief pressure Leakage test pressure
78

Unit: kPa (kg/em'

.psi)

mmfc

( - , 11 - 14)


98 (, 14)

lC

/"

ENGINE FUEL & EMISSION -CONTROL SYSTEM

SECTIONEF

&

EC
EF & ECEF & ECEF & ECEF & EC2 3 4 9 EF & EC- 16 EF & EC- 26 EF & EC- 31 EF & EC EF & EC EF & EC EF & EC

CONTENTS
PREPARATION PRECAUTIONS """""""""""""""'"'''''''''''''''''''''''''''''''''''' ENGINE AND EMISSION CONTROL OVERALL SYSTEM ENGINE AND EMISSION CONTROL PARTS DESCRIPTION ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION TROUBLE DIAGNOSES FUEL INJECTION CONTROL SYSTEM INSPECTION EVAPORATIVE EMISSION CONTROL SYSTEM CRANKCASE EMISSION CONTROL SYSTEM SERVICE DATA AND SPECIFICATIONS (S.D.S.)

When you read wiring diagrams: . Read GI section, "HOW TO READ WIRING DIAGRAIVIS". See El section, "POWER SUPPLY ROUTING" for power distribution circuit.

When you perform trouble diagnoses, read GI section, "HOW TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES".

E.C.C.S. Wiring Diagram -

See pull-out following EL section.

PREPARATION
SPECIAL SERVICE TOOL
Tool number (Kent-Moore No.) Tool name EG
( Description

Ignition coil adapter harness

Measuring engine speed

EF & EC-2

PRECAUTIONS
E.C.U. Do not disassemble E.C.C.S. control unit. (E.C.U.) Do not turn diagnosis mode selector forcibly.

. .

. .
.

If a batteryterminalis disconnected, the memory will return to the ROM value. The E.C.C.S.' will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a problem. Do not replace parts because of a slight variation.

Do not apply undue force to mounting bracket. Before connecting or disconnecting E.C.U. connector, make sure red and green LEOs are off after turning ignition key off. Always install the properly specified E.C.U. on car; otherwise, erroneous engine operation may result. Disconnect connector by pulling it (not the harness) straight out. Before connecting connector, make sure all pins are straight.

BATTERY . Always use a 12 volt battery as a power source.

Do not disconnectbattery
cables while the engine is running. Do not reverse polarity of battery when connecting it. Otherwise, E.C.U. and/or injectors may be burned.

INJECTOR Do not disconnect injector har~ ness connectors with engine running. Do not apply battery power directly to injectors; otherwise injectors will be damaged.

WIRELESS EQUIPMENT When installing a C.B. ham radio or a mobile phone, be sure to observe the following, as installation location may affect the electronic control systems. 1) Keep antenna as far as possible away from electronic control units. 2) Keep antenna feeder line more than 20 cm ( in) away from harness of electronic controls. Do not let them run parallel for a long distance. 3) Adjust antenna and feeder line so that standing-wave ratio can be kept smaller. 4) Be sure to ground radio to vehicle body.

. .

FUEL PUMP Do not operate fuel pump when there is no fuel in lines. Do not reuse fuel hose clamps. Tighten fuel hose clamps to the specified torque.

. . . .

E.C.C.S. PARTS HANDLING Handle air flow meter carefully to avoid damage. Do not disassemble air flow meter. Do not clean air flow meter with detergent. . Do not jolt or jar the crank angle sensor.

. . .

~~
WHEN STARTING Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. . Do not rev up engine just prior to shutdown.

. .

SEFH

E.C.C.S. HARNESS HANDLING Securely connect E.C.C.S. harness connectors. A poor connection can cause extremely high voltage to develop in the coil and condenser, resulting in damage to ICs. Keep E.C.C.S. harness at least 10 cm ( in) away from adjacent harnesses, to prevent an E.C.C.S. systerri malfunction due to receiving external noise, degraded operation of ICs, etc. Keep E.C.C's' parts and harnesses dry. Before removing parts, turn off ignition switch and then disconnect battery ground cable.

.
. .

EF & EC-3

ENGINE AND EMISSION CONTROL OVERALL SYSTEM E.C.C.S./Component Parts Location

. Fuelpumprelay

arenaqq.us

Fuel pump

-E.G.R. control valve Exhaust gas temperature sensor (For California model) Pressure regulator Pressure regu lator control solenoid valve

~~b

~
~'iWIW

arenaqq.usl

LA.A. unit

~.~,
Fuel filter

~
~

A'I'V'

I
.

control solenoid valve

0 a

"

Ignition coil and power transistor

Distributor

~~
G

E. .R . control solenoid valve

-.w~ ~~;:~~ ..f


sensor

~.,~. ~"

A;,flowm.'"

Exhaust gas sensor

SEFH

EF & EC-4

E.G.R. control Exhaust gas temperature sensor I. (For California model) \

solenoid valve7

"\

Ignition

switch

Throttle valve

: r~-L- -'

.sensol 7

m
m (")
I C1I

"TI J20
\

Crank angle sensor built-in distributor

lFuel pressure regulator I'.


!.. Engine

Transmission

temperatu re sensor

\'1'
\.Spark \1 plug '11

C.

lSJ

Vehicle speed sensor Exhaust gas sensor

~
Q:

Carbon canister

A.I.V. control solenoid valve A.I.V. Intake air flow

Air flow me

en m

Exhaustgasflow

'"
:I

"TI

ENGINE AND EMISSION CONTROL OVERALL SYSTEM System Chart


.1
I

E.C.C.S. CONTROL SYSTEM


I

r
Fuel injection & mixture ratio control
Injectors

Crankanglesensor

Air flow meter

.
Ignition timing control Power transistor

Engine temperature sensor

Exhaust gas sensor

Idle speed control

Auxiliary air control (arenaqq.us valve

Ignition switch

.
A.I.V. control

A:I.V. control solenoid valve

Starter switch

.
. .
~

E.G.R. control & Canister control

E.G.R. control solenoid valve

Idle switch

Throttle sensor

E.C.C.S.
control unit
,"

Fuel pump control

Fuel pump

"
[

Air conditioner switch

.~ Air regulator control

Air regulator

Neutral switch (M/T) Inhibitor switch (AiT) Acceleration cut control Air conditioner relay

Vehicle speed sensor

Power steering oil pressure switch

S.C.V. (Swirl control valve)control

S.C.V. control solenoid valve

Battery

Exhaust gas sensor monitor & self-diagnosis

Inspection lamps (On the control unit)

Exhaust gas temperature sensor (For California model)

Pressu re regu lator control

Pressu re regulator control solenoid valve

Fail-safe function

. Air flowmeter . Throttle sensor . Enginetemperaturesensor

EF & EC-6

ENGINE AND EMISSION CONTROL OVERALL SYSTEM Vacuum Hose Drawing


@
-@-a s.c. V. actuator

@-b
E.G.R. control valve

~TWI~ @ @

Air regurator

tJi)
@ ./"'1
Canister

@/
1

Vacuum tubes-1 Air duct

SEFH

EF 8r. EC- 7

FUSIBLE LINK

-c8J-

I GNITION SWITCH OFFACCON ST


(

( ( FUSE Jrs}
34

Ij/]

CK

CONNECTOR

'/ CHECK LI GHT C ENGINE@


5 24 25 46 I

r<"7I
NJ. NlOR

E. C. C. S. RELAY
<t ::BA TTERY

No.2
No.3

= =

10 I

CONTROL
SOLENOID

PRESSURE

REGULATOR VALVE


IDS

rm J>r -<

4 47

E. G. R. CONTROL SOLENOID VALVE A. 1. V. CONTROL SOLENOID VALVE S. C. V. CONTROL SOLENOID VALVE A. A. C. VALVE LT LJ

"U :[ :] c ::I "U

lIB;
!:
J

No. 4r= L

SWITCH I NHI BIT

12


[Tl <

LJ LJ
AIR REGULATOR FUELLJ

METER
I

AI R FLOW

r T
I
I

>--

m
." f20

To tachometer

gAUST
::SENSOR

mm-

I "

16 17 39 48 19

I NHI B RELAY r-=

3
I

>J >J
en

--<
45
43 44

PUMP

M
THROTTLE
VALVE
SWITCH

I NHIB RELA

-=

m
(")
I

RESISTOR

{O
I

PDWER

TRANSISTOR

6
13

co

I GNITI ON COIL

DISTRIBUTOR

W
CONDENSER 3D 31 11

Z -i ;0 0 r c Z -i

("") 0

5TH POSITION SWITCH


POWER STEERING OIL PRESSURE

SWI TCH 33 35 41


II

<::,FULL -v 'Q IDLE

NEUTR

' SWITC


18

ENGINE TEMPERATURE
SENSOR EXHAUS T GAS

coco- co-

co- co-

SPARK PLUG

: :

For
A/T

Cal ifornla
model

ANGLE SENSOR

CRANK
For U. S. A.

$
( MJ

tt

22 4D

- __n_--_nn _n--_--_--_

SENSOR C TEMPERA@URE

2D @:
37

THROTTLE

.HEAD-U DISPLA UNIT

f
r

SENSOR

CONT

M/T model

@:

For

Canada
lIS 28

32

1 I I
A/T UNIT CONTR&L

: A/T modeI wi th A.S. C.D. : A/T mode I without (/) m " w 0
:x:

A.S. C.D.

I
With heaa-up display

Without

head-up

display

'--

SENSOR

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION E.C.C.S. Control Unit (E.C.U.)
The EC.U. consists of a microcomputer, inspection lamps, a. diagnostic mode selector, and connectors for signal input and output and for power supply. The unit controls the engine.

Crank Angle Sensor


The crank angle sensor is a basic component of the entire EC.C.S. It monitors engine speed and piston position, and sends signals to the E.C.U. to control fuel injection, ignition timing and other functions. The crank angle sensor has a rotor plate and a wave-forming circuit. The rotor plate has slits for 10 signal and 4 slits for signal. Light Emitting Diodes (arenaqq.us) and photo diodes are built in the wave-forming circuit. When the rotor plate passes between the L.E.D. and the photo diode, the slits in the rotor plate continually cut the light being transmitted to the photo diode from the arenaqq.us This generates rough-shaped pulses which are converted into on-off signals by the wave-forming circuit, which are then sent to the E.C.U.

Photo Wave forming SEFB

diode circuit Rotor plate

signal slit for No.1 cylinder

Rotor plate

SEFB

Air Flow Meter


Battery sou rce Output voltage Ground

A Air flow meter B c

16 E.C.C.S. 17 control unit

SEFH
Temperature compensation

resistor

.. r-f
RH;:~-Hot wire

The air flow meter measures the mass flow rate of intake air. Measurements are made so that the control circuit will emit an electrical output signal corresponding to the amount of heat dissipated from a hot wire placed in the stream of intake air. The airflow past the hot wire removes the heat from the hot wire. The temperature of the hot wire is very sensitive to the mass flow rate. The higher the temperature of the hot wire, the greater its resistance value. This temperature change (resistance) is determined by the mass air flow rate. The control circuit accurately regulates current (I) in relation to the varying resistance value (RH) so that VA always equals VB. The air flow meter transmits a voltage value VA to the control unit where the output is converted into an intake air signal.

RH RK RA. RB

: Hot wire resistance : Temperature compensation resistance : Constant resistance SEFB

EF & EC-9

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION


Engine Temperature Sensor
The engine temperature sensor detects the engine temperature, which is dependent on engine coolant temperature, and transmits a signal to the E.C.U. The temperature sensing unit employs a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise.

Throttle Sensor & Soft/Hard Idle Switch


The throttle sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms the throttle valve position into output voltage, and emits the voltage signal to the E.C.U. In addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal to the E.C.U. Idle position of the throttle valve is determined by the E.C.U. receiving the signal from the throttle sensor. This system is called "soft idle switch" and controls engine operation such as fuel cut. On the other hand, "hard idle switch", which is built in the throttle sensor unit, is used not for engine control but for self-diagnosis.

SEFD

>
Not used

~
:5 ~ 0

~
~

.,' 3 )

switch)

(Full throttle

Supply voltage: 5V (Applied between

terminal

NO.4 and 6)

Output voltage between terminal NO.4 and 5

Idle switch Throttle sensor

~
.

6}

~ '" ! '" -0

f

~
5

9" 0

g "

45 90 Throttle valve opening angle (deg)

SEFD

Fuel Injector
The fuel injector is a small, elaborate solenoid valve. As the E.C.U. sends injection signals to the injector, the coil in the injector pulls the needle valve back and fuel is released ,into the intake manifold through the nozzle. The injected fuel is controlled by the E.C.U. in terms of injection pulse duration. Brass wire is used in the injector coil and thus the resistance is higher than a conventional injector.
SEFH

EF &. EC

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

0 vacuum manifold Intake


Air chamber

Pressure Regulator
The pressure regulator maintains the fuel pressure at kPa ( kg/cm2, 43,4 psi). Since the injected fuel amount depends on injection pulse duration, it is necessary to maintain the pressure at the above value.

Fuel chamber To fuel tank Q

Fuel return from injector

SEF

Exhaust Gas Sensor


Louver

Holder

Connector Isolation bushing Contact plate


SECA

?:
;; '" 0> ~ 0
C.

The exhaust gas sensor, which is placed into the exhaust manifold, monitors the amount of oxygen in the exhaust gas. The sensor has a closed-end tube made of ceramic zirconia. The outer surface of the tube is exposed to exhaust gas, and the inner surface to atmosphere. The zirconia of the tube compares the oxygen density of exhaust gas with that of atmosphere, and generates electricity. In order to improve the generating power of the zirconia, its tube is coated with pratinum. The voltage is approximately 1V in a richer condition of the mixture ratio than the ideal air-fuel ratio, while approximately OV in leaner conditions. The radical change from 1V to OV occurs at around the ideal mixture ratio. In this way, the exhaust gas sensor detects the amount of oxygen in the exhaust gas and sends the signal of approximately 1V or OV to the E.C.U.

> :J

8 0I
Rich

~ I
Ideal ratio Mixture ratio --Lean SEFD

Outlet 0

Fuel Pump
Fuel damper

The fuel pump with a fuel damper is a submergible type, and are located in the fuel tank.

Motor

1) Inlet

SEFC

Power Transistor
The ignition signal from the E.C.U. is amplified by the power transistor, which turns the ignition coil primary circuit on and off, inducing the proper high voltage in the secondary circuit. The ignition coil is a small, molded type.

SEFH

EF & EC

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION Air Regulator


-

The air regulator provides an air by-pass when the engine is cold for a fast idle during warm-up. A bimetal, heater and rotary shutter are built into the air regulator. When the bimetal temperature is low, the air by-pass port opens. As the engine starts and electric current flows through a heater, the bimetal begins to turn the shutter to close the by-pass port. The air passage remains closed until the engine stops and the bimetal temperature drops.
SEFB

Idle Air Adjusting (I.A.A.) Unit


Idle adjusting screw

The I.A.A. unit is made up of the AA.C. valve, F.I.C.D. solenoid valve and idle adjust screw. It receives the signal from the E.C.U. and controls the idle speed at the preset value. The F.I.C.D. solenoid valve compensates for changes in idle speed caused by the operation of. the air compressor. A vaCl/um control valve is also installed in this unit to prevent an abnd'rmal rise in intake manifold vacuum pressure during deceleratton.
SEFH

Auxiliary Air Control (A.A. C.) Valve


The E.C.U. actuates the A.A.C. valve by an ON/OFF pulse. The longer that ON pulse is received, the larger the amount- of air that will flow through the A.A.C. valve.

Air SEFE

Power Steering Oil Pressure Switch


The power steering oil pressure switch is attached to the power steering high-pressure tube and detects the power steering load, sending the load signal to the E.C.U. The E.C.U. then sends the idle-up signal to the I.S.C. valve.

SEFH

Magnetic

line

Vehicle Speed Sensor


Reed
(sS
I
//

\ /'
~SWitch N S

Reed
N

N) switch M;;Qnetic \ I. me I

Fieldplate

0 : G

The vehicle speed sensor provides a vehicle speed signal to the E.C.U. The speed sensor consists of a reed switch, which is installed on the transmission unit and transforms vehicle speed into a pulse signal.

"{

t;\

y-/
SEFB

Fieldplate

EF & EC

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

E.G.R. Control Valve


The E.G.R. control valve controls the quantity of exhaust gas to. be led to the intake manifold through vertical movement of the taper valve connected to the diaphragm, to which vacuum is applied in response to the opening of the throttle valve.

SEFB

To E.G.A. control valve Air filter

B.P.T. Valve
Vacuum signal source

".'.1' ~~~'ff'

The B.P.T. valve monitors exhaust pressure to activate' the diaphragm, controlling throttle chamber vacuum applied to the E.G.R. control valve. In other words, recirculated exhaust gas is controlled in response to positioning of the E.G.R. control valve or to engine operation.

t
Exhaust pressure
ECA

Air Induction Valve (AJ.V.)


The air induction valve sends secondary air to the exhaust manifold, using a vacuum created by exhaust pulsation in the exhaust manifold. When the exhaust pressure is below atmospheric pressure (negative pressure), secondary air is sent to the exhaust manifold. When the exhaust pressure is above atmospheric pressure, the reed valves prevent secondary air from being sent back to the air cleaner.
SEFH

\.

EF & EC

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION A.I.V. Control Solenoid Valve
The A. LV. control solenoid valve cuts the intake manifold vacuum signal for A.I.V. control. It responses to the ON/OFF signal from the E.C.U: When the solenoid is off, the vacuum signal from the intake manifold is cut. When the control unit sends an ON signal, the coil pulls the plunger downward and feeds the vacuum signal to the A.I.V. control valve.

E.G.R. Control Solenoid Valve


SEFH

The E.G.R. system is controlled only by the E.C.U. At both lowand high-speed engine revolutions, the solenoid valve turns on and accordingly the E.G.R. valve cuts the exhaust gas leading to the intake manifold.

Pressure Regulator (P.R.) Control Solenoid Valve


The solenoid valve responds to the ON/OFF signal from the E.C.U. When it is off, a vacuum signal from the intake manifold is fed into the pressure regulator. When the control unit sends an ON signal, the coil pulls the plunger downward and cuts the

vacuum signal.

S.C.V. Control Solenoid Valve


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Nissan Sx Repair Manual Service

: Nissan NissanNissanSx-Repair-Manual nissannissansx-repair-manual nissan pdf

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~.,,-, '. f \ , ~\ '.~«J.. , ,,"'.,. ".' ,- \~. \ , \ , "NI5SAN h \ ) SX - ,'. , / .. . , . t":"', V -~ .~ SERVICE< MANUAL " " \, ~ QUICK REFERENCE INDEX NISSAN j 24DSX MODEL - S13 SERIES . GENERALINFORMATION GI MAINTENANCE MA ENGINEMECHANICAL EM ENGINELUBRICATION & COOLING SYSTEMS- LC ENGINEFUEL& EMISSIONCONTROL SYSTEM- EF ENGINECONTROL, FUEL& EXHAUST SYSTEM- FE CLUTCH CL MANUALTRANSMISSION MT AUTOMATIC TRANSMISSION AT PROPELLER SHAFT& DIFFERENTIAL CARRIER- PD FRONTAXLE& FRONTSUSPENSION FA REARAXLE& REARSUSPENSION RA BRAKESYSTEM SR STEERING SYSTEM ST BODY SF HEATER & AIRCONDITIONER HA ELECTRICAL SYSTEM EL , cg NISSAN MOTOR CO., LTD. Printed in U.S.A. Not to be reproduced in who~e or in part without the prior written permission of Ni~n .. <"" Motor Company Ltd., Tokyo, Japan. &EC FOREWORD This manual contains maintenance and repair procedures for the Nissan SX. In order to assure your safety and the efficient functioning of the vehicle, this manusl should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at a~y time without notice. IMPORTANT SAFETYNOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, 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 jeopardiz~d by the service method selected. . NISSAN MOTORCo.,LTD. Overseas Service Department Tokyo, Japan . GENERAL INFORMATION I GI SECTION CONTENTS PRECAUTIONS GI- 2 HOW TO USE THIS MANUAL GI- 5 HOW TO READ WIRING DIAGRAMS ~ GI- 7 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES GI IDENTIFICATION INFORMATION GI """'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' LIFTING POINTS AND TOW TRUCK TOWING GI TIGHTENING TORQUE OF STANDARD BOLTS GI - PRECAUTIONS Observe the following precautions ~o ensure safe and proper servicing. 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 inflammable 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. SGI 2. Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. SGI 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. SGI 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. SGI GI-2 PRECAUTIONS 6. Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint. SGI 7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set. Arrange the disassembled parts in accordance with their assembled locations and sequence. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. Use only the lubricants specified in MA section. Use approved bonding agent, sealants or their equivalents when required. Use tools and recommended special tools where specified for safe and efficient service repairs. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. Precautions for E.F.I. or E.C.C.S. Engine SGI 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 eliminate danger. 3. Be careful not to jar components such as control unit and air flow meter. GI-3 PRECAUTIONS Precautions for Catalyst Clean floor SG 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 compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on inflammable material. Keep inflammable material off the exhaust pipe. Precautions for Fuel Unleaded gasoline of at least 87 AKI number (RON 91) GI-4 HOW TO USE THIS MANUAL 1. A QUICK REFERENCE INDEX, a black tab (arenaqq.us18) 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. 2. THE CONTENTS are listed on the first page of each section. 3. THE TITLE is indicated on the upper portion of each page and shows the part or system. 4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. "BR-5"). 5. THE lARGE IllUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. "Example" Pad retainer r;~'~ Torque member ~ ~ ~ ,/I J~ ~ 5~ ~ ~. ::;:; / . Pin boot r- Main pin IE! to sliding portion / Outer shim SBRA 6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary. 7. The followings SYMBOLS AND ABBREVIATIONS are used: ~ E1I ~ rJ ~ ~ EaI~ @> : "f:l : * S.O.S. L.H., R.H. . Tightening torque Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. Should be lubricated with oil. Sealing point Checking point Always replace after every disassembly. Apply petroleum jelly. Apply A.T.F. Select with proper thickness. Adjustment is required. Service Data and Specifications Left-Hand, Right-Hand GI-5 M/T A/T Tool L.H.D. R.H.D. A.T.F. 0, 02 03 D. 22 2, 12 1, Manual Transaxle/Transmission Automatic Transaxle/Transmission Special Service Tools Left-Hand Drive Right-Hand Drive Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear ",. HOW TO USE THIS MANUAL 8. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. "Example" Tightening torque: 59 - 78 Nom ( - kg-m, 43 - 58 ft-Ib) 9. TROUBLE DIAGNOSES are included in sections dealing with complicated components. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. . . . BOLD TYPED STATEMENTSexcept WARNING and CAUTIONgive you helpfulinformation. GI-6 HOW TO READ WIRING DIAGRAMS ""'= WIRING DIAGRAM Symbols used in WIRING DIAGRAM are shown below: Example CONNECTOR Th is shows that these con nectors white 6 terminal connectors. POWER SUPPLY -This shows the ignition switch position in which the system can be ope rated. - See POWER SUPPLY ROUTING in EL section for the detai led wiring diagram. are BRANCH M/T model n ~ . '-LAMP-! 1m lG~ . ~B~ A/T model ~ . ~ 2 ~~ ~~B-SCLG~ ~ : MfT model @ : AfT model > I I lyw IiliJ ~Whi"~ m G ~ LOCATION NUMBER This number shows where the connector is located. See HARNESS LAYOUT in EL section. The number is identical with the one in HARNESS LAYOUT. I t ABBREVIATIONS ~@! I: ~ l-l SWITCH .rn '""".~ '"" ~ SWITCH This shows that continuity exists between terminals CD and CID, when the switch is turned to ON position. Instrument harness g 'WIRE -b BODY D GROUN ~ COLOR CODING BR B -BI,,' OR W R G Y L P PU GY SB LG ~ ~ ~ ~~ White Red Green Blue Yellow . ~ ~ ~ ~ ~ ~ Brown Orange Pink Purple Gray Sky Blue ht Green ~ Llg . d the base is stripe, . When. the iven wire first, co orfollowe d by the stripe color as IS gshown below: Example: I L/W ~ Blue with Whtte Stripe M: Main harness S G SWITCH POSITIONS Normally open ~~ ~ Normally closed = , 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. .. . ~ SELE GI-7 HOW TO READ WIRING DIAGRAMS CONNECTOR SYMBOLS All connector symbols in wiring diagrams are shown from the terminal side. Example . Connector SG Example EE . M.~ te,m;nal . ~ Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams. G";d'-[~ Connector Connector symbol Female terminal Efj Guide Connector Connector symbol SG MULTIPLESWITCH The continuity of the multiple switch is identified in the switch chart in wiring diagrams. Example WIPER SWITCH Continuity circuit of wiper switch SWITCH POSITION -B/Y -R. -W/B -L/Y CONTINUITY CIRCUIT OFF B E C (f) 1 5 @ 2 -B. INT 3 - 4,5 - 6 LO HI WASH 1 -6 -yo Example: Wiper switch in LO position Continuity circuit: Red wire - @ terminal - CID terminal - Wiperswitch (@ - @: LO) - @ terminal - CD terminal - Black wire SG GI-8 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 STARTING SYSTEM Wiring Diagram W w SUPER MULTIPLE JUNCTION (S.M.J.) arenaqq.us g rnIJ ~ SYSTEM FF Dm3 A"angament Check 0 0 [ ,=fd:0CI~ crhKk 0 - '" ~ ], ,~ r- liJ 0 j ¥ := Super Multiple Junction (S.M.J.) y--R .S.M.J. L--S 't Refer to last page ( (Foldout page). J r-R~ ~B (Main harness) DO L +-+ BR~ (Instrument harness) r-B (Main harness) (Instrument harness) BRl. SELF GI-9 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES m" ( INSPECTION START) ~m -=- SG I iii ~ lu I iii CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". _MECT [ill rill ~ CHECK POWER SUPPLY. Check the following items. 1) Turn ignition switch "ON" .~ [ IN.G. 1) Harness continuity betWeen 2) Check voltage between crank angle sensor and battery. terminal @ and ground. 2) E.C.C.S. relay-1 (See page EF & T~Battery voltage should exist. EC) 3) "BR" fusible link O.K. 2 4) Power source for E.C.U. (See page EF & EC) 5) Ignition switch ~~ 00 2) Disconnect crank angle sensor harness connector. 3) Check resistance betWeen terminal @ and ground. Resistance: Approximately Check the following items. 1) Harness continu ity betWeen crank angle sensor and I N.G~ grou nd 2) Ground circuit for E.C.U. (See page EF & EC) on I SG O.K. NOTICE The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check" or the "Symptom Chart". 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pin Point Check. If you must perform circuit continuity between harness connectors more detail, such as in case of sub harness is used, refer to Wiring Diagram and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be "OFF" . 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as it was. GI HOW TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES HOW TO FOllOW ITJ m THIS FLOW CHART Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. I CHECK POWER SUPPLY. 1) Turn ignition switch "ON". 2) Check Check voltage between terminal @ and ground. Battery voltage should exist. item being performed. Procedure, measurement } steps or results O.K. I2J Measurement results Required results are indicated in bold type in the corresponding block, as shown below. These have the following meanings: Battery voltage ~ 11 14V or approximately 12V Voltage: Approximately OV ~ Less than 1V - ~ Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. For example, symbol m indicated in the left upper portion of each illustration corresponds with the symbol in the flowchart for easy identification. More precisely, the procedure under the "CHECK POWER SUPPLY" outlined previously is indicated by an illustration m . @] Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Example View from terminal side Connector symbol ~ Direction mark ~ View from harness side Connector Connector symbol ~ [it Direction 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. . . ~: View f,om lermlnel side n' r.s. All connector symbols shown from the terminal side are enclosed by a single line. ~: Viewf,omhernessside .n H.S. All connector symbols shown from the harness enclosed by a double line. mark SGI GI side are HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES Key to symbols signifying measurements or procedures Symbol Symbol explanation cT IV CONNECT £) @- 00 00 OOACC F Symbol Symbol explanation Check after disconnecting the connector to be measured. AIC switch Check after connecting the connector to be measured. AIC switch is "ON". Insert key into ignition switch. REC switch is "ON". Turn ignition switch to "OFF" position. REC switch is "OFF". Turn ignition switch to "ON" position. DEF switch is "ON". Turn ignition switch to "START" position. VENT switch is "ON". Turn ignition switch from "OFF" to "ACC" position. Fan switch is "ON". (At any position except for "OFF" position) Turn ignition switch from "ACC" to "OFF" position. Fan switch is "OFF". "cfi Turn ignition switch from "OFF" to "ON" position. OOF 0 trJ Apply battery voltage directly to components. 7 Turn ignition switch from "ON" to "OFF" position. Drive vehicle. Do not start engine,or check Disconnect battery negative cable. with engine stopped. Start engine. or check is "OFF". with engine Depress running. brake pedal. Apply parking brake. Release brake pedal. Release parking brake. Depress accelerator pedal. CffH Check after engine is warmed up sufficiently. Release accelerator pedal. l!V Voltage should be measured with a voltmeter. - La) II CIUIIT foi-- Circuit resistance should be measured with an ohmmeter. € II - Le1J Currentshould be measuredwith an ammeter. GI Pin terminal check for S.M.J. type arenaqq.us AIT control unit connectors. For details regarding the terminal arrangement, refer to the foldout page. ' IDENTIFICATION INFORMATION Model Variation Destination Model Body Transmission Engine Coupe HLS13FU Fastback RHLS13FU Coupe HLS13AU Fastback RHLS13AU Coupe HLS13FV Fastback RHLS13FV Coupe HLS13AV Fastback RHLS13AV Coupe HLS13FN Fastback RHLS13FN Coupe HLS13AN Fastback RHLS13AN Differential carrier FS5W71C Non-California RE4R01A FS5W71C California KA24E R RE4R01A FS5W71 C Canada RE4R01A Prefix and suffix designations: R 0: R : Coope Fastba~ H: KA24E engine L: L.H. drive H L S13 A N (R) L T (R) : With A.B.S. N : Canada V : California U: Non-California A : Automatic transmission F : 0 : means no indication. GI 5-speed manual transmission IDENTIFICATION INFORMATION Identification Number Vehicle identification plate Vehicle identification number (Chassis number) F.M.V certification Vehicle identification label number plate SGI VEHICLE IDENTIFICATION NUMBER ARRANGEMENT IN 1 H S 3 6 P X K W Manufacturer I IT IN 1: N issan passenger vehicle Engine type H: KA24E Vehicle serial number Manufacture plant W: Kyushu Model year K: year model . Vehicle line S: NISSAN SX Check digit (0 to 9 or XI The code for the check digit is determined by mathematical computation. Model change (0 to 91 Body type 4: Coupe 6: Fastback Restraint system S: Standard P: Automatic GI IDENTIFICATION INFORMATION Identification Number (Cont'd) IDENTIFICATION PLATE NISSAN MOTORCO.,LTD. JAPAN ~:it ~i:J ill 1 2 3 4 5 6 7 8 9 CHASSIS NO NO DE CHASIS MODEL .& MOOElO 0 I &" ",-COlOR TRiM f 'Jk COlOR GUMNICION ;,.0 '/;,.0 ENGIN[ MOTOR ;; ';~: ; ~ElE 0 ffi& && CC & & I tf; S jJt ~ ItJ :if[** :it ~ U A MADEINJAPAN Type Vehicle identification number (Chassis numbed Model Body color code Trim color code Engine model Engine displacement Transmission model Axle model SGI ENGINE SERIAL NUMBER KA24E engine TL M MANUAL TRANSMISSION NUMBER AUTOMATIC SGI TRANSMISSION NUMBER SGI GI IDENTIFICATION INFORMATION Dimensions Unit: mm (in) Coupe Fastback Overall length 4, () 4, () Overall width 1, () 1, () Overall height 1, () 1, () Front tread 1, () 1, () Rear tread 1, () 1, () Wheelbase 2, () 2, () Wheels and Tires Road wheel Steel 6-JJx 15 Aluminum 6-JJx 15 Offset Tire size mm (in) 40 () Conventional /60R 15 86H /60R 15 89H * Spare T/70D 15 *: Option GI LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand WARNING: Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat. . . Garage jack points SGI GI LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines. Sill ~ Put the sill in the slit of the lift pad to prevent the sill from deforming. If the pad does not have lift pad // the slit, prepare a suitable attachment with slit. Note: Lift-up points are the same as pantograph jack points. SGI 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. When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral (UN" position). NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated. 'i::ij,iiii.2ii;~1',,,';1tiii:.; -. SG GI LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont'd) TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (With rear wheels on ground) Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. TOWING POINT Alwayspull the cable straightout from the arenaqq.us pull on the hook at a sidewaysangle. Front Rear CE1 DD9M GI TIGHTENINGTORQUE OF STANDARD BOLTS Grade Bolt size Bolt dia- meter* mm Tightening torque (Without lubricant) Pitch mm Hexagon head bolt N.m 4T M6 M8 M10 M12 M14 M6 M8 7T M10 M12 9T 13 9 15 11 13 9 16 12 25 18 29 22 25 19 30 22 42 31 51 38 46 34 56 41 74 54 88 65 10 7 21 15 25 18 22 16 26 20 41 30 48 35 43 32 51 38 71 52 84 62 77 57 92 68 94 M6 12 9 15 11 M8 29 22 35 31 23 37 26 27 59 43 70 51 62 46 74 54 98 72 87 80 M12 M14 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. 4T 7T 9T kg-m M14 M10 Grade ft-Ib Hexagon flange bolt N.m ft-Ib kg-m *: Nominal diameter Mark 4 7 9 M 1 GI 6 """"L- Nominal diameter of bolt threads (Unit: mm) Metric screw threads '..~ MAINTENANCE MA .J SECTION I CONTENTS PERIODIC MAINTENANCE MA- 2 GENERAL MAINTENANCE. MA- 4 RECOMMENDED LUBRICANTS AND FLUIDS MA- 6 ENGINE MAINTENANCE MA- 8 "'"'''''''''''' CHASSIS AND BODY MAINTENANCE SERVICE DATA AND SPECIFICATIONS (S.D.S.) MA :" MA", l1li PERIODIC MAINTENANCE The following charts show the normal maintenance schedule. Under severe driving conditions, additional or more frequent maintenance will be required. Refer to "Maintenance under severe driving conditions". The periodic maintenance schedule is repeated beyond the last mileage and period shown by returning to the first 15, miles (24, km) or 12 months. EMISSION CONTROL SYSTEM MAINTENANCE MAINTENANCE. OPERATION Perform at number of miles, kilometers or months, whichever comes first. Drive belts MAINTENANCE 15 30 INTERVAL 45 60 Miles x 1, (km x 1,) (12) (24) (48) (72) (96) 6 12 24 36 48 1* Months See NOTE (1). Replace every 30, miles (48, km). 1* 1* 1* 1* Air cleaner filter Vapor lines Fuel lines Fuel filter See NOTE (2)*. R Engine coolant Egnine oil R Engine oil filter (Use Nissan PREMIUM R R Then replace every 7, . miles (12, km) or 6 months. Then replace every second oil change. type or equivalent.) Ignition wires MA-8 MA MA MA-9 MA MA-8 MA MA Replace every 30, miles (48, km). Inspect every 3 years. * Spark plugs Reference page MA MA CHASSIS AND BODY MAINTENANCE MAINTENANCE OPERATION Perform at number of miles, kilometers or months, whichever comes first. Miles x 1, 15 (km x 1,) (24) 12 Months Break lines & cables I I I Brake pads & discs Manual and automatic transmission & differential gear oil Steering gear & linkage, and axle & suspension parts Exhaust system MAINTENANCE INTERVAL 30 45 (48) 24 I I I I I (72) 36 I I I 60 Reference page (96) 48 I I I I I MA MA MA,15,16 MA, FA-4,RA-4 MA NOTE: (1) After 60, miles (96, km) or 48 months, inspect every 15, miles (24, km). (2) If vehicle is operated under extremely adverse weather conditions or in arees where ambient temperatures are either extremely low or extremely high, the filters might become clogged. In such an event, replace them immediately. (3) Maintenance items and intervals with "." are recommended by NISSANfor reliable vehicle operation. The owner need not perform such maintenance in order to ~aintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required. Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. MA-2 PERIODIC MAINTENANCE MAINTENANCE UNDER SEVERE DRIVING CONDITIONS The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance is required to. be performed on the following items as shown in the table. Severe driving conditions A - Repeated short trips less than 5 miles (8 km) and outside temperatures remain below freezing B - Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use C - Driving in dusty conditions D - Driving on rough, muddy, or salt spread roads E - Towinga trailer, usinga camper or a car-top carrier Driving condition C ABC A. . A. DE C D E . item Maintenance interval Reference More frequently' MA Engine oil & oil filter R Every 3, miles (5, km) or 3 months MA Every 7, miles (12, km) or 6 months MA Every 30, miles (48, km) or 24 months MA, 15, 16 Brake pads & discs D . Steering gear & linkage, and axle & suspension parts Maintenance operations: operation R Manual and automatic transmission & differential gear oil D E Maintenance Air cleaner filter D E CD. . Maintenance R page MA, FA-4, RA-4 Every 7, miles (12, km) or 6 months Steering linkage ball joints & front suspension ball joints Exhaust system MA,FA-4 MA I = Inspect. Correct or replace if necessary. R = Replace. 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 vehicl~isto continue operating properly. The owners can perform the checks and inspectionsthemselvesor they can have their NISSANdealers do them for a nominal charge. Item Reference page OUTSIDE THE VEHICLE The ma!ntenance 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 excessivewear. 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, km (7, miles.) MA Wheel alignment and balance If the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. MA FA-6 RA-6 Windshieldwiper blades Check for cracks or wear if they do not wipe properly. Doors and engine hood Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate 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 frequently. INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Lights Make sure that the headlights, stop lights, taillights, tUrn signal lights, and other lights are all operating properly and installed securely. Also check headlight aim. MA 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 excessivefree play, hard steering or strange noises. Free play: Lessthan 35 mm ( 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 restrains 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 folding-down rear seatbacks. . Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage. MA-4 MA GENERAL MAINTENANCE Item Reference page Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free travel. CL-5 Brakes Check that the brake does not pull the vehicle to one side when applied. 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. BR-7 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. BR 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.g. each time you check the engine oil or refuel). Windshieldwasher fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant levelwhen the engine is cold. MA-9 Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or loose connections. Brake and clutch fluid levels Makesure that the brake and clutch fluid levelsare between the "MAX" and "MIN" lines on the reservoir. MA,16 Engine drive belts Makesure that no belt is frayed, worn, cracked or oily. MA-8 Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine. MA Power steering fluid level and lines Check the level when the fluid is cold and the engine is turned off. Check the lines for proper attachment, leaks, cracks, etc. MA Automatic transmission fluid level Check the level on the dipstick after putting the selector lever in "P" with the engine idling. MA Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it. MA Underbody The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise 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, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. MA-5 RECOMMENDED LUBRICANTS AND FLUIDS Lubricants and Fluids Capacity (Approximate) Engine oil (Refill) With oil filter Without oil filter Cooling system (with reservoir tank) Reservoir tank Manual transmission Differential oil gear oil Automatic transmission fluid Power steering fluid Recommended lubricants and fluids US measure Imp measure Liter /4 qt /8 qt /8 qt /8 qt /8 qt /8 qt 3/4 qt 5/8 qt /8 pt /4 pt API GL-4*2 /4 pt /4 pt API GL-5*2 /4 qt /4 qt 1 qt 3/4 qt Genuine Nissan Motor Oil*1 or equivalent (Energy Conserving Oils of API SF or SG)*2, *3 Anti-freeze coolant (Ethylene glycol base) Genuine Nissan ATF*1 or equivalent Type DEXRON TM Type DEXRON TM Brake fluid Genuine Nissan Brake Fluid*1 or equivalent DOT 3 (US FMVSS No. ) Multi-purpose grease NLGI No.2 (Lithium soap base) *1: Available in mainland U.S.A. through you Nissan dealer. *2: For further details, see "SAE Viscosity Number". *3: Energy Conserving Oils These oils can be identified by such labels as energy conserving, energy saving, improved fuel economy, etc. MA-6 RECOMMENDED LUBRICANTS AND FLUIDS SAE Viscosity Number Outside Temperature Anticipated ENGINE Outside Temperature Range Anticipated Before Next Oil Change GEAROIL Range Before Next Oil Change OIL . °C",OF ++"'--++86 - +++ +32 +50 ~ -5W T T 10W is preferable if the ambient temperature is above °C (0° F). 20W and 20W are usable if the ambient temperature is above 10°C (50° F) for all seasons. MA-7 8OW is preferable if the ambient temperature is below 40°C (°F). ENGINE MAINTENANCE Power steering oil pump IAJ Water pump lAJQ' l:~:o, I Crank pulley T : Tension checking points IAJ: Adjusting bolts lAJA;,,ood;,;oo", Checking Drive Belts 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: Inspect drive belt deflections when engine is cold. compressor Unit: mm (in) 8MAOO2C Used belt deflection Set deflection of new belt Limit Adjusted deflection. Alternator 11 () ( - ) ( - ) Air conditioner compressor 12 () ( - ) ( Power steering oil pump 13 () ( - ) ( - ) Applied pushing force - ) 98 N (10 kg, 22 Ib) Changing Engine Coolant ~~~ [~O m ~ ~ m .- 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. 8M AOO3C 2. Open drain cock at the bottom of radiator, and remove radiator cap. MA-8 "'. ENGINE MAINTENANCE 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. to;J 44 N.m ( - kg-m, 25 - 33 ft-Ib) L . J - 5. Open air relief plug. . 6. 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. Repeat step 2 through step 9 until clear water begins to drain from radiator. Drain water. Open radiator cap and air relief plug. Fill rafdiator with coolant up to specified level. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity. (With reservoir tank) Q (/8 US qt, /8 Imp qt) Pour coolant through coolant filler neck slowly to allow air in system to escape. MAX. MIN. Close air relief plug. Remove reservoir tank, drain coolant, then clean reservoir tank. Install reservoir tank and fill it with coolant up to "MAX" level and then install radiator cap. Run engine and warm it up sufficiently. Race engine 2 or 3 times under no-load. Stop engine and cool it down, then add coolant as necesary. SMAB Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts. MA-9 ENGINE MAINTENANCE Checking Fuel Lines CAUTION: 3 mm in) , ~--,'-' . (Cont'd) Tightenhigh-pressurerubber hose clamp so that clamp end is 3 mm ( in) from hose end. Ensure that screw does not contact adjacent parts. , --T-+-+--J__J.-_J SMAA Changing Fuel Filter WARNING: Before removing fuel filter, release fuel pressure from fuel line. 1. Remove fuse for fuel pump. 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is 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 shop towel to absorb fuel. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. . . . Whentighteningfuel hose clamps, refer to "CheckingFuel Lines". Changing Air Cleaner Filter The viscous paper type filter does not need cleaning between renewals. MA ENGINE MAINTENANCE Changing Engine Oil WARNING: Be careful not to burn yourself, as the engine Is hot. 1. Warm up engine, and check for oil leakage from engine components. 2. Remove drain plug and oil filler cap. 3. Drain oil and refill with new engine oil. Refill oil capacity (Approximate): ~ Front SMAOO9C Unit: liter (US qt, Imp qt) With oil filter change (/4,/8) Without oil filter change (/8,/8) CAUTION: . Be sure to clean drain plug and Install with new washer. Drain plug: tOJ - 39 N.m . . ( - kg-m, 22 - 29 ft-Ib) Use recommended engine 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. SMAC Changing Oil Filter 1. Remove oil filter with a suitable tool. WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot. 2. Before installing new oil filter, clean the oil filter mounting surface on cylinder block, and coat the rubber seal of oil filter with a little engine oil. ~ SMA MA ENGINE MAINTENANCE Changing Oil Filter (Cont'd) 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. 2/3 of a turn SMAB Changing N.G. O.K. Spark Plugs 1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire. SMA 2. Remove spark plugs with spark plug wrench. Spark plug: Standard type ZFR5D Hot type ZFR4D Cold type ZFR6D R 16mmV1 'arenaqq.us~ SEMA Side electrode iii 3. Check plug gap of each new spark plug. Gap: - mm ( - 0~ in) 4. Install spark plugs. Reconnect ignition wires according to nos. indicated on them. Spark plug: ~ - 29 N.m ( - kg-m, 14 - 22 ft-Ib) SMA 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 kil .If it exceeds the limit, replace the ignition wire with a new one. ~ SMAA MA ENGINE MAINTENANCE Checking Vapor Lines 1. Visually inspect vapor lines for. improper 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 EF & EC section. /" " MA . CHASSIS AND BODY MAINTENANCE Checking Exhaust System . Check exhaust pipes, muffler and mounting for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. SMAA Checking Clutch Fluid Level and Leaks . Max. If fluid level is extremely low, check clutch system for leaks. Min. SMAB Checking M/T Oil 1. Check for oil leakage. , SMAA 2. If leakage is found, check oil level. Never start engine while checking oil level. Filler plug: ~: 25 - 34 N.m ( - kg-m, 18 - 25 ft-Ib) K SMA Changing 1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: Q (/8 US pt, /4 Imp pt) Drain plug: ~: 25 - 34 N.m ( - kg-m, 18 - 25 ft-Ib) ~~~ .,. M/T Oil ~.;. ~"~ SMAA MA CHASSIS AND BODY MAINTENANCE Checking AIT Fluid 1. Check for fluid leakage. . . SMAA . Front side Hot: 50 - aooc ( - °F) Add" 2. If leakage is found, check fluid level. Fluid level should be checked using "HOT" range on dipstick at fluid temperatures of 50 to 80°C ( to °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 °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 overfill. O.K. ~ 3. Check fluid condition. Check fluid for contamination. If fluid is very dark or smells burned, or contains frictional material (clutches, band, etc.), check operation of AlT. Refer to section AT for checking operation of AlT. Check fluid for contamination. SMAB Changing AIT Fluid 1. Drain fluid by removing oil pan. 2. Replace gasket with new one. 3. Refill with fluid and then check fluid level. Oil capacity (With torque converter): Q (/4 US qt, /4 Imp qt) ~ SMAB MA CHASSIS AND BODY MAINTENANCE Checking Differential Gear Oil 1. Check differential carrier for oil leakage. SMAC 2. If leakage is found, check oil level. Filler plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib) - - SMA A Changing ~~ Differential Gear Oil 1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: Q (/4 US pt, /4 Imp pt) Drain plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib) - 0,,;" PI~ - ~ SMAA Checking Brake Fluid Level and Leaks . = If fluid level is extremely low, check brake system for leaks. MAX = MIN Checking Brake Lines and Cables . Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc. SMAA MA CHASSIS AND BaDY MAINTENANCE Checking Disc Brake . Check condition of disc brake components. ROTOR . Check condition and thickness. Unit: mm (in) Front Rear CL22VB CL9H Standard thickness () () Minimum thickness () () Disc brake type SMAA CALIPER . Check operationand for leakage. SMAA PAD Check for wear or damage. . Unit: mm (in) Disc brake type Standard thickness Minimum thickness Front Rear CL22VB CL9H () () () SMAB Balancing . Wheels Adjust wheel balance using road wheel center. Wheel balance (Maximum allowable unbalance at rim flange): Refer to S.D.S. Tire balancing weight: Refer to S.D.S. MA CHASSIS AND BODY MAINTENANCE Tire Rotation FRONT ! 0 . Do not include the T-type spare tire when rotating the tires. Wheel nuts: ~: 98 - N.m ( - kg-m, 72 - 87 ft-Ib) A! 0 SMAB Checking Steering Gear and Linkage STEERING GEAR Check gear housing and boots for looseness, damage or grease leakage. Check connection with steering column for looseness. STEERING LINKAGE Check ball joint, dust cover and other component parts for looseness, wear, damage or grease leakage. . . . . Q : Check grease leakage : Check tightening torque SMA B Checking Power Steering Fluid and Lines SMAB . Check fluid level, when the fluid is cold. . Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. SSTB MA CHASSIS AND BODY MAINTENANCE LUBRICATING LOCKS, HINGES AND HOOD LATCHES Fastback lEI =~~ m m. SMAB CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS CAUTION: 1. AUseat bait arenaqq.us, including retractors and attaching hardwares such as guida rail set, etc" should ba inspacted after any collision. Nin recommends that aUseet bait amblies in use during a collision ba replaced unless the collision was minor and the baits show no damage and continue to operete properly. Seat bait assemblies not in use during a collision should allO ba inspacted and replaced if eithar damage or improper operation is noted. 2. If tha condition of any component of a seat bait is questionable, do not have seat bait repaired, but raplaced as a bait mbly. 3. If wabbing is cut, frayed, or damaged, replace bait assembly. 4. Do not spill drinks, oil, etc. on inner lap bait buckle. Never oil tongue and buckle. 5. Use a NISSAN genuine arenaqq.us bait assembly. ~ Anchor bolt N.m ( - kg-m, 17 - 23 ft-Ib) For automatic seat bait, refer to BF section. Rear seat belt Check function of buckles and tongues when buckled and released. Front seat belt MA SMAOO1C SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Maintenance Spark plug INSPECTION AND ADJUSTMENT Drive belt deflection Unit: mm (in) Used belt deflection Adjusted deflection Limit Alternator Set deflection of new belt 11 () ( - I ( - ) ( - I ( - ) Air conditioner compressor 12 () Power steering oil pump 13 ( 1() ( ) ZFR5D Hot type ZFR4D Cold type ZFR6D Plug gap - mm ( . in) Ignition wire Resistance kS1 TIGHTENING I Applied pushing force Standard type 98 N (10 kg, 22 Ib) N'm kg-m ft-Ib Spark plug 29 - 22 25 - 33 Oil capacity (Refill) Unit: 2 (US qt, Imp qt) (/4,/8) Without (/8,/8) oil filter Coolant capacity Unit: 2 (US qt, Imp qt) With reservoir tank TORQUE Unit Drain plug With oil filter Less than 30 (,/8) MA - Engine block 34 44 Oil pan SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance Brake INSPECTION AND ADJUSTMENT Clutch Unit: mm (in) Unit: mm (in) - () Pedal free height "H" Pedal free play" A" - ( ) Disc brake Pad Standard thickness CL22VB () CL9H () Minimum thickness CL22VB Front axle and front suspension(Unladen)* -1°30' Camber degree Caster degree Toe-in mm (in) to 0° () CL9H 6°00' . ~30' Rotor Standard th ickness CL22VB 0 - 2 (0 - ) (Total toe-in) degree 0' - 12' Kingpin inclination degree 12°30'- 14°00' () () CL9H Minimum thickness CL22VB Front wheel turning angle Full turn Inside/outside d () 39° egree ° /33° () CL9H *: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. () Pedal Free height M/T A/T Rear axle and rear suspension (Unladen)* Camber degree Toe-out mm (in) (Total arenaqq.us) degree -1°36' - ( - ) Free play 1 - 3 ( - ) to -0°36' Depressed hElight [under force of N (50 kg, Ib) with engine running] 0 - 5 (0 . ) 0' - 28' I - ( - ) *: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. () or more Parking brake Number of notches [at pulling force N (20 kg, 44 Ib)] Wheel bearing Wheel bearing axle end mm (in) play Wheel bearing lock nut Tightening torque N.m (kg-m, ft-Ib) Front Rear () or less () or less - - (15 22, (, ) ) Wheel balance Wheel balance (Maximum allowable unbalance at rim flange) g (OZ) Tire balance weight MA g (OZ) 10 () ( ) Spacing 5 () SERVICE DATA AND SPECIFICATI'ONS(S.D.S.) Chassis and Body Maintenance (Cont'd) TIGHTENING TORQUE Unit N'm Clutch Pedal stopper lock nut Clutch switch lock nut 16 22 - 15 - 12 - 16 12 - 9 - 11 Drain and filler plugs Final drive Drain plug 25 - 34 - 18 - 25 59 6 - 10 Filler plug Front axle and front 59 6 - 10 37 - 46 - 27 - 34 - 91 - Manual transmission suspension Tie-rod lock nut kg-m . - ft-Ib Camber adjusting pin Rear axle and rear suspension Toe adjusting pin 69 51 - 65 Camber adjusting pin 69 51 Brake system Air bleed valve - Brake lamp switch lock nut 12 - 15 - 9 - 11 Brake booster input rod lock nut 16 - 12 - 16 - 72 Wheel and tire Wheel nut 98 - MA ENGINEMECHANICAL EM SECTION EM CONTENTS PRECAUTION EM- 2 PREPARATION EM- 3 OUTER COMPONENT PARTS EM- 6 COMPRESSION PRESSURE EM- 7 OIL PAN EM- 8 TIMING CHAIN EM OIL SEAL REPLACEMENT EM CYLINDER HEAD EM ENGINE REMOVAL EM CYLINDER BLOCK EM SERVICE DATA AND SPECIFICATIONS (S.D.S.) """'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' EM PRECAUTION LIQUID GASKET APPLICATION ~~ Groove ' . . I~r Side Bolt hole SEMC PROCEDURE a. Before applying liquid gasket, remove all traces of old liquid gasket from mating surface using a scraper. b. Apply a continuous bead of liquid gasket to mating surface. (Use Genuine Liquid Gasket or equivalent.) c. Be sure liquid gasket is to mm ( to in) wide (for oil pan). Be sure liquid gasket is to mm ( to in) wide (in areas except oil pan). d. Apply liquid gasket to inner sealing surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) e. Wait at least 30 minutes before refilling engine oil and engine coolant. EM-2 PREPARATION SPECIAL SERVICE TOOLS Tool number (arenaqq.us No.) Tool name Description STS ( - Disassembling and assembling ) Engine stand assembly CD ST ( ) - Engine stand @ ST ( Base - ) ~ KV ) ( Engine attachment - KVSO ) ( Valve spring compressor - CD Disassembling and assembling valve components CI< KV - ( ) Compressor @KV ) ( Adapter - KVB ( ) Valve oil seal drift - ~ Installing valve oil seal ~ KV ( - Disassembling and assembling piston with connecting rod ) Piston pin press stand assembly CD KV ( ) Cap @ KV ( ) Spacer @ ST ( ) Press stand @ ST ( ) Spring @ KV ( ) Drift @ KV ( ) Center shaft 3 ~ ?~~ EM-3 PREPARATION Tool number (Kent-Moore No.) Tool name Description EM (J ) Piston ring compressor ~ Installing piston assembly into cylinder bore (J) Valveoil seal remover ~ Displacement valve oil seal KV ( - ) Seal cutter WS - ( ) Tube presser ST (J) Pilot bushing puller ~ T Removing oil pan Pressing the tube of liquid gasket ~ EM-4 PREPARATION COMMERCIAL SERVICE TOOLS Tool name Spark plug wrench Description c:Y Q 16mm ( in) Pulley holder r ~ -- Valve seat cutter set ~ \ ~~.- Valve guide drift installing Holding camshaft pulley while tightening or loosening camshaft bolt Finishing valve seat dimensions .- - ~ ~ Piston ring expander Removingand spark plug Removing and installing piston ring Removing and installing valve guide Diameter: A¥:~ mm (in) Intake Exhaust A () () B () () Reaming valve guide (CD) or hole for oversize valve guide (@) Valve guide reamer Diameter: ~- @ D. EM;.5 mm (in) Intake Exhaust 01 7 () 8 () Os () '() OUTER COMPONENT PARTS KA24E ENGINE ~ ~ - 16 21 (_,12 ) 16 ( , ) B.P.T. valve . I A A umt LI-I~~ I.-L ~ rA'.. (, ) ,r" Adjusting bar ~ ~~ (,7 - 9) ( , ) ~ : N.m (kg-m, ft-Ib) rJ : Apply liquid gasket. SEMC EM-6 COMPRESSION PRESSURE Measurement of Compression 1. 2. 3. 4. 5. Pressure Warm up engine. Turn ignition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable. Q) 6. Attach a compression tester to NO.1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution. Compression pressure: kPa (kg/cm2,. psi)/rpm Standard 1, (, )/ Minimum (10, )/ Difference limit between cylinders 98 (, 14)/ If cylinder compression in one or more cylinders is loyi. 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. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat Is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is I,akage past the gasket surface. If so, replace cylinder head gasket. . SEM B . . . EM-7 OIL PAN 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. @ 0 (jJ) 0 Q 2- Front 0 @ @ Loosen bolts in reverse order. @ SEMC 6. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. Do not insert screwdriver, or oil pan flange will be deformed. . . (2) Slide Tool by tapping its side with a hammer, and remove oil pan. SEMA 7. Pull out oil pan from front side. EM-8 OIL PAN Installation Scraper 1. Before installing oil pan, remove all traces of liquid gasket . from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block. SEMC 2. Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent. . SEMC Cut here. ~ Liquid gasket . Be sure liquid gasket is to mm ( to in) wide. :J SLC 7 mm in) --Lt-. 3. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. 4. Install oil pan. Wait at least 30 minutes before refilling engine oil. . . Inner side Groove Bolt hole SEMB EM-9 . TIMING CHAIN r ~ ~ Camshaft sprocket ' , - (1:~ain'tenSioner 08 5.' ( . , ~ ~ ~ ~ rJ ~ I L Qj Front cover .~ ., . Crankshaft sprocket ( , 9 . L. ~ : N.m (kg-m, ft-Ibl rJ : ApplV liquid gasket. SEMC . CAUTION: \ After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. EM TIMING CHAIN Removal 1. 2. 3. 4. .. . Disconnect battery terminal. Drain coolant from radiator. Remove radiator shroud and cooling fan. Remove the following belts. Power steering drive belt Compressor drive belt Alternator drive belt 5. Remove all spark plugs. 6. Set NO.1 piston,at T.D.C. on its compression stroke. Q Front SEMC 7. Remove the following parts. Power steering pump, idler pulley and power steering pump brackets Compressor idler pulley Crankshaft pulley Oil pump with pump drive spindle . .. .. Rocker SEMC SEMC EM-" cover . TIMING CHAIN Removal (Cont'd) 8. Remove oil pan. (Refer to OIL PAN.) 9. Remove front cover. SEMC Remove the following parts. . Chain tensioner . Chain guides . Timing chain and sprocket . Oil thrower, oil pump drive gear and crankshaft sprocket Crank~h3ft sprocket SEMC Inspection Check for cracks and excessivewear at roller links. Replace if necessary. Jf) ~ ,~ ' SEMC EM TIMING CHAIN crankShaft Crankshaft ~prOCket ~ ~ Installation 1. Install crankshaft sprocket, oil pump drive gear and oil thrower. . Make sure that mating marks of crankshaft sprocket face engine front. . "4~ . O;I:;:~~~'\ n ~ 0 Front. SEMC 2. Install camshaft sprocket. 3. Confirm that NO.1 piston is set at T.D.C. on its compression stroke. 4. Install timing chain. Set timing chain by arenaqq.us its mating marks with those of crankshaft sprocket and camshaft sprocket. ~~~ '/0 ~ (O@ . \ ~. '~ " ~ \\ II ~ Can ,",ocke< )) " ii ~r C"ok .p-" " e: Punchmark SEMC 5. Tighten camshaft sprocket bolt. 6. Install chain guide and chain tensioner. EM TIMING CHAIN Installation (Cont'd) 7. Apply liquid'gasket to front cover. ~ mm 8. Apply lithium grease to sealing lip of crankshaft oil seal. ( . inl die. 9. Install front cover. Be careful not to damage cylinder head gasket. Do not forget seal. .. SEMC Install rubber plug. (Refer to "Installation" HEAD.) Install oil pan. (Refer to Oil PAN.) of CYLINDER Install oil pump and distributor driving spindle with new gasket in front cover. (1) Assemble oil pump and driving spindle, aligning punchmark on driving spindle with oil hole. ~ Punchmark SEMC EM TIMING CHAIN Installation (Cont'd) (2) Make sure that driving spindle is set as shown in figure. Front Q SEMC Install distributor. Make sure that NO.1 piston is set at T.D.C. and that distributor rotor is set at NO.1 cylinder spark position. Q Front SEMC EM OIL SEAL REPLACEMENT VALVE OIL SEAL 1. Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove valve spring and valve oil seal with Tool or suitable tool. Piston concerned should be set at T.D.C. to prevent valve from falling. (J) KV ( - 4. Apply engine oil to new valve oil seal and install it with Tool. Before installing valve oil seal, install valve spring seat. ) () Valve spring seat Unit: mm (in) SEMC OIL SEAL INSTALLING DIRECTION Engine inside . Oil seal lip Engine outside Dust seal lip SEMA FRONT OIL SEAL 1. Remove radiator shroud and crankshaft pulley. 2. Remove front oil seal. Be careful not to damage crankshaft. EM 9i- SEAL REPLACEMENT 3. Apply engine oil to new oil seal and install it using suitable tool. SEMB REAR OIL SEAL 1. Remove flywheel or drive plate. 2. Remove rear oil seal retainer. 3. Remove traces of liquid gasket using scraper. 4. Remove rear oil seal from retainer. .J'I; l it 5. Apply engine oil to new oil seal and install it using suitable tool. Diameter of Iiqu id gasket: - mm ~ ( 6. Apply liquid gasket to rear oil seal retainer. - in) EM CYLINDER HEAD ~~-8 .,' , ' ' Valve rocker cover- Rocker cover gasket ~ 37 - 41 ( - , 27 - 30) Valve and spring Intake Spring retainer Valve '~w, ~ ,\;~ ~ ,\ ~J @ , ~~ E'M":~ Oilseal @ springseatA \\ V"Wg";..~~ Valve seat ~ . ~ ~ Cylinder head \J @<~ 'b@cg ~ Head bolt ~: N'm (kg-m, ft-Ib) SEMC EM CYLINDER HEAD CAUTION: When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. . When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts. . . O.K. Hydraulic valve lifters are installed in each rocker arm. If hydraulic valve lifter is kept on its side, even when installed in rocker arm, there is a possibility of air entering it. After removal, always set rocker arm straight up, or when laying it on its side, have it soak in new engine oil. Ii SEMB N.G. . . Do not disassemble hydraulic valve lifter. Attach tags to valve lifters so as not to mix them up. SEMB Removal 1. Drain coolant from radiator and drain plug of block. 2. Remove the following parts. Power steering drive belt Power steering pump, idler pulley and power steering brackets Vacuum hoses of S.C.v. and pressure control solenoid valve Accelerator wire bracket 3. Disconnect E.G.R. tube from exhaust manifold. 4. Remove bolts which hold intake manifold collector to intake manifold. 5. Remove bolts which hold intake manifold to cylinder head while raising collector upwards. 6. Remove rocker cover. When removing rocker cover, do not hit rocker cover against rocker arm. . . .. EM CYLINDER HEAD ~ Removal (Cont'd) 7. Set NO.1 piston at T.D.C. on its compression stroke. -5/0° 5° 10° 15° 20° Red painted / ~ Front SEMC 8. Loosen camshaft sprocket bolt. Support timing chain by using Tool as shown in figure. . SEMC 9. Remove camshaft sprocket. EM CYLINDER HEAD Removal (Cont'd) Remove front cover tightening bolts to cylinder head. SEM
Источник: [arenaqq.us]

المنتدى > الفئة التقنية و الاتصالات > أنظمة التشغيل و البرامج Operating System > البرامج > أكبر مكتبه تضم جميع برامج + آخر تحديثات برامج الفيروسات


المساعد الشخصي الرقمي

مشاهدة النسخة كاملة : أكبر مكتبه تضم جميع برامج + آخر تحديثات برامج الفيروسات



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S13

SERIES

PROPELLER SHAFT DIFFERENTIAL & CARRIERFRONT AXLE& FRONT SUSPENSION REAR AXLE& REAR SUSPENSION BRAKE SYSTEM STEERING SYSTEM
BODY

HEATER AIRCONDITIONER & ELECTRICAL SYSTEM

,
cg NISSAN MOTOR CO., LTD.
..

Printed in U.S.A.
Motor Company Ltd., Tokyo, Japan.

Not to be reproduced in who~e or in part without the prior written permission of Ni~n < ""

FOREWORD
This manual contains maintenance and repair procedures for the Nissan SX. In order to assure your safety and the efficient functioning of the vehicle, this manusl should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at a~y time without notice.

IMPORTANT AFETY S NOTICE


The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, 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 jeopardiz~d by the service method selected.

NISSAN MOTORCo.,LTD.
Overseas Service Department Tokyo, Japan

GENERAL INFORMATION I SECTION

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GI- 2 GI- 5
~

CONTENTS
PRECAUTIONS HOW TO USE THIS MANUAL

HOW TO READ WIRING DIAGRAMS


HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES IDENTIFICATION INFORMATION
"""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

GI- 7
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LIFTING POINTS AND TOW TRUCK TOWING TIGHTENING TORQUE OF STANDARD BOLTS

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PRECAUTIONS
Observe the following precautions ~o ensure safe and proper servicing. 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 inflammable 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.
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2. Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.
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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.

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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.

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PRECAUTIONS
6. Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint.

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7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set. Arrange the disassembled parts in accordance with their assembled locations and sequence. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. Use only the lubricants specified in MA section. Use approved bonding agent, sealants or their equivalents when required. Use tools and recommended special tools where specified for safe and efficient service repairs. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.

Precautions for E.F.I. or E.C.C.S. Engine


1. Before connecting or disconnecting E.F.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 eliminate danger. 3. Be careful not to jar components such as control unit and air flow meter.

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PRECAUTIONS Precautions for 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 compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on inflammable material. Keep inflammable material off the exhaust pipe.

Clean floor SG

Precautions for Fuel


Unleaded gasoline of at least 87 AKI number (RON 91)

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HOW TO USE THIS MANUAL


1. A QUICK REFERENCE INDEX, a black tab (arenaqq.us18) 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. 2. THE CONTENTS are listed on the first page of each section. 3. THE TITLE is indicated on the upper portion of each page and shows the part or system. 4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. "BR-5"). 5. THE lARGE IllUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG.
"Example"
Pad retainer

r;~'~
Torque
member

~
~
,/I

J~
~
~.

::;:;

~
.

5~

/
/

r-


Main pin

IE!

to sliding portion

Pin boot

Outer shim

SBRA

6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary. 7. The followings SYMBOLS AND ABBREVIATIONS are used:

~
E1I

~ rJ ~ ~
EaI~

@>
"f:l

:
:

S.O.S. L.H., R.H. .

Tightening torque Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. Should be lubricated with oil. Sealing point Checking point Always replace after every disassembly. Apply petroleum jelly. Apply A.T.F. Select with proper thickness. Adjustment is required. Service Data and Specifications Left-Hand, Right-Hand

M/T A/T Tool L.H.D. R.H.D. A.T.F. 0,


02 03 D. 22 2, 12 1,

Manual Transaxle/Transmission Automatic Transaxle/Transmission Special Service Tools Left-Hand Drive Right-Hand Drive Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear

",.

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HOW TO USE THIS MANUAL


8. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. "Example" Tightening torque: 59 - 78 Nom ( - kg-m, 43 - 58 ft-Ib) 9. TROUBLE DIAGNOSES are included in sections dealing with complicated components. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed.

. . .

BOLD TYPED STATEMENTS except WARNING and CAUTIONgive you helpfulinformation.

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HOW TO READ WIRING DIAGRAMS


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WIRING DIAGRAM Symbols used in WIRING DIAGRAM are shown below:


Example
CONNECTOR Th is shows that these con nectors white 6 terminal connectors. POWER SUPPLY are -This shows the ignition switch position in which the system can be ope rated. - See POWER SUPPLY ROUTING in EL section for the detai led wiring diagram.

BRANCH M/T model

n
~
~B~

'-LAMP -!

.
I

lG~

A/T model

~
~ CLG~ ~B-S
~
@
: MfT model : AfT model

1m
~~

SWITCH This shows that continuity exists between terminals CD and CID, when the switch is turned to ON position.

>

~ 2

~Whi"~
G

.rn '""".~
'"" ~ ~

lyw IiliJ
l-l

~
SWITCH

ABBREVIATIONS

LOCATION NUMBER This number shows where the connector is located. See HARNESS LAYOUT in EL section. The number is identical with the one in HARNESS LAYOUT. I

-b
BODY D GROUN

'WIRE

COLOR CODING

BR

Brown Orange Pink Purple Gray Sky Blue

B -BI,,'
W R G Y L LG ~ ~ ~ ~ ~ White Red Green Blue Yellow
. ht Green

OR
P PU GY SB I

~@!
I: Instrument harness

M: Main harness S G

. d the base is stripe, . When. the iven first, or wire co followe d by the stripe color as g IS shown below: Example: L/W
~

~ Llg

Blue with Whtte Stripe

SWITCH POSITIONS
Normally open

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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.

. . .

Normally closed

~
SELE

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HOW TO READ WIRING DIAGRAMS


Example

CONNECTOR SYMBOLS All connector symbols in wiring diagrams are shown from the terminal side.


Example

Connector SG

EE

.
Efj

M.~ te,m;nal

Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

Connector symbol

G";d'-[~ Connector

Female terminal

Guide

Connector Connector symbol


SG

MULTIPLESWITCH The continuity of the multiple switch is identified in the switch chart in wiring diagrams.

Example

WIPER SWITCH

Continuity circuit of wiper switch


SWITCH POSITION -B/Y OFF INT CONTINUITY CIRCUIT 3 - 4,5 - 6 1 -6

-W/B -L/Y

-B.
-yo

-R.

B E C (f)

1 5 @ 2

LO HI WASH

Example: Wiper switch in LO position

Continuity circuit:

Red wire - @ terminal -

CID terminal

- Wiperswitch (@ - @:

LO) - @ terminal - CD terminal - Black wire

SG

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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 Wiring Diagram

STARTING

SYSTEM

SUPER MULTIPLE JUNCTION (S.M.J.)


arenaqq.us A"angament

w
'"

rnIJ ~

],
liJ

[ ,=fd:0CI~ crhKk 0
,~
r

Dm3

g
FF

0 0 0

Check

:=

y--R

Super Multiple Junction (S.M.J.)

.S.M.J.

L--S

't

( (Foldout
r-R~
~B
(Main harness)

Refer to last page


page).

DO

L
BR~ (Instrument harness)

+-+

r-B

(Main harness)

(Instrument

harness)

BRl.

SELF

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HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

m"

(
~m

INSPECTION START)

rill
I

-=-

SG I

iii

~ lu
_MECT

iii

CHECK POWER SUPPLY. Check the following items. 1) Turn ignition switch "ON" .~ [ IN.G. 1) Harness continuity betWeen 2) Check voltage between crank angle sensor and battery. terminal @ and ground. 2) E.C.C.S. relay-1 (See page EF & T~Battery voltage should exist. EC) 3) "BR" fusible link O.K. 2 4) Power source for E.C.U. (See page EF & EC) 5) Ignition switch Check the following items. 1) Harness continu ity betWeen crank angle sensor and I N.G~ grou nd 2) Ground circuit for E.C.U. (See page EF & EC)

CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF".

[ill

~ ~ 00
SG

2) Disconnect crank angle sensor harness connector. 3) Check resistance betWeen terminal @ and ground. Resistance: Approximately
I

on

O.K.

NOTICE The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check" or the "Symptom Chart". 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pin Point Check. If you must perform circuit continuity between harness connectors more detail, such as in case of sub harness is used, refer to Wiring Diagram and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be "OFF" . 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as it was.

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HOW TO FOllOW

FLOW CHART IN TROUBLE DIAGNOSES


HOW TO FOllOW
ITJ

THIS FLOW CHART

Work and diagnostic procedure


Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. I

CHECK POWER SUPPLY. 1) Turn ignition switch "ON".


2) Check

Check

item being performed.

voltage between

Procedure,

steps or
results

terminal @ and ground. Battery voltage should exist.

measurement

O.K. I2J Measurement results

Required results are indicated in bold type in the corresponding block, as shown below. These have the following meanings: Battery voltage ~ 11 14V or approximately 12V Voltage: Approximately OV ~ Less than 1V

Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. For example, symbol m indicated in the left upper portion of each illustration corresponds with the symbol in the flowchart for easy identification. More precisely, the procedure under the "CHECK POWER SUPPLY" outlined previously is indicated by an illustration m .

@] Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. 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.

Example View from terminal side

Connector symbol

Direction

mark

~
View from harness side
Connector symbol

.
.

View f,om lermlnel side n' r.s. All connector symbols shown from the terminal side are enclosed by a single line.

~:

~:

View f,omhernessside .n

H.S.

Connector

~ [it
Direction mark

All connector symbols shown from the harness enclosed by a double line.

side are

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HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES


Key to symbols signifying measurements or procedures
Symbol Symbol explanation Check after disconnecting the connector to be measured. Symbol Symbol explanation
AIC switch is "OFF".

IV
) @CONNECT

cT

Check after connecting the connector to be measured. Insert key into ignition switch. Turn ignition switch to "OFF" position.
Turn ignition switch to "ON" position. Turn ignition switch to "START" position.

AIC switch is "ON". REC switch is "ON". REC switch is "OFF".


DEF switch is "ON". VENT switch is "ON".

00 00
OOACC

Turn ignition switch from "OFF" to "ACC" position.


Turn ignition switch from "ACC" to "OFF" position. Turn ignition switch from "OFF" to "ON" position. "cfi

Fan switch is "ON". (At any position except for "OFF" position)
Fan switch is "OFF".

Apply battery voltage directly to components.

OOF

Turn ignition switch from "ON" to "OFF" position.

Drive vehicle.

0
trJ

Do not start engine,or check


with engine stopped.
Start engine.
running.

Disconnect battery negative cable.

or check

with engine

Depress

brake

pedal.

Apply parking brake.

Release brake pedal.

Release parking brake. Check after engine is warmed up sufficiently.

Depress accelerator pedal.

CffH

Release accelerator pedal.

l!V
La)
Le1J

Voltage should be measured with a voltmeter.

II CIUIIT-foi

II

Circuit resistance should be measured with an ohmmeter.

Pin terminal check for S.M.J. type arenaqq.us AIT control unit connectors. For details regarding the terminal arrangement, refer to the foldout page.

'

Currentshould be measuredwith an ammeter.

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IDENTIFICATION INFORMATION

Model Variation
Destination Body Coupe Fastback Non-California Coupe Fastback Coupe Fastback California Coupe Fastback Coupe Fastback Canada Coupe Fastback HLS13AN RE4R01A RHLS13AN HLS13AV RE4R01A RHLS13AV HLS13FN FS5W71 C RHLS13FN HLS13AU RE4R01A RHLS13AU HLS13FV FS5W71C RHLS13FV KA24E R Model HLS13FU FS5W71C RHLS13FU Engine Transmission Differential carrier

Prefix and suffix designations:


R H L S13 A N (R)

(R) : With A.B.S. N : Canada V : California U: Non-California

0: R : H: L:

Coope Fastba~
KA24E engine L.H. drive

A : Automatic transmission F : 5-speed manual transmission

0 : means no indication.

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IDENTIFICATION

INFORMATION

Identification Number
Vehicle identification plate

Vehicle identification

number (Chassis number)

F.M.V certification Vehicle identification number plate

label

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VEHICLE IDENTIFICATION

NUMBER ARRANGEMENT IN 1 H S 3 6 P X K W

Manufacturer IN 1: N issan passenger vehicle Engine type H: KA24E

IT

Vehicle serial number

Manufacture plant W: Kyushu Model year K: year model Check digit (0 to 9 or XI The code for the check digit is determined by mathematical computation. Restraint system S: Standard P: Automatic

. Vehicle line
S: NISSAN SX Model change (0 to 91 Body type 4: Coupe 6: Fastback

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IDENTIFICATION

INFORMATION
PLATE

Identification Number (Cont'd)


IDENTIFICATION
NISSAN MOTORCO.,LTD. JAPAN

~:it
CHASSIS NO NO DE CHASIS MODEL MOOElO

~i:J
&"

ill

.&
",-COlOR TRiM f 'Jk COlOR GUMNICION

0
I ;,.0

ffi& &&

0
CC

ENGIN[
MOTOR

'/;,.0

;; ';~: ; ~ElE

& &
I tf; A
MADEINJAPAN

1 2 3 4 5 6 7 8 9
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Type Vehicle identification number (Chassis numbed Model Body color code Trim color code Engine model Engine displacement Transmission model Axle model

S jJt ~ ItJ :if[** :it ~ U

ENGINE SERIAL NUMBER KA24E engine

TL M

MANUAL TRANSMISSION

NUMBER

AUTOMATIC

TRANSMISSION

NUMBER

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IDENTIFICATION INFORMATION

Dimensions
Coupe
Overall length Overall width Overall height Front tread Rear tread Wheelbase 4, () 1, () 1, () 1, () 1, () 2, ()

Unit: mm (in)

Fastback
4, () 1, () 1, () 1, () 1, () 2, ()

Wheels and Tires


Road wheel Steel Aluminum Offset Tire size Conventional Spare *: Option mm (in) 6-JJx 15 6-JJx 15 40 () /60R 15 86H /60R 15 89H * T/70D 15

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LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand
WARNING: Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.

. .

Garage jack points

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LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift


WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines.

Sill

Put the sill in the slit of the lift pad to prevent the sill from deforming. If the pad does not have lift pad

//

the slit, prepare

a suitable

attachment

with slit.

Note: Lift-up points are the same as pantograph jack points.

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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. When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral (UN" position).

~ ~

NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated.

'i::ij,iiii. ii;~1',,,';1tiii:.; 2

-.

SG

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LIFTING

POINTS

AND TOW TRUCK

TOWING

Front

Tow Truck Towing (Cont'd) TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (With rear wheels on ground) Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. TOWING POINT Alwayspull the cable straightout from the arenaqq.us pull on the hook at a sidewaysangle.

Rear

CE1 DD9M

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TIGHTENINGTORQUE OF STANDARD BOLTS


dia-

Grade

Bolt size

Bolt

meter* mm

Pitch mm N.m

Tightening torque (Without lubricant) Hexagon head bolt kg-m ft-Ib 9 9 18 19 31 34 54 15 16 30 32 52 57 94 9 22 23 43 46 72 80 Hexagon flange bolt N.m ft-Ib kg-m 15 16 29 30 51 56 88 10 25 26 48 51 84 92 15 35 37 70 74 11 12 22 22 38 41 65 7 18 20 35 38 62 68 11 26 27 51 54 87

M6 M8 4T M10 M12 M14 M6 M8 7T M10 M12 M14 M6 M8 9T M10 M12 M14

13 13 25 25 42 46 74 21 22 41 43 71 77 12 29 31 59 62 98

1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head.
Grade 4T 7T 9T Mark 4 7 9

*: Nominal diameter M

6
""""L-

Nominal diameter of bolt threads (Unit: mm)


Metric screw threads

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'..~

MAINTENANCE
.J

SECTION

MA

l1li

CONTENTS
PERIODIC MAINTENANCE GENERAL MAINTENANCE. RECOMMENDED LUBRICANTS AND FLUIDS ENGINE MAINTENANCE "'"'''''''''''' CHASSIS AND BODY MAINTENANCE SERVICE DATA AND SPECIFICATIONS (S.D.S.) :" MA- 2 MA- 4 MA- 6 MA- 8 MA MA",

PERIODIC MAINTENANCE
The following charts show the normal maintenance schedule. Under severe driving conditions, additional or more frequent maintenance will be required. Refer to "Maintenance under severe driving conditions". The periodic maintenance schedule is repeated beyond the last mileage and period shown by returning to the first 15, miles (24, km) or 12 months. EMISSION CONTROL SYSTEM MAINTENANCE
MAINTENANCE. OPERATION Perform at number of miles, kilometers or months, whichever comes first. Drive belts
Air cleaner filter Miles x 1, (km x 1,) Months

(12) 6

MAINTENANCE 15 30 (24) 12 (48) 24

INTERVAL 45 60 (72) 36 (96) 48 1* Reference page

See NOTE (1).

MA-8 MA MA MA-9 MA MA-8 MA

Vapor lines Fuel lines Fuel filter Engine coolant Egnine oil
Engine oil filter (Use Nissan PREMIUM type or equivalent.)

Replace every 30, miles (48, km). 1* 1* 1* 1* See NOTE (2)*. R


R

Then replace every 7, . miles (12, km) or 6 months.


Then replace every second oil change.

MA MA MA

Spark plugs Ignition wires

Replace every 30, miles (48, km). Inspect every 3 years. *

CHASSIS AND BODY MAINTENANCE


MAINTENANCE OPERATION Perform at number of miles, kilometers or months, whichever comes first. Break lines & cables Brake pads & discs Manual and automatic transmission & differential gear oil Steering gear & linkage, and axle & suspension parts Exhaust system
Miles x 1, (km x 1,) Months

15 (24) 12 I I I

MAINTENANCE INTERVAL 30 45 (48) 24 I I I I I (72) 36 I I I

60 (96) 48 I I I I I

Reference page

MA MA MA,15,16 MA, FA-4,RA-4 MA

NOTE: (1) After 60, miles (96, km) or 48 months, inspect every 15, miles (24, km). (2) If vehicle is operated under extremely adverse weather conditions or in arees where ambient temperatures are either extremely low or extremely high, the filters might become clogged. In such an event, replace them immediately. (3) Maintenance items and intervals with "." are recommended by NISSANfor reliable vehicle operation. The owner need not perform such maintenance in order to ~aintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.
Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary.

MA-2

PERIODIC MAINTENANCE
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance is required to. be performed on the following items as shown in the table. Severe driving conditions A - Repeated short trips less than 5 miles (8 km) and outside temperatures remain below freezing B - Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use C - Driving in dusty conditions D - Driving on rough, muddy, or salt spread roads E - Towinga trailer, usinga camper or a car-top carrier
Maintenance operation

Driving condition C ABC DE

Maintenance

item

Maintenance interval

Reference

page

Air cleaner filter


Engine oil & oil filter

R R

More frequently'
Every 3, miles (5, km) or 3 months Every 7, miles (12, km) or 6 months

MA MA

A.

C D E

Brake pads & discs

MA

D E

Manual and automatic transmission & differential gear oil Steering gear & linkage, and axle & suspension parts Steering linkage ball joints & front suspension ball joints Exhaust system I = Inspect. Correct or replace if necessary. R

Every 30, miles (48, km) or 24 months

MA, 15, 16

D . . A. . CD. .
D E

MA, FA-4, RA-4 Every 7, miles (12, km) or 6 months

MA,FA-4

MA

Maintenance operations:

= Replace.

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 vehicl~isto continue operating properly. The owners can perform the checks and inspectionsthemselvesor they can have their NISSANdealers do them for a nominal charge.
Item
OUTSIDE THE VEHICLE The ma!ntenance 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 excessivewear. 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, km (7, miles.) Wheel alignment and balance If the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. Windshieldwiper blades Check for cracks or wear if they do not wipe properly. Doors and engine hood Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate 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 frequently. INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Lights Make sure that the headlights, stop lights, taillights, tUrn signal lights, and other lights are all operating properly and installed securely. Also check headlight aim. 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 excessivefree play, hard steering or strange noises. Free play: Lessthan 35 mm ( 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 restrains 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 folding-down rear seatbacks. . Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage. MA MA MA FA-6 RA-6
Reference page

MA

MA-4

GENERAL MAINTENANCE
Item 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. 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. 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. 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. BR-7 Reference page

CL-5

BR

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). Windshieldwasher fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant levelwhen the engine is cold. Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or loose connections. Brake and clutch fluid levels Makesure that the brake and clutch fluid levelsare between the "MAX" and "MIN" lines on the reservoir. Engine drive belts Makesure that no belt is frayed, worn, cracked or oily. Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine. Power steering fluid level and lines Check the level when the fluid is cold and the engine is turned off. Check the lines for proper attachment, leaks, cracks, etc. Automatic transmission fluid level Check the level on the dipstick after putting the selector lever in "P" with the engine idling. Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it. Underbody The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise 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, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. MA,16 MA-8 MA MA MA MA-9

MA

MA-5

RECOMMENDED LUBRICANTS AND FLUIDS Lubricants and Fluids


Capacity (Approximate) US measure
Engine oil (Refill) With oil filter Without oil filter

Imp measure

Recommended lubricants and fluids Liter

/4 qt /8 qt /8 qt 3/4 qt


oil

/8 qt /8 qt /8 qt 5/8 qt /4 pt /4 pt /4 qt 3/4 qt

Genuine Nissan Motor Oil*1 or equivalent (Energy Conserving Oils of API SF or SG)*2, *3

Cooling system (with reservoir tank) Reservoir tank


Manual transmission Differential gear oil

Anti-freeze coolant (Ethylene glycol base)


API GL-4*2 API GL-5*2

/8 pt /4 pt /4 qt 1 qt

Automatic transmission fluid Power steering fluid Brake fluid Multi-purpose grease


Genuine Nissan ATF*1 or equivalent


Type DEXRON Type DEXRON
TM

TM

Genuine Nissan Brake Fluid*1 or equivalent DOT 3 (US FMVSS No. ) NLGI No.2 (Lithium soap base)

*1: Available in mainland U.S.A. through you Nissan dealer. *2: For further details, see "SAE Viscosity Number". *3: Energy Conserving Oils These oils can be identified by such labels as energy conserving, energy saving, improved fuel economy, etc.

MA-6

RECOMMENDED LUBRICANTS AND FLUIDS SAE Viscosity Number


Outside Temperature Anticipated ENGINE OIL

Range

Before Next Oil Change

Outside Temperature Range Anticipated Before Next Oil Change GEAROIL

C",OF

.

++

++"'--++86

+

+50

+32

-5W

T

T

10W is preferable if the ambient temperature is above C (0 F). 20W and 20W are usable if the ambient temperature is above 10C (50 F) for all seasons.

8OW is preferable if the ambient temperature is below 40C (F).

MA-7

ENGINE MAINTENANCE

Power steering oil pump IAJ Water pump

Checking Drive Belts


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: Inspect drive belt deflections when engine is cold.
Unit:
Used belt deflection Limit Adjusted deflection. ( - ) ( - ) ( - ) 98 N (10 kg, 22 Ib)
mm (in)

lAJQ'
Crank pulley T : Tension checking points IAJ: Adjusting bolts

l:~:o,

lAJA;,,ood;,;oo",
compressor
8MAOO2C

Set deflection of new belt ( - )


(

Alternator Air conditioner compressor Power steering oil pump Applied pushing force

11 ()

12 ()

- )

13 ()

( - )

Changing Engine Coolant

~~~
[~O

~ ~

.-

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.

8M AOO3C

2. Open drain cock at the bottom of radiator, and remove radiator cap.

MA-8
"'.

ENGINE MAINTENANCE 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. to;J 44 N.m ( - kg-m, 25 - 33 ft-Ib)

5. Open air relief plug.

6. 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. Repeat step 2 through step 9 until clear water begins to drain from radiator. Drain water.

Open radiator cap and air relief plug. Fill rafdiator with coolant up to specified level. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity. (With reservoir tank) Q (/8 US qt, /8 Imp qt) Pour coolant through coolant filler neck slowly to allow air in system to escape.

MAX. MIN.

Close air relief plug. Remove reservoir tank, drain coolant, then clean reservoir tank. Install reservoir tank and fill it with coolant up to "MAX" level and then install radiator cap. Run engine and warm it up sufficiently. Race engine 2 or 3 times under no-load. Stop engine and cool it down, then add coolant as necesary.

SMAB

Checking Fuel Lines


Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts.

MA-9

ENGINE MAINTENANCE Checking Fuel Lines CAUTION: (Cont'd)

3 mm in)

~--,'-'

--T-+-+--J__J.-_J

Tightenhigh-pressurerubber hose clamp so that clamp end is 3 mm ( in) from hose end. Ensure that screw does not contact adjacent parts.

SMAA

Changing Fuel Filter


WARNING: Before removing fuel filter, release fuel pressure from fuel line.

1. Remove fuse for fuel pump. 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is 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 shop towel to absorb fuel. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter.

. .

. Whentighteningfuel hose clamps, refer to "CheckingFuel Lines".

Changing

Air Cleaner

Filter

The viscous paper type filter does not need cleaning between renewals.

MA

ENGINE MAINTENANCE

Changing Engine Oil


WARNING: Be careful not to burn yourself, as the engine Is hot. 1. Warm up engine, and check for oil leakage from engine components. 2. Remove drain plug and oil filler cap. 3. Drain oil and refill with new engine oil. Refill oil capacity (Approximate):
Unit: liter (US qt, Imp qt) With oil filter change
Without oil filter change

Front SMAOO9C

(/4,/8) (/8,/8)

CAUTION:

Be sure to clean drain plug and Install with new washer. Drain plug:

tOJ: 9 - 39 N.m 2

( - kg-m, 22 - 29 ft-Ib) Use recommended engine

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.

SMAC

Changing

Oil Filter

1. Remove oil filter with a suitable tool. WARNING:

Be careful not to burn yourself, as the engine and the engine oil are hot.

2. Before installing new oil filter, clean the oil filter mounting surface on cylinder block, and coat the rubber seal of oil filter with a little engine oil.

~

SMA

MA

ENGINE MAINTENANCE Changing Oil Filter (Cont'd)


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.
2/3 of a turn

SMAB

O.K.

N.G.

Changing

Spark Plugs

1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire.

SMA

R
16mmV1
'arenaqq.us~
SEMA Side electrode

2. Remove spark plugs with spark plug wrench. Spark plug: Standard type ZFR5D Hot type ZFR4D Cold type ZFR6D

iii
SMA

3. Check plug gap of each new spark plug. Gap: - mm ( - 0~ in) 4. Install spark plugs. Reconnect ignition wires according to nos. indicated on them. Spark plug:
~

- 29

N.m

( - kg-m, 14 - 22 ft-Ib)

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 kil .If it exceeds the limit, replace the ignition wire with a new one.
SMAA

MA

ENGINE MAINTENANCE

Checking Vapor Lines


1. Visually inspect vapor lines for. improper 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 EF & EC section.
/"

"

MA

CHASSIS AND BODY MAINTENANCE

Checking Exhaust System

Check exhaust pipes, muffler and mounting for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.

SMAA

Checking Clutch Fluid Level and Leaks


Max. Min.

If fluid level is extremely low, check clutch system for leaks.

SMAB

Checking

M/T Oil

1. Check for oil leakage.

,
SMAA

2. If leakage is found, check oil level. Never start engine while checking oil level. Filler plug: ~: 25 - 34 N.m ( - kg-m, 18 - 25 ft-Ib)

SMA

Changing

M/T Oil

~~~
~.;. ~"~

.,.

1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: Q (/8 US pt, /4 Imp pt) Drain plug: ~: 25 - 34 N.m ( - kg-m, 18 - 25 ft-Ib)

SMAA

MA

CHASSIS AND BODY MAINTENANCE

Checking

AIT Fluid

1. Check for fluid leakage.

.
SMAA

Front side Hot: 50 - aooc ( - F) Add"

O.K.

2. If leakage is found, check fluid level. Fluid level should be checked using "HOT" range on dipstick at fluid temperatures of 50 to 80C ( to 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 50C (86 to 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 overfill.

3. Check fluid condition. Check fluid for contamination. If fluid is very dark or smells burned, or contains frictional material (clutches, band, etc.), check operation of AlT. Refer to section AT for checking operation of AlT.

Check fluid for contamination. SMAB

Changing

AIT Fluid

1. Drain fluid by removing oil pan. 2. Replace gasket with new one. 3. Refill with fluid and then check fluid level. Oil capacity (With torque converter): Q (/4 US qt, /4 Imp qt)

SMAB

MA

CHASSIS AND BODY MAINTENANCE

Checking Differential Gear Oil


1. Check differential carrier for oil leakage.

SMAC

2. If leakage is found, check oil level. Filler plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib)

SMA A

Changing

Differential Gear Oil

~~
0,,;" PI~

1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: Q (/4 US pt, /4 Imp pt) Drain plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib)

~
SMAA

Checking Brake Fluid Level and Leaks


=

If fluid level is extremely low, check brake system for leaks.

MAX

MIN

Checking Brake Lines and Cables

Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc.

SMAA

MA

CHASSIS AND BaDY MAINTENANCE

. Check condition of disc brake components. ROTOR . Check condition and thickness.
Unit: mm (in) Front
Disc brake type
SMAA

Checking Disc Brake

Rear CL9H () ()

CL22VB () ()

Standard thickness Minimum thickness

CALIPER

. Check operationand for leakage.

SMAA

PAD Check for wear or damage.

Unit: mm (in)

Front Disc brake type


Standard thickness

Rear CL9H

CL22VB ()

()

Minimum thickness
SMAB

()

Balancing

Wheels

Adjust wheel balance using road wheel center.


Wheel balance (Maximum allowable unbalance at rim flange): Refer to S.D.S. Tire balancing weight: Refer to S.D.S.

MA

CHASSIS AND BODY MAINTENANCE Tire Rotation

FRONT

Do not include the T-type spare tire when rotating the tires. Wheel nuts: ~: 98 - N.m ( - kg-m, 72 - 87 ft-Ib)

A!

SMAB

Checking Steering Gear and Linkage


STEERING GEAR Check gear housing and boots for looseness, damage or grease leakage. Check connection with steering column for looseness. STEERING LINKAGE Check ball joint, dust cover and other component parts for looseness, wear, damage or grease leakage.

. . .
.

.
Q

: Check grease leakage


: Check tightening torque SMA B

Checking Power Steering Fluid and Lines


Check fluid level, when the fluid is cold.

SMAB

Check lines for improper attachment, leaks, cracks, damage,

loose connections, chafing and deterioration.

SSTB

MA

CHASSIS AND BODY MAINTENANCE


LUBRICATING LOCKS, HINGES AND HOOD LATCHES
Fastback

lEI

=~~

m.
SMAB

CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS

CAUTION: 1. AUseat bait arenaqq.us, including retractors and attaching hardwares such as guida rail set, etc" should ba inspacted after any collision. Nin recommends that aUseet bait amblies in use during a collision ba replaced unless the collision was minor and the baits show no damage and continue to operete properly. Seat bait assemblies not in use during a collision should allO ba inspacted and replaced if eithar damage or improper operation is noted. 2. If tha condition of any component of a seat bait is questionable, do not have seat bait repaired, but raplaced as a bait mbly. 3. If wabbing is cut, frayed, or damaged, replace bait assembly. 4. Do not spill drinks, oil, etc. on inner lap bait buckle. Never oil tongue and buckle. 5. Use a NISSAN genuine arenaqq.us bait assembly.

~ Anchor boltN.m


( - kg-m, 17 - 23 ft-Ib) For automatic seat bait, refer to BF section.

Rear seat belt


Check function of buckles and tongues when buckled and released.

Front seat belt

SMAOO1 C

MA

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Maintenance


INSPECTION AND ADJUSTMENT Drive belt deflection
Unit: mm (in) Used belt deflection Limit Adjusted deflection Set deflection of new belt

Spark plug
Standard type Hot type Cold type Plug gap

ZFR5D
ZFR4D ZFR6D - mm ( . in)

Alternator

11 ()

( - I ( - ) ( - I ( - )

Ignition wire
Resistance kS1
Less than 30

Air conditioner compressor

12 ()

Power steering oil pump


I

TIGHTENING
Unit Spark plug Drain plug
Engine block

TORQUE
N'm 29
34 44

13 ( 1() ( )


98 N (10 kg, 22 Ib)

kg-m -

ft-Ib 22 25 - 33

Applied pushing force

Oil pan

Oil capacity (Refill)


Unit: 2 (US qt, Imp qt)
With oil filter Without oil filter

(/4,/8) (/8,/8)

Coolant capacity
Unit: 2 (US qt, Imp qt)
With reservoir tank

(,/8)

MA

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance


INSPECTION AND ADJUSTMENT Clutch
Unit: mm (in) Pedal free height "H" Pedal free play" A"

Brake
Unit: mm (in) Disc brake Pad Standard thickness CL22VB CL9H

- ()

- ( )

() ()

Front axle and front suspension(Unladen)*


Camber Caster Toe-in (Total toe-in) Kingpin inclination degree degree mm (in) degree degree ' to 0

Minimum thickness CL22VB CL9H Rotor Standard th ickness CL22VB CL9H

() ()

' . ~30' 0 - 2 (0 - )

() ()

0' - 12' '- '


Minimum thickness CL22VB

Front wheel turning angle Full turn Inside/outside d egree 39

() ()

/33

CL9H
Pedal Free height M/T A/T

*: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position.

- ( - )

- ( - ) 1 - 3 ( - )

Rear axle and rear suspension (Unladen)*


Camber Toe-out (Total arenaqq.us) degree mm (in) degree I ' to '

Free play Depressed hElight [under force of N (50 kg, Ib) with engine running] Parking brake Number of notches [at pulling force N (20 kg, 44 Ib)]

0 - 5 (0 . ) 0' - 28'

() or more

*: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.

Wheel bearing
Front Wheel bearing axle end mm (in) play Wheel bearing lock nut Tightening torque N.m (kg-m, ft-Ib) () or less Rear () or less

Wheel balance
Wheel balance (Maximum allowable unbalance at rim flange) g (OZ) Tire balance weight g (OZ) 10 ()

(15 22,

(,

)

)

( ) Spacing 5 ()

MA

SERVICE DATA AND SPECIFICATI'ONS(S.D.S.) Chassis and Body Maintenance (Cont'd)


TIGHTENING Unit Clutch Pedal stopper lock nut Clutch switch lock nut
Manual transmission

TORQUE
N'm kg-m ft-Ib

16 22 12 25

- 15 - 34

- - - 6 - 10 6 - 10

12 - 16 9 - 11 18 - 25

Drain and filler plugs Final drive Drain plug Filler plug Front axle and front
suspension Tie-rod lock nut Camber adjusting pin Rear axle and rear suspension Toe adjusting pin Camber adjusting pin Brake system Air bleed valve Brake lamp switch lock nut Brake booster input rod lock nut Wheel and tire Wheel nut

59 59

37 - 46

- -

27 - 34 91 -

-

69 69


12 16

-

51 - 65 51 9 - 11 12 - 16

- 15

- -

98 -

-

72

MA

ENGINE MECHANICAL

SECTION

EM
EM- 2 EM- 3 EM- 6 EM- 7 EM- 8 EM EM EM EM EM

EM

CONTENTS
PRECAUTION PREPARATION OUTER COMPONENT PARTS COMPRESSION PRESSURE OIL PAN TIMING CHAIN OIL SEAL REPLACEMENT CYLINDER HEAD ENGINE REMOVAL CYLINDER BLOCK
SERVICE DATA AND SPECIFICATIONS (S.D.S.)

"""'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' EM

PRECAUTION
LIQUID GASKET APPLICATION PROCEDURE

~~
Groove

'

I~r Side

Bolt hole

SEMC

a. Before applying liquid gasket, remove all traces of old liquid gasket from mating surface using a scraper. b. Apply a continuous bead of liquid gasket to mating surface. (Use Genuine Liquid Gasket or equivalent.) c. Be sure liquid gasket is to mm ( to in) wide (for oil pan). Be sure liquid gasket is to mm ( to in) wide (in areas except oil pan). d. Apply liquid gasket to inner sealing surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) e. Wait at least 30 minutes before refilling engine oil and engine coolant.

EM-2

PREPARATION
SPECIAL SERVICE TOOLS
Tool number (arenaqq.us No.) Tool name STS
(

Description

Disassembling and assembling

Engine stand assembly CD ST ( )

Engine stand @ ST


( Base

KV ) ( Engine attachment

KVSO ) ( Valve spring compressor

~
CI<

Disassembling and assembling valve components

CD

KV

( ) Compressor @KV ) ( Adapter

KVB ( ) Valve oil seal drift

~
3

Installing valve oil seal

KV
(

Disassembling and assembling piston with connecting rod

Piston pin press stand assembly CD KV ( ) Cap @ KV ( ) Spacer @ ST ( ) Press stand @ ST ( ) Spring @ KV ( ) Drift @ KV ( ) Center shaft

~
?~~
EM-3

PREPARATION
Tool number (Kent-Moore No.) Tool name EM (J ) Piston ring compressor

Description

Installing piston assembly into cylinder bore

(J) Valveoil seal remover

KV
(

Seal cutter

WS
( ) Tube presser

ST (J) Pilot bushing puller

~ T
~

Displacement valve oil seal

Removing oil pan

Pressing the tube of liquid gasket

EM-4

PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name Spark plug wrench
Description

Q
16mm

( in)

Pulley holder

c:Y
~

Removing and
spark plug

installing

r
Valve seat cutter set

--

Holding camshaft pulley while tightening or loosening camshaft bolt

~
\

Finishing valve seat dimensions


.-

~~.-

Piston ring expander

Valve guide drift

~
A:~

Removing and installing piston ring

Removing and installing valve guide


Diameter:

A B

mm (in) Intake () () Exhaust () ()

Valve guide reamer

Reaming valve guide (CD) or hole for oversize valve guide (@) Diameter:
Intake 01 Os 7 () () mm (in) Exhaust 8 () '()

~D.

EM;.5

OUTER COMPONENT
KA24E ENGINE

PARTS

16

(

.

, )

16 21 (_,12

)

B.P.T. valve . I A A umt

LI-I~~

I.-L ~

rA'..

)

( ,

,r"

Adjusting bar

( , )

~~

(,7 - 9)

rJ : Apply liquid gasket.


SEMC

: N.m (kg-m, ft-Ib)

EM-6

COMPRESSION

PRESSURE

Measurement of Compression
1. 2. 3. 4. 5. Warm up engine. Turn ignition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable.

Pressure

Q)
6. Attach a compression tester to NO.1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution. Compression pressure: kPa (kg/cm2,. psi)/rpm Standard 1, (, )/ Minimum (10, )/ Difference limit between cylinders 98 (, 14)/ If cylinder compression in one or more cylinders is loyi. 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. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat Is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is I,akage past the gasket surface. If so, replace cylinder head gasket.

SEM B

.
.

EM-7

OIL PAN

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.


@ 0
(jJ) 0

Front

0 @

Q

2SEMC

@ @ Loosen bolts in reverse order.

6. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. Do not insert screwdriver, or oil pan flange will be deformed.

. .

(2) Slide Tool by tapping its side with a hammer, and remove oil pan.

SEMA

7. Pull out oil pan from front side.

EM-8

OIL PAN Installation


Scraper

1. Before installing oil pan, remove all traces of liquid gasket

from mating surface using a scraper.


Also remove traces of liquid gasket from mating surface of cylinder block.

SEMC

2. Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent.

SEMC

Be sure liquid gasket is to mm ( to in) wide.

Cut here.

~
Liquid gasket

:J
SLC

7 mm

in)

--Lt-.
Inner side Groove
Bolt hole SEMB

3. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. 4. Install oil pan. Wait at least 30 minutes before refilling engine oil.

. .

EM-9

TIMING CHAIN

r
~
~

,6 -

'

Camshaft sprocket

(1:~ain'tenSioner


(

08 5.'
. ,

rJ

L

Qj

Front cover

.,
.

.~

Crankshaft sprocket

( , 9 .

L.

rJ : ApplV liquid gasket.


CAUTION:

: N.m (kg-m, ft-Ibl

SEMC

After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.

EM

TIMING CHAIN Removal


1. 2. 3. 4. Disconnect battery terminal. Drain coolant from radiator. Remove radiator shroud and cooling fan. Remove the following belts. Power steering drive belt Compressor drive belt Alternator drive belt

. . .

5. Remove all spark plugs. 6. Set NO.1 piston,at T.D.C. on its compression stroke.

Q
Front
SEMC

7. Remove the following parts. Power steering pump, idler pulley and power steering pump brackets Compressor idler pulley Crankshaft pulley Oil pump with pump drive spindle

. . . . .

Rocker

cover

SEMC

SEMC

EM-"

TIMING CHAIN Removal (Cont'd)


8. Remove oil pan. (Refer to OIL PAN.) 9. Remove front cover.

SEMC

Remove the following parts. . Chain tensioner . Chain guides . Timing chain and sprocket

Oil thrower, oil pump drive gear and crankshaft sprocket

Crank~h3ft sprocket

SEMC

Inspection Check for cracks and excessivewear at roller links. Replace if necessary.

Jf) ~

,~

'

SEMC

EM

TIMING CHAIN
crankShaft Crankshaft ~prOCket

~ ~
~

Installation
.

"4~

1. Install crankshaft sprocket, oil pump drive gear and oil thrower. . Make sure that mating marks of crankshaft sprocket face engine front. .

O;I:;:~~~ '\ n 0 ~
Front.

SEMC

~~~
'/0

(O@
\ ~.
'~ " \\
))
"

2. Install camshaft sprocket. 3. Confirm that NO.1 piston is set at T.D.C. on its compression stroke. 4. Install timing chain. Set timing chain by arenaqq.us its mating marks with those of crankshaft sprocket and camshaft sprocket.

~
II ~ Can ,",ocke<
"

ii

~r C"ok .p-"

e: Punchmark
SEMC

5. Tighten camshaft sprocket bolt.

6. Install chain guide and chain tensioner.

EM

TIMING CHAIN Installation (Cont'd)


7. Apply liquid'gasket to front cover.

mm

8. Apply lithium grease to sealing lip of crankshaft oil seal.

( . inl die.

9. Install front cover. Be careful not to damage cylinder head gasket. Do not forget seal.

. .

SEMC

Install rubber plug. (Refer to "Installation" HEAD.) Install oil pan. (Refer to Oil PAN.)

of CYLINDER

Install oil pump and distributor driving spindle with new gasket in front cover. (1) Assemble oil pump and driving spindle, aligning punchmark on driving spindle with oil hole.

Punchmark

SEMC

EM

TIMING CHAIN Installation (Cont'd)


(2) Make sure that driving spindle is set as shown in figure.

Front

SEMC

Install distributor. Make sure that NO.1 piston is set at T.D.C. and that distributor rotor is set at NO.1 cylinder spark position.

Q
Front
SEMC

EM

OIL SEAL REPLACEMENT


VALVE OIL SEAL 1. Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove valve spring and valve oil seal with Tool or suitable tool. Piston concerned should be set at T.D.C. to prevent valve from falling.

(J)

KV
(

4. Apply engine oil to new valve oil seal and install it with Tool. Before installing valve oil seal, install valve spring seat.

Valve spring seat

()

Unit: mm (in)

SEMC

OIL SEAL INSTALLING DIRECTION

Engine inside

Engine outside Dust seal lip

Oil seal lip

SEMA

FRONT OIL SEAL 1. Remove radiator shroud and crankshaft pulley. 2. Remove front oil seal. Be careful not to damage crankshaft.

EM

9i-

SEAL REPLACEMENT
3. Apply engine oil to new oil seal and install it using suitable tool.

SEMB

REAR OIL SEAL 1. Remove flywheel or drive plate. 2. Remove rear oil seal retainer. 3. Remove traces of liquid gasket using scraper.

4. Remove rear oil seal from retainer.

it

.J'I;

5. Apply engine oil to new oil seal and install it using suitable tool.

Diameter of Iiqu id gasket: - mm

6. Apply liquid gasket to rear oil seal retainer.

~ (

in)

EM

CYLINDER HEAD

~~-8
.,' Valve rocker cover-

, ' '

Rocker cover gasket

37 - 41 ( - , 27 - 30)

Valve and spring

Intake Spring retainer Valve

'~w,

Oilseal

springseatA

V"Wg";..~~
Valve seat

,\;~ ~ , \ ~J
@
~~
@

E'M":~
.

\\

\J @<~ 'b@cg

Cylinder head

Head bolt

~:

N'm (kg-m, ft-Ib) SEMC

EM

CYLINDER HEAD
CAUTION: When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. . When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts.

O.K.

Hydraulic valve lifters are installed in each rocker arm. If hydraulic valve lifter is kept on its side, even when installed in rocker arm, there is a possibility of air entering it. After removal, always set rocker arm straight up, or when laying it on its side, have it soak in new engine oil.

Ii
SEMB

N.G.

. .

Do not disassemble hydraulic valve lifter. Attach tags to valve lifters so as not to mix them up.

SEMB

Removal 1. Drain coolant from radiator and drain plug of block. 2. Remove the following parts. Power steering drive belt Power steering pump, idler pulley and power steering brackets Vacuum hoses of S.C.v. and pressure control solenoid valve Accelerator wire bracket 3. Disconnect E.G.R. tube from exhaust manifold. 4. Remove bolts which hold intake manifold collector to intake manifold. 5. Remove bolts which hold intake manifold to cylinder head while raising collector upwards. 6. Remove rocker cover. When removing rocker cover, do not hit rocker cover against rocker arm.

. . . .

EM

CYLINDER HEAD Removal (Cont'd)


7. Set NO.1 piston at T.D.C. on its compression stroke.

-5/0

5 10 15 20

Red painted

~
Front
SEMC

8. Loosen camshaft sprocket bolt. Support timing chain by using Tool as shown in figure.

SEMC

9. Remove camshaft sprocket.

EM

CYLINDER HEAD Removal (Cont'd)


Remove front cover tightening bolts to cylinder head.

SEM

<ID

CID

Remove cylinder head. Head warpage or cracking could result from removing in incorrect order. Cylinder head bolts should be loosened in two or three steps.

. .

- SEMC Disassembly'

0
10

@
0

@
0

@
0

@
01

(Q

~ (])

~ @

~ @

Q) CD
SEMC

1. Remove rocker shaft assembly. a. When loosening bolts, evenly loosen from outside in sequence. b. Bolts should be loosened in two or three steps. 2. Remove camshaft. Before removing camshaft, measure camshaft end play. (Refer to "Inspection".)

KV ( )

3. Remove valve components with Tool. 4. Remove valve oil seals. (Refer to OIL SEAL REPLACEMENT.)

EM

CYLINDER HEAD Inspection


CYLINDER HEAD DISTORTION Head surface flatness: Less than mm ( in) If 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" The maximum limit is as follows: A + B = mm ( in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced. Nominal cylinder head height: - mm ( - 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):
0 - mm (0 - in) 2. If it exceeds the limit, replace camshaft.

CAMSHAFT CAM HEIGHT 1. Measure camshaft cam height. Standard cam height:

Cam wear limit: mm ('in) 2. If wear is beyond the limit, replace camshaft.

- mm ( -

in)

SEMA

CAMSHAFT

JOURNAL

CLEARANCE

1, Install camshaft bracket and rocker shaft and tighten bolts


to the specified torque. 2. Measure inner diameter of camshaft bearing. Standard inner diameter:

"

- mm (

-

in)

EM

CYLINDER HEAD Inspection (Cont'd)


3. Measure outer diameter of camshaft journal. Standard outer diameter: - mm ( - , in) 4. If clearance exceeds the limit, replace camshaft and/or
cylinder head.

Camshaft journal clearance: Standard - mm ( - in) Limit mm ( in) CAMSHAFT END PLAY

1. Install camshaft in cylinder head. 2. Measure camshaft end play. Camshaft end play: Standard - mm ( - in) Limit mm ( in)

SEMC

CAMSHAFT

SPROCKET

RUNOUT

1. Install sprocket on camshaft. 2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit mm ( in) 3. If it exceeds the limit, replace camshaft sprocket.

SEMC

VALVE GUIDE CLEARANCE 1. Measure valve deflection in a right-angled direction with camshaft. (Valve and valve guide mostly wear in this direction.) . Valve deflection limit (Dial gauge reading): mm ( in)

SEMC

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: Standard - mm ( - in) (Intake) - mm ( - in) (Exhaust) Limit mm ( in) c. If it exceeds the limit, replace'valve or valve guide.

EM

\ \ \

CYLINDER HEAD
Inspection (Cont'd)
VALVE GUIDE REPLACEMENT 1. To remove valve guide, heat cylinder head to to C ( to F).

2. Drive out valve guide with a press [under a 20 kN (2 t, US ton, Imp ton) pressure] or hammer and suitable tool.
.'

SEMC

3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake - mm ( - in) Exhaust - mm ( - in)

4. Heat cylinder head to to C ( to F) and press service valve guide onto cylinder head. Projection "L": - mm ( - in)

SEMC

5. Ream valve guide. Finished size: Intake - mm ( - in) Exhaust - mm ( - in)

"

EM

CYLINDER HEAD Inspection (Cont'd) VALVESEATS


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 seat. Cut with both hands to uniform the cutting surface.

REPLACING

VALVE SEAT FOR SERVICE PARTS

I
Recess diameter
I

SEMA

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 [ mm ( in)): Intake - mm ( - in) Exhaust - mm ( - in) Reaming should be done to the concentric circles to valve guide center so that valve seat will have the correct fit.

3. Heat cylinder head to to C ( to F).

SEMOO8A

"::I SEMB

4. Cut or grind valve seat using suitable tool at the specified dimensions as shown in S.o.S. 5. After cutting, lap valve seat with abrasive compound. 6. Check valve seating condition. Seat face angle" a ": 45 deg. Contacting width "W" Intake - mm ( - in) Exhaust - mm ( - in)

EM

CYLINDER HEAD Inspection (Cont'd)


T (Margin thickness)

cr d

VALVE DIMENSIONS Check dimensions in each valve. For dimensions, refer to S.O.S. When valve head has been worn down to mm ( in) in margin thickness, replace\lalve. Grinding allowance for valve stem tip is mm ( in) or less.

L
SEMA

JdiSEMA EM

VALVE SPRING Squareness 1. Measure "s" dimension. Out-of-square: Outer Intake Less than mm ( in) Exhaust Less than mm ( in) Inner Intake Less than mm ( in) Exhaust Less than mm ( in) 2. If it exceeds the limit, replace spring. Pressure Check valve spring pressure. Pressure: N (kg, Ib) at height mm (in) Standard Outer Intake (, ) at () Exhaust (, ) at () Inner Intake (, ) at () Exhaust (, ) at () Limit Outer Intake (, ) at () Exhaust (, ) at () Inner. Intake (, ) at () Exhaust (, ) at () If it exceeds the limit, replace spring.

EM

CYLINDER

HEAD

Inspection (Cont'd) ROCKER SHAFT AND ROCKER ARM 1. Check rocker shafts for scratches, seizure and wear. 2. Check outer diameter of rocker shaft. Diameter mm (in): - mm ( - in)

3. Check inner diameter of rocker arm. Diameter mm (in): - mm ( - in) Rocker arm to shaft clearance mm (in): - mm ( - in) Keep rocker arm with hydraulic valve lifter standing to prevent air from entering hydraulic valve lifter when checking.

SEMC

Assembly 1. Install valve component parts. Always use new valve oil seal. Refer to OIL SEAL REWide pitch

Cylinder head side


Place upside.

Narrow

pitch

. . . .

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 head side. After installing valve component parts, use plastic hammer to lightly tap valve stem tip to assure a proper fit.

SEM

2. Mount camshaft onto cylinder head, placing knock pin at front end to top position. Apply engine oil to camshaft when mounting onto cylinder head.

SE MC

3. Install camshaft brackets. Front mark is punched on the camshaft bracket.

SEMC

EM

'"

CYLINDER HEAD Assembly (Cont'd)


4. Install rocker shaft with rocker arms.

Front

Intake

Exhaust

Exhaust SEMC

Install retainer with cutout facing direction shown in figure at left.

Front

Cutout SEMC

5. Tighten bolts as shown in figure at left.

(j)

@
0

~
[Q: @

CD 0

@ 0

@ Q)

.Q.

.Q.

.Q.

QJ @)
SEMC

EM

CYLINDER HEAD

Installation
1. Set No.1 piston at T.D.C. on its compression stroke as follows: (1) Align mark on crankshaft pulley with "0" position and confirm that distributor rotor head is set as shown in figure.

-5~ 10 15 20

Red painted

Q
Front
SEMC

(2) Confirm that knock pin on camshaft is set at the top.

SEMC

.
2. Install cylinder head with new gasket and tighten cylinder

CD @
I I

. Do not rotate crankshaft and camshaft separately, valves will hit piston heads. . Tightening procedure (1) Tighten all bolts to 29 Nom ( kg-m, 22 ft-Ib).
(2) Tighten all bolts to 78 Nom ( kg-m, 58 ft-Ib). (3) Loosen all bolts completely. (4) Tighten all bolts to 29 Nom ( kg-m, 22 ft-Ib).
(5) Turn all bolts 80 to 85 degrees
SEMC @
I

head bolts in numerical

order.

or

(j)

CID

clockwise

with an angle

wrench, or if an angle wrench is not available, tighten all bolts to 74 to 83 Nom ( to kg-m, 54 to 61 ft-Ib).

EM

CYLINDER HEAD Installation (Cont'd)


3. Set chain on camshaft sprocket by aligning each mating mark. Then install camshaft sprocket to camshaft.

Silver

4. Tighten camshaft sprocket bolt.

5. Install rubber plugs as follows: (1) Apply liquid gasket to rubber plugs.

Rubberplugsshouldbe replacedwithnewones.
Rubber plugs should be installed within 5 minutes of applying liquid gasket.

(2) Install rubber plugs. then move them with your fingers to uniformly spread the gasket on cylinder head surface. Rubber plugs should be installed flush with the surface. Do not start the engine for 30 minutes after installing rocker cover. Wipe clean excessive liquid gasket from cylinder head top surface.

. . .

--N.G.

o/!I!IIJl
Good
SEMB

EM

CYLINDER HEAD Installation (Cont'd)


6. Check hydraulic valve lifter. (1) Push hydraulic valve lifter forcefully with your finger. Be sure to check It with rocker arm In Its free position.

(2) If valve lifter moves more than 1 mm ( in), air may be inside of it. (3) Bleed air off by running engine at 1, rpm under no-load for about 20 minutes. (4) If hydraulic valve lifters are still noisy, replace them and bleed air off again in the same manner as in step (3).

7. Install rocker cover. Be sure to avoid Interference rocker arm.

between

rocker

cover

and

~:J
@
SEMC

8. Tighten bolts as follows: (1) Tighten 2 bolts to 3 N.m ( kg-m, ft-Ib) temporarily in order shown in figure.

@ @\

.g,

@ @
,0,

(2) Then tighten bolts to 7 to 10 N.m ( to kg-m, to ft-Ib) in order shown in figure. 9. Install any parts removed.

-""6'CD @

.-JJ@
SEMC

EM

ENGINE REMOVAL

M/T model

tC!] 3 1

( )

M~ . ( - 32 - 41)

tC!] 4

(4A)

~ j
0 ~ ~

tC!] 4

(

- 41)

~
,

r ~
'-, ~

tC!]2 2
( )
.I?:

L~


(

LtC!] 22

)

( - - 21)

//'

'''"'

~/

lOJ : N.m (kg-m. ft-Ib)


SEMC

EM

..

ENGINE REMOVAL
WARNING: a. Situate vehicle on a flat and solid surface. b. Place chocks at front and back of rear wheels. c. 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. e. Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to "Releasing Fuel Pressure" in section EF & EC. f. Be sure to hoist engine and transmission in a safe manner. g. 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.

. .

"5
:1,; ",.

.,"'"

EM

CYLINDER BLOCK

Main bearing

cg

Drain plug (, ~

~
.

rJ

: N'm (kg-m, ft-Ib) : Apply liquid ga\et. SEMC

EM

CYLINDER BLOCK

Disassembly
PISTON AND CRANKSHAFT 1. 2. 3. 4. 5. 6.
SEM

/;~y

,
I I.~'
~

~\ ~ I~(
II

~~O1
ST

Place engine on a work stand. Remove timing chain. Drain coolant and remove water pump. Drain oil. Remove oil pan and oil pump. Remove cylinder head.

-)

7. Remove pistons. When disassembling piston and connecting. rod, remove snap rings, then heat piston to 60 to 70C ( to F) or use piston pin press stand at room temperature.

SEMB

KV

EM

8. Remove main bearing beam and crankshaft. Before removing main bearing beam, measure crankshaft end play. Bolts should be loosened in two or three steps.

. .

Inspection PISTON AND PISTON PIN CLEARANCE 1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp": - mm ( - in)
;

..
SEMB

EM

CYLINDER BLOCK Inspection (Cont'd)


2. Measure outer diameter of piston pin "Dp". Standard diameter "Dp":

- mm ( - in)


3. Calculate interference fit of piston pin to piston.

dp - Dp = 0 - mm (0 - In)
If it exceeds the above value, replace pi!3ton assembly with pin.

SEM B

PISTON RING SIDE CLEARANCE Side clearance: Top ring


- mm ( - In)

SEMC

2nd ring - mm ( - In) ring - mm ( - in) Max. limit of side clearance: mm ( in) If out of specification, replace piston and/or piston ring assembly.

PISTON RING END GAP


End gap: Top ring - mm ( - in) 2nd ring - mm ( - in) (R or T is punched on- the ring.) - mm ( - in) (N is punched on the ring.) Oil ring - mm ( - in) Max. limit of ring gap: mm ( 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

SEMC

and piston rings.


Refer to S.D.S.

EM

CYLINDER BLOCK Inspection (Cont'd)


CONNECTING ROD BEND AND TORSION Bend: Limit mm ( in) per mm ( in) length Torsion: Limit mm ( in) per mm ( in) length If it exceeds the limit, replace connecting rod assembly.
SEMB

Measuring points

Distortion: Less than mm (

in)

CYLINDER BLOCK DISTORTION AND WEAR 1. Clean upper face of cylinder block and measure the distortion. Limit: mm ( in) 2. If out of specification, arenaqq.us The resurfacing limit is determined by cylinder head resurfacing in engine. Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing is "B" The maximum limit is as follows: A + B = mm ( in) Nominal cylinder block height from crankshaft center: ( - in) mm 3. If necessary, replace cylinder block.

SEMC

-_N O!CD""
MM

ffi
,
I I I

ON '00
I I I

. . ~.

N CD

, ,

Unit: mm (in)

PISTON-TO-BORE CLEARANCE 1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. Standard inner diameter: - mm ( - in) Wear limit: mm ( in) Out-of-round (X-V) limit: mm ( in) Taper (A-B) limit: mm ( 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.

EM

CYLINDER BLOCK

.
Q
Front
SEMC

Inspection

(Cont'd)

If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block upper surface.

3. Measure piston skirt diameter. Piston diameter" A": Refer to S.D.S. Measuring point "a" (Distance from the top): 52 mm ( in) 4. Check that piston-to-bore clearance is within specification.
a

Piston-to-bore clearance "B": . - mm ( - in)

SEMC

5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to S.D.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 C: Honing allowance mm ( 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 mm ( in) or so in diameter at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

A B

CRANKSHAFT cracks. 2. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X-Y): Main journal Less than mm ( in) Crank pin Less than mm ( in) Taper (A-B): Main journal Less than mm ( in) Crank pin Less than mm ( in) EM

1. Check crankshaft main and pin journals for score, wear or

x
y
Taper: Out-of-round: A- B X- Y SEMA

CYLINDER BLOCK Inspection (Cont'd)


3. Measure crankshaft runout. Runout (Total indicator reading): Less than mm ( in)

BEARING

CLEARANCE

Method A (Using bore gauge and micrometer) Main bearing 1. Set main bearings in their proper positions on cylinder block and main bearing cap.

SEMC

2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. Refer to "Assembly". 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: - mm ( - in) Limit: mm ( 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 fillet roll is more than the specified limit. "L": mm ( In) b. Refer to S.D.S. for grinding crankshaft and available service parts.

SEM

EM

CYLINDER BLOCK Inspection (Cont'd)


0 0

,Q

rg
Front

bl

roJ

[5j

rd

8. ;If crankshaft is reused, measure main bearing clearance and select thickness of main bearing. If crankshaft is replaced with a new one, it is necessary to select thickness of main bearings as follows: a. Grade number of each cylinder block main journal is punched on the respective cylinder block.

SEMC

Journal grade number

b. Grade number of each crankshaft main journal is punched on crankshaft.

SEMC

c. Select main bearing with suitable thickness according to the following table. Main bearing grade number:

Crankshaft journal grade number 0

0 1

1 2 3

2 3 4

For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 =3

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.

EM

CYLINDER BLOCK Inspection (Cont'd)


4. Measure outer diameter "Dp" of each crankshaft pin journal. 5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C Dp Standard: ' - mm ( - in) Limit: mm ( 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. Refer to step 7 of "BEARING CLEARANCE - Main bearing".

8.

If crankshaft is replaced with a new one, select connecting bearing according to the following table.

rod

Connecting rod bearing grade number: Crank pin


grade number 0
SEMB

Connecting rod bearing grade number 0

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 a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained.

. .

EM

CONNECTING ROD BUSHING CLEARANCE (Small end) 1. Measure inner diameter "c" of bushing.

SEMB

EM

CYLINDER BLOCK Inspection (Cont'd)


2. Measure outer diameter "Dp" of piston pin. 3. Calculate connecting rod bearing clearance.

C - Dp = - mm ( - in) (Standard)


mm ( in) (Limit) If it exceeds the limit, replace connecting and/or piston set with pin.
Micrometer SEMA

rod assembly

REPLACEMENT

OF CONNECTING

ROD

BUSHING

(Small end) 1. Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes. 2. After driving in small end bushing, ream the bushing so that clearance between small end bushing and piston pin is specified valve. Clearance between small end bushing and piston pin: - mm ( - in)
SEMA

FLYWHEEL/DRIVE

PLATE RUNOUT

Runout (Total indicator reading): Flywheel (M/T model) Less than mm ( in) Drive plate (A/T model) Less than mm ( in)

SEM C

Dial gauge

Assembly PISTON 1. Install new snap ring on one side of piston pin hole.

SEMB

2. Heat piston to 60 to lOoC ( to F) 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.

Cylinder number
SEMC

EM

CYLINDER BLOCK Assembly (Cont'd)

KV (

EM

3. Set piston rings as shown.


p~markSide
1""""-

,'"

g;r

'

rn

SEMC Oil ring

expander

..
Front

*
i?

V-

~ -""'-.) K'

.8

8 Top ring

upper rail

Ojl ring

/"')

!/ "~

Oil ring

lower rail
SEM

CRANKSHAFT

~~
t2
Front

1. Set main bearings in their proper positions on cylinder block and main bearing beam. Confirm that correct main bearings are used. Refer to "Inspection" of this section.

~ ~~:O.5 50 ~ ~
No.3 No.1 No.2
SEM44BC

2. Install crankshaft and main bearing beam and tighten bolts to the specified torque. Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction. '. Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.

. . .

EM

CYLINDER BLOCK Assembly (Cont'd)


3. Measure crankshaft end play.
Crankshaft end play: Standard - mm ( - in) Limit mm ( in) If beyond the limit, replace bearing with a new one.

4. Install connecting rod bearings in connecting rods and

J
SEMB

. connecting rod caps. bearings are used. Confirm that correct Refer to "Inspection". . Install bearings so that oil hole in connecting oil hole of bearing.

rod aligns with

5. Install pistons with connecting rods. a. Install them into corresponding cylinders with Tool. Be careful not to scratch cylinder wall 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 arenaqq.us torqu~. . Connecting rod bearing nut: (1) Tighten to 14 to 16 N.m ( to kg-m, 10 to 12 ft-Ib). (2) Tighten bolts 60 to 65 degrees clockwise with an angle wrench, or if an angle wrench is not available, tighten them to 38 to 44 N.m ( to kg-m, 28 to 33 ft-Ib).
6. Measure connecting rod side clearance. Connecting rod side clearance: Standard

- mm (

-

in)

Limit mm ( in) If beyond the limit, replace connecting rod and/or crankshaft.

EM

CYLINDER

BLOCK

ST (J) or su itable tool

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).

Crankshaft side

..

M/T

A/T
SEMB

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
Engine model Cylinder arrangement Displacement Bore x stroke Valve arrangement Firing order Number of piston rings Compression Oil Number of main bearings Compression ratio cm' (cu in) mm (in) KA24E 4, in-line 2, () 89 x 96 ( x ) O.H.C.

2 1 5

Unit: kPa (kg/cm2 ,psi)/rpm Compression pressure Standard Minimum Differential limit between cylinders

1,

(,

) /

(10,)/

98 (, 14)/

EM

SERVICE DATA AND SPECIFICATIONS

(S.D.S.)

Inspection and Adjustment


CYLINDER BLOCK
10 ()

60 ()

() H

SEMC Unit: mm (in)

Standard Distortion
Grade 1 Inner diameter Cylinder bore Out-of-round (X-V) Taper (A-B) Difference in inner diameter between cylinders Piston-to-cylinder clearance Cylinder block height (From crankshaft cented
* Wear limit ** Total amount of cylinder head resurfacing and cylinder block resurfacing

Limit ()

- ( - ) - ( - ) - ( - ) Less than ) Less than () Less than () - ( - ) - ( - ) Grade 2 Grade 3

()*

()

()**

CYLINDER

HEAD
Unit: mm (in)

Standard Height (H) Surface distortion


* Total amount resurfacing of cylinder

Limit )* ()


and cylinder block

- ( - ) ()


head resurfacing

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.)


VALVE GUIDE

Inspection and Adjustment (Cont'd)

tL

SEM B SEMC Unit: mm (in)

Standard Intake
Length (L) ()

Service Exhaust
()

Limit Exhaust
()

Intake
()

Outer diameter (D) Inner diameter (d) (Finished size) Cylinder head hole diameter Interference fit Stem to guide clearance Tapping length (Q)

- ( - ) - ( - ) - ( - )

- ( - ) - 8.Q18 ( - ) - ( - )

- ( - ) - ( - ) ( - )

- ( - ) - 8.Q18 ( - ) - ( - )

- ( - )


- ( - ) - ( - )

- ( - ) ()

- ( - )

- ( - )

EM

SERVICE DATA AND SPECIFICATIONS (S.O.S.) Inspection and Adjustment (Cont'd)

Standard

Service

I
D1

I
D1

SEM

SEM

Unit:

mm (in)

Standard Intake Cylinder head seat recess diameter Valve seat outer diameter (D1 ) - ( - ) - (1 - ) 45 Exhaust - ( - ) - ( ) 45 Intake - ( - ) - ( - ) 45

Service Exhaust - ( - ) - ( - ) 45 ( - )

Face angle (a) Contacting width (W)

-
( - )

-
( - )

-
( - )

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.)


VALVE

Inspection and Adjustment (Cont'd)

T (Margin thickness)

SEMA

Valvehead diameter (D) Valvelength (LI Valvestem diameter (d)

Standard Limit
Unit: mm (in)

In.
Ex.

( )


- ( - )

In.
Ex. In. Ex. In.
Valve face angle (01) Ex. In. Valve head margi n (T) Ex.

()


- ( - ) - ( - )
-

( - ) '


45 30' - ( - )

() - ( - )

VALVE SPRING
Unit: mm (in)

Standard Intake Outer Free height (H) Inner Pressu re N (kg,lb) at height Outer () (, ) at () (,) at () () (, ) at () (, ) at () (,) at () (,) at () () () () Exhaust () Intake -

Limit Exhaust

(, ) at (,) (,) at () () ()

Inner Outer

Out-of-square Inner

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd)


CAMSHAFT AND CAMSHAFT BEARING

..

;#
. DC
EM Unit: mm (in)

SEMA

Standard Cam height (A) Valve lift (h) Wear limit of cam height Camshaft journal to bearing clearance Inner diameter of camshaft bearing - ( - ) ()

limit

() ()

- ( - ) - ( - )

Outer diameter of camshaft journal (D) Camshaft f1Inout Camshaft end play ) a b c Valvetiming (Degreeon crankshaft! d e
f

- ( - )

0 (0 )
- ( - ) 3 57 12 56

()

ROCKER ARM AND ROCKER SHAFT


Unit: mm (in) Rocker arm to shaft clearance - ( - ) - ( - ) - ( - )

Rocker shaft diameter Rocker arm rocker shaft hole diameter

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd)


PISTON, PISTON RING AND PISTON PIN Piston Pistonring
Unit: mm (in)

==
Top

Standard - ( - ) (

limit ()

d
Side clearance 2nd

-

)
-

()

a
Oil

- ( )

()

Top

-
(

- )

()

SEMC Unit: mm (in)

Ring gap

2nd

- - )*1 )*2

)

Grade No.1 Standard Piston skirt diameter (A) Grade No.2 Grade No.3

- ( - ) - ( - ) ( - ) - ( - ) - ( - )

Oil Irail ring)

- (

- )

()

*1: R or T is punched on the ring. *2: N is punched on the ring.

CONNECTING

ROD


Service (Oversize) () ()

Dimension (a) Piston pin hole diameter (d) Piston-to-c:ylinderbore clearance/'

Approximately 52 () - ( )

- ( - ) S


SEMA Unit: mm (in)

Piston pin
Unit: mm (in) Standard Piston pin outer diameter Interference fit of piston pin to piston pin hole limit

==
Center distance IS)

Standard - - )

limit

)
()

()


0 - (0 - ) ( )

()

Bend [per mm ( in)] Torsion


[per mm ( in)] Piston pin bushing inner diameter (d)*
Connecting rod big end iner diameter (D)* Side clearance

-

Piston pin to connecting rod bearingclearance

- )

- - )

- )

)

* Without

bearing

EM

SERVICE DATA AND SPECIFICATIONS


CRANKSHAFT

(S.D.S.)

Inspection and Adjustment (Cont'd)

Out-of-round

@- Ci)

Taper@ .@

~. Om
Op
SEM Unit: mm (in) No.O Main journal diameter (Dm) Grade No.1 No.2 No.O Pin journal diameter (Op) Grade No.1 No.2 Center distance (r) Standard Journal Taper of journal and pin I@ - @] Pin Journal Pin - ( - ) - ( - ) - ( - ) - ( - ) - ( - ) - ( - ) - ( - ) Limit () () () () () ()

\J57
EM

Out-of-round of journal and pin I@ -Ci)] , Runout IT.I.R.] * Free end play Fillet roil
* Total indicator reading

- ( - ) More than ()

BEAR ING CLEARANCE


Unit: mm (in)

Standard Main bearing clearance Connecting rod bearing clearance - ( - ) - ( - )

limit ()

()

EM

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd)


AVAILABLE MAIN BEARING Standard
Grade number
0 Thickness mm (in) - - ) - 1 - ) Identification color Black Brown Green Yellow Blue 2

AVAILABLE CONNECTING ROD BEARING


Standard
Grade number
0 Thickness mm (in) 1 - ( - ) - ( - ) - - ) Brown Green
Identification color

2 3
4

- 1 - ) - - ) - - )

Undersize (service)
Unit: mm (in) Thickness Crank pin journal diameter "Dp"

Undersize

(service)
Unit: mm (in) Thickness
Mein journal diameter "Dm" ) () - ( - ) - 1 - ) - - )

)

- )

Grind so that bearing clearance is the specified value.

Grind so that bearing clearance is the specified value.

)

MISCELLANEOUS

COMPONENTS
Unit: mm (in)

Camshaft sprocket runout [T.I.R.] * Flywheel runout Drive plate runout


* Total indicator [T.I.R.] [T.I.R.] reading * *

less than () less than ()


less than )

EM

ENGINE LUBRICATION & COOLING SYSTEMS


I

SECTION

LC
; lC- 2
,.. lC- 3
lClC

CONTENTS
PREPARATION


."..
""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''"""''''''''''''''''''''''''''''''''
''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

ENGINElUBRICATION SYSTEM "


ENGINE COOLING SYSTEM CONDENSER FAN MOTOR ELECTRICAL CIRCUIT SERVICE DATA AND SPECIFICATIONS (S.O.S.)

""

lC

PREPARATION
SPECIAL SERVICE TOOLS
Tool number (Kent-Moore No.) Tool name ST (J ) Oil pressure gauge

Description

U!!

ST (J) Hose

EG
(

a
[j

Adapting oil pressure gauge to cylinder block

Radiator cap tester adapter

Adapting radiator cap tester to radiator filler neck

LC-2

+

Oil gallery in cylinder block By-passpassage Intermittently oiling portion


0 iI passage

--

--

<i=

Pump drive gear

r0-

O I
W

Hydraulic valve lifter


I

Cam ;Urlace I

'" r

(') co I\)
:r>

ENGINE LUBRICATION SYSTEM Oil Pressure Check


WARNING: Be careful not to burn yourself, as the engine and may hoL / pressure check should be done in "Neutral" gear position.

. .

1. Check oil level. 2. Remove oil pressure switch.

3. Install pressure gauge. 4. Start engine and warm it up to normal operating temperature. 5. Check oil pressure with engine running under no-load.
ST (J)

Engine rpm

Approximate discharge pressure kPa (kg/cm2, psi) More than 78 (, 11) (,)

Idle speed 3,


SLC

If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.

LC-4

ENGINE LUBRICATION SYSTEM Oil Pump


\
Drive spindle

~tOJ

6. 10 ( - ,)
body Gasket

> /pump

tOJ:

N.m (kg-m, ft-Ib) SLC

.
.

iT.

~~1~
Punchmark
Oil

~AU) ~~"4A

Always replace with new oil seal and gasket. When removing oil pump, turn crankshaft so that No.1 piston is at T.D.C. on its compression stroke. When installing oil pump, align punchmark on drive spindle and oil hole on oil pump.

hole

Front

~
REGULATOR VALVE INSPECTION

1. Visually inspect components for wear and damage. 2. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump assembly.

EL

LC-5

ENGINE LUBRICATION SYSTEM


OIL PRESSURE RELIEF VALVE INSPECTION Inspect oil pressure relief valve for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove valve by prying it out with suitable tool. Install a new valve in place by tapping it.

Oil Pump (Cont'd)

OIL PUMP INSPECTION


CD

Using a feeler gauge, check the following clearance.


Unit: mm (in)

Rotor

tip clearance CD

Less than ()

Outer rotor to body clearance

- ( - ) - ( - )

Side clearance (with gasket) CID

If it exceeds the limit, replace gear set or entire oil pump assembly.

SLC

LC-6

ENGINE COOLING SYSTEM Cooling Circuit

Thermostat: Thermostat:

Open Closed

Radiator

Intake man ifold

Thermostat

SLCA

System Check
WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. CHECKING COOLING SYSTEM HOSES

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

LC-7

ENGINE COOLING SYSTEM


System Check (Cont'd) CHECKING COOLING SYSTEM FOR lEAKS To check for leakage. apply pressure to the cooling system with a tester. Testing pressure: 98 kPa ( kg/cm2, 14 psi)
CAUTION:

Higher than the specified pressure may cause radiator damage.


SMAA

CHECKING RADIATORCAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure:
78

- 98 kPa ( - kg/cm2,11 - 14 psi)

SLC

Water Pump

~
::~~~.~.~.m~

12'~'
\

~',P/

)!!7

.
SLCA

INSPECTION Check for excessive end play and rough operation.

(f

SLC

INSTAllATION Remove liquid gasket from mating surface of pump housing using a scraper.

. . .

Be sure liquid gasket in grooves Is also removed.

Remove liquid gasket from mating surface of cylinder block. Clean all traces of liquid gasket using white gasoline.

SLCA

LC-8

ENGINE COOLING SYSTEM Water Pump (Cont'd)

. .

Cut off tip of nozzle of liquid gasket tube at point shown in figure. Use Genuine Liquid Gasket or equivalent.

Cut here.

~
KP Diameter of liquid gasket: mm in)

]
SLC

of pump housing as shown. a. Be sure diameter of liquid gasket Is within to mm ( to In) dla. range. b. Attach pump housing to cylinder block within five minutes of applying liquid gasket. c. After Installing pump housing, walt at least 30 minutes before starting engine.

Apply a continuous bead of liquid gasket to mating surface

SLCA

Thermostat INSPECTION 1. Check for valve seating condition at ordinary temperatures. It should arenaqq.usly.

Water inlet
SLCA

Upward

A~

~~

2. Check valve opening

temperature and maximum valve lift.


() 8/90 (/)

Jiggle valve

Valve opening temperature c (oF) Max. valve lift mmfC (infF)

--~
SLC

3. Then check if valve closes at 5C (9F) below valve opening

temperature.

After Installation, run engine for a few minutes, and check>., for leaks.

SLC

LC-9

ENGINE COOLING SYSTEM Thermostat


INSTAllATION

(Cont'd)

. .

Remove liquid gasket from mating surface of thermostat using a scraper. Similarly, remove liquid gasket from mating surface of cylinder block. Clean all traces of liquid gasket using white gasoline.

SLC

Cut here.

. .
KP()

Cut off tip of nozzle of liquid gasket tube at point shown in figure. Use Genuine LiqLJidGasket or equivalent. ..~

]
SLC

Apply a continuous bead of liquid gasket to mating surface of water inlet. a. Be sure diameter of liquid gasket is within to mm ( to in). b. Attach water inlet to cylinder block within five minutes after applying liquid gasket. c. After installing water inlet, wait at least 30 minutes before refilling coolant and starting engine.

SLC

'( .~

LC -1 0

ENGINE COOLING SYSTEM

Radiator
A/T model only ~3 2 ,

)

7 ~
@I

Automatic transmission

~
~

'~ ~~ . ,""lIlY , )

LJ

~:

N-mIkg-m,ft-lb)

Radiator shroud SLCA

CAUTION: When filling radiator with coolant, refer to MA section.

Cooling Fan
DISASSEMBLY AND ASSEMBLY

-~

'\"

Fan

<1( L-.J

~:

N'm (lrg-m;ft-Ibl
SLC

\~ ~o.~~ ,)

INSPECTION Check fan coupling for rough operation, oil leakage or bent bimetal.

SLC

LC

I GNITI ON SWITCH ON or- START

I GNI TI ON SWITCH ACC or- ON

BATTERY fus Ib I e

FUSE

@D~
36

AIR RELAY

CONDI TI ON

r(")
I ~

t'1 P P
!fI

11 41 THERMOSWITCH

n a z -I a r c z -I

To ther-mo

contro

I amp.

M
41
-=

CONDENSER FAN MOTOR

36

@4Ib

0
!II r 0 I\,) w m

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT Wiring Diagram


AIR Green) Ie IlnkI GNITI ON SWI TCH ACC or ON

=
(Sub-h arness) CONNECTOR-ll

~ -

CONDENSER F AN MOTOR

@)

lR;l ~ 't1H
~ "
I ~::;CD

Ii [!t

L/OR

~ mIi]
y..>r;;;,

@
S. M. J.

Ii]

~
<ff~
'"
CD

I
IGNITION ON or SWITCH START

UP

[Refer to (Fo Idout


(Eng i ne harness) room L/OR

last page page). J


L/OR

CONNECTOR-I

~13Id
~

~CD

0
>-

G
~

FUSE BLOCK (Refer to pPOWER SUPPL Y ROUTINGp In EL section.)

@)

(Main harness)

[!t

lBIB@
~

[EttBr;;--,
r--

@l@)

(E. F. I. harness)

1i
BODY GROUND

, '" ,

>I

'" '"

,, CD) , ,

To thermo

contro

I amp.

'"

E. ~ ~ S (Refer to

CONTROL UNIT EF&EC sect Ion. )

SLCA

SLCA

LC

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT

Trouble Diagnosis

@i5
'+ L

00
-

Even though air conditioner operates normally under high engine temperature conditions [above 9SoC (20SoF)] the condenser fan motor does not rotate.

m
CHECK CONDENSER FAN MOTOR. 1) Turn ignition and air conditioner switch "OFF". 2) Disconnect condenser fan motor harness connector-I. 3) Check continuity between connector-H terminal @ and connector-I terminal @. Continuity should exist. If N.G. replace condenser fan motor-. O.K. [!] CHECK GROUND CIRCUIT. Check harness continuity between motor harness connector-I terminal @ and ground. Continuity should exist. If N.G., repair harness.


m
_MEeT

-= SLCA

Iu

CHECK POWER SUPPLY (Motor side). 1) Disconnect condenser fan motor harness connector-H. 2) Turn ignition switch, air conditioner switch and blower switch "ON". 3) Check voltage between fan motor harness connector-II terminal @ and ground. Battery voltage should exist.

O.K.

[ill

iJ
SLCA

N.G.

Ii
CHECK POWER SUPPLY (Motor side). 1) Turn ignition switch "OFF" 2) Disconnector fan motor harness connector-I. 3) Turn ignition switch "ON". 4) Check voltage between terminal @ and ground. Battery voltage should exist.

[!]

@i5
[]I]

Ii]

O.K.

SLCA

lo.K.
N.G. Repair or replace harness between terminals @ and @.

Ii]

'

CHECK THERMOSWITCH. Check continuity between thermoswitch terminals @ and CD. Condition ContinuitY Above Yes 92 C ( -2OSF) Below No 92 C ( -2OSF)

lu
Ii

DISCONNECT

iii
CHECK POWER SUPPLY (Relay side). 1) Turn ignition "OFF". 2) Disconnect air conditioner relay. 3) Turn ignition "ON". 4) Check voltage between terminals @, @ and ground. Battery voltage should exist. O.K. CHECK RELAY. Refer to HA section. @is

O.K.
Check sub-harness for thermoswitch continuity. If N.G., repair or replace them.

SLCA

@is N.G. L--to

Check the followings: 8 Harness continuity between

terminal @ and battery


terminal. 8 "G" fusible link If N.G. replace them.
I

EB

i5
.

00

Check the followings: 8 Harness continuity between

terminal @ and battery


l. N.G. terminal 8 Fuse 8 Ignition switch

EB

00

O.K.
-= SLCA

r Replace relay.

LC

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT Trouble Diagnosis (Cont'd)

iii 34
~ lOK

i5l
0
[it
-=

SLCA

CHECK HARNESS CONTINUITY, 1) Turn ignition switch "OFF", 2) Check continuity between relay harness connector terminal @ and fan motor harness connector-I terminal @. Continuity should exist.

N.G.

Repair or replace harness or connectors between terminals @ and (d) .

[R]

~i5@

SLCA

"-

LC

SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Lubrication System


Oil pressure check
Engine rpm Idle speed Approximate discharge pressure kPa (kg/em' , psi)
More than 78 (, 11)

Oil pump
Unit: mm (in)

Rotor tip clearance Outer rotor to body clearance Side clearance (with gasket)

Less than ()

- ( - ) - ()

(,60

- 70)

Engine Cooling System


Thermostat
Valve opening temperature
Max. valve lift

Radiator
c (OF) (infF) () 8/90 (/) Cap relief pressure Leakage test pressure
78

Unit: kPa (kg/em'

.psi)

mmfc

( - , 11 - 14)


98 (, 14)

lC

/"

ENGINE FUEL & EMISSION -CONTROL SYSTEM

SECTIONEF

&

EC
EF & ECEF & ECEF & ECEF & EC2 3 4 9 EF & EC- 16 EF & EC- 26 EF & EC- 31 EF & EC EF & EC EF & EC EF & EC

CONTENTS
PREPARATION PRECAUTIONS """""""""""""""'"'''''''''''''''''''''''''''''''''''' ENGINE AND EMISSION CONTROL OVERALL SYSTEM ENGINE AND EMISSION CONTROL PARTS DESCRIPTION ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION TROUBLE DIAGNOSES FUEL INJECTION CONTROL SYSTEM INSPECTION EVAPORATIVE EMISSION CONTROL SYSTEM CRANKCASE EMISSION CONTROL SYSTEM SERVICE DATA AND SPECIFICATIONS (S.D.S.)

When you read wiring diagrams: . Read GI section, "HOW TO READ WIRING DIAGRAIVIS". See El section, "POWER SUPPLY ROUTING" for power distribution circuit.

When you perform trouble diagnoses, read GI section, "HOW TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES".

E.C.C.S. Wiring Diagram -

See pull-out following EL section.

PREPARATION
SPECIAL SERVICE TOOL
Tool number (Kent-Moore No.) Tool name EG
( Description

Ignition coil adapter harness

Measuring engine speed

EF & EC-2

PRECAUTIONS
E.C.U. Do not disassemble E.C.C.S. control unit. (E.C.U.) Do not turn diagnosis mode selector forcibly.

. .

. .
.

If a batteryterminalis disconnected, the memory will return to the ROM value. The E.C.C.S.' will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a problem. Do not replace parts because of a slight variation.

Do not apply undue force to mounting bracket. Before connecting or disconnecting E.C.U. connector, make sure red and green LEOs are off after turning ignition key off. Always install the properly specified E.C.U. on car; otherwise, erroneous engine operation may result. Disconnect connector by pulling it (not the harness) straight out. Before connecting connector, make sure all pins are straight.

BATTERY . Always use a 12 volt battery as a power source.

Do not disconnectbattery
cables while the engine is running. Do not reverse polarity of battery when connecting it. Otherwise, E.C.U. and/or injectors may be burned.

INJECTOR Do not disconnect injector har~ ness connectors with engine running. Do not apply battery power directly to injectors; otherwise injectors will be damaged.

WIRELESS EQUIPMENT When installing a C.B. ham radio or a mobile phone, be sure to observe the following, as installation location may affect the electronic control systems. 1) Keep antenna as far as possible away from electronic control units. 2) Keep antenna feeder line more than 20 cm ( in) away from harness of electronic controls. Do not let them run parallel for a long distance. 3) Adjust antenna and feeder line so that standing-wave ratio can be kept smaller. 4) Be sure to ground radio to vehicle body.

. .

FUEL PUMP Do not operate fuel pump when there is no fuel in lines. Do not reuse fuel hose clamps. Tighten fuel hose clamps to the specified torque.

. . . .

E.C.C.S. PARTS HANDLING Handle air flow meter carefully to avoid damage. Do not disassemble air flow meter. Do not clean air flow meter with detergent. . Do not jolt or jar the crank angle sensor.

. . .

~~
WHEN STARTING Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. . Do not rev up engine just prior to shutdown.

. .

SEFH

E.C.C.S. HARNESS HANDLING Securely connect E.C.C.S. harness connectors. A poor connection can cause extremely high voltage to develop in the coil and condenser, resulting in damage to ICs. Keep E.C.C.S. harness at least 10 cm ( in) away from adjacent harnesses, to prevent an E.C.C.S. systerri malfunction due to receiving external noise, degraded operation of ICs, etc. Keep E.C.C's' parts and harnesses dry. Before removing parts, turn off ignition switch and then disconnect battery ground cable.

.
. .

EF & EC-3

ENGINE AND EMISSION CONTROL OVERALL SYSTEM E.C.C.S./Component Parts Location

. Fuelpumprelay

arenaqq.us

Fuel pump

-E.G.R. control valve Exhaust gas temperature sensor (For California model) Pressure regulator Pressure regu lator control solenoid valve

~~b

~
~'iWIW

arenaqq.usl

LA.A. unit

~.~,
Fuel filter

~
~

A'I'V'

I
.

control solenoid valve

0 a

"

Ignition coil and power transistor

Distributor

~~
G

E. .R . control solenoid valve

-.w~ ~~;:~~ ..f


sensor

~.,~. ~"

A;,flowm.'"

Exhaust gas sensor

SEFH

EF & EC-4

E.G.R. control Exhaust gas temperature sensor I. (For California model) \

solenoid valve7

"\

Ignition

switch

Throttle valve

: r~-L- -'

.sensol 7

m
m (")
I C1I

"TI J20
\

Crank angle sensor built-in distributor

lFuel pressure regulator I'.


!.. Engine

Transmission

temperatu re sensor

\'1'
\.Spark \1 plug '11

C.

lSJ

Vehicle speed sensor Exhaust gas sensor

~
Q:

Carbon canister

A.I.V. control solenoid valve A.I.V. Intake air flow

Air flow me

en m

Exhaustgasflow

'"
:I

"TI

ENGINE AND EMISSION CONTROL OVERALL SYSTEM System Chart


.1
I

E.C.C.S. CONTROL SYSTEM


I

r
Fuel injection & mixture ratio control
Injectors

Crankanglesensor

Air flow meter

.
Ignition timing control Power transistor

Engine temperature sensor

Exhaust gas sensor

Idle speed control

Auxiliary air control (arenaqq.us valve

Ignition switch

.
A.I.V. control

A:I.V. control solenoid valve

Starter switch

.
. .
~

E.G.R. control & Canister control

E.G.R. control solenoid valve

Idle switch

Throttle sensor

E.C.C.S.
control unit
,"

Fuel pump control

Fuel pump

"
[

Air conditioner switch

.~ Air regulator control

Air regulator

Neutral switch (M/T) Inhibitor switch (AiT) Acceleration cut control Air conditioner relay

Vehicle speed sensor

Power steering oil pressure switch

S.C.V. (Swirl control valve)control

S.C.V. control solenoid valve

Battery

Exhaust gas sensor monitor & self-diagnosis

Inspection lamps (On the control unit)

Exhaust gas temperature sensor (For California model)

Pressu re regu lator control

Pressu re regulator control solenoid valve

Fail-safe function

. Air flowmeter . Throttle sensor . Enginetemperaturesensor

EF & EC-6

ENGINE AND EMISSION CONTROL OVERALL SYSTEM Vacuum Hose Drawing


@
-@-a s.c. V. actuator

@-b
E.G.R. control valve

~TWI~ @ @

Air regurator

tJi)
@ ./"'1
Canister

@/
1

Vacuum tubes-1 Air duct

SEFH

EF 8r. EC- 7

FUSIBLE LINK

-c8J-

I GNITION SWITCH OFFACCON ST


(

( ( FUSE Jrs}
34

Ij/]

CK

CONNECTOR

'/ CHECK LI GHT C ENGINE@


5 24 25 46 I

r<"7I
NJ. NlOR

E. C. C. S. RELAY
<t ::BA TTERY

No.2
No.3

= =

10 I

CONTROL
SOLENOID

PRESSURE

REGULATOR VALVE


IDS

rm J>r -<

4 47

E. G. R. CONTROL SOLENOID VALVE A. 1. V. CONTROL SOLENOID VALVE S. C. V. CONTROL SOLENOID VALVE A. A. C. VALVE LT LJ

"U :[ :] c ::I "U

lIB;
!:
J

No. 4r= L

SWITCH I NHI BIT

12


[Tl <

LJ LJ
AIR REGULATOR FUELLJ

METER
I

AI R FLOW

r T
I
I

>--

m
." f20

To tachometer

gAUST
::SENSOR

mm-

I "

16 17 39 48 19

I NHI B RELAY r-=

3
I

>J >J
en

--<
45
43 44

PUMP

M
THROTTLE
VALVE
SWITCH

I NHIB RELA

-=

m
(")
I

RESISTOR

{O
I

PDWER

TRANSISTOR

6
13

co

I GNITI ON COIL

DISTRIBUTOR

W
CONDENSER 3D 31 11

Z -i ;0 0 r c Z -i

("") 0

5TH POSITION SWITCH


POWER STEERING OIL PRESSURE

SWI TCH 33 35 41


II

<::,FULL -v 'Q IDLE

NEUTR

' SWITC


18

ENGINE TEMPERATURE
SENSOR EXHAUS T GAS

coco- co-

co- co-

SPARK PLUG

: :

For
A/T

Cal ifornla
model

ANGLE SENSOR

CRANK
For U. S. A.

$
( MJ

tt

22 4D

- __n_--_nn _n--_--_--_

SENSOR C TEMPERA@URE

2D @:
37

THROTTLE

.HEAD-U DISPLA UNIT

f
r

SENSOR

CONT

M/T model

@:

For

Canada
lIS 28

32

1 I I
A/T UNIT CONTR&L

: A/T modeI wi th A.S. C.D. : A/T mode I without (/) m " w 0
:x:

A.S. C.D.

I
With heaa-up display

Without

head-up

display

'--

SENSOR

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION E.C.C.S. Control Unit (E.C.U.)
The EC.U. consists of a microcomputer, inspection lamps, a. diagnostic mode selector, and connectors for signal input and output and for power supply. The unit controls the engine.

Crank Angle Sensor


The crank angle sensor is a basic component of the entire EC.C.S. It monitors engine speed and piston position, and sends signals to the E.C.U. to control fuel injection, ignition timing and other functions. The crank angle sensor has a rotor plate and a wave-forming circuit. The rotor plate has slits for 10 signal and 4 slits for signal. Light Emitting Diodes (arenaqq.us) and photo diodes are built in the wave-forming circuit. When the rotor plate passes between the L.E.D. and the photo diode, the slits in the rotor plate continually cut the light being transmitted to the photo diode from the arenaqq.us This generates rough-shaped pulses which are converted into on-off signals by the wave-forming circuit, which are then sent to the E.C.U.

Photo Wave forming SEFB

diode circuit Rotor plate

signal slit for No.1 cylinder

Rotor plate

SEFB

Air Flow Meter


Battery sou rce Output voltage Ground

A Air flow meter B c

16 E.C.C.S. 17 control unit

SEFH
Temperature compensation

resistor

.. r-f
RH;:~-Hot wire

The air flow meter measures the mass flow rate of intake air. Measurements are made so that the control circuit will emit an electrical output signal corresponding to the amount of heat dissipated from a hot wire placed in the stream of intake air. The airflow past the hot wire removes the heat from the hot wire. The temperature of the hot wire is very sensitive to the mass flow rate. The higher the temperature of the hot wire, the greater its resistance value. This temperature change (resistance) is determined by the mass air flow rate. The control circuit accurately regulates current (I) in relation to the varying resistance value (RH) so that VA always equals VB. The air flow meter transmits a voltage value VA to the control unit where the output is converted into an intake air signal.

RH RK RA. RB

: Hot wire resistance : Temperature compensation resistance : Constant resistance SEFB

EF & EC-9

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION


Engine Temperature Sensor
The engine temperature sensor detects the engine temperature, which is dependent on engine coolant temperature, and transmits a signal to the E.C.U. The temperature sensing unit employs a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise.

Throttle Sensor & Soft/Hard Idle Switch


The throttle sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms the throttle valve position into output voltage, and emits the voltage signal to the E.C.U. In addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal to the E.C.U. Idle position of the throttle valve is determined by the E.C.U. receiving the signal from the throttle sensor. This system is called "soft idle switch" and controls engine operation such as fuel cut. On the other hand, "hard idle switch", which is built in the throttle sensor unit, is used not for engine control but for self-diagnosis.

SEFD

>
Not used

~
:5 ~ 0

~
~

.,' 3 )

switch)

(Full throttle

Supply voltage: 5V (Applied between

terminal

NO.4 and 6)

Output voltage between terminal NO.4 and 5

Idle switch Throttle sensor

~
.

6}

~ '" ! '" -0

f

~
5

9" 0

g "

45 90 Throttle valve opening angle (deg)

SEFD

Fuel Injector
The fuel injector is a small, elaborate solenoid valve. As the E.C.U. sends injection signals to the injector, the coil in the injector pulls the needle valve back and fuel is released ,into the intake manifold through the nozzle. The injected fuel is controlled by the E.C.U. in terms of injection pulse duration. Brass wire is used in the injector coil and thus the resistance is higher than a conventional injector.
SEFH

EF &. EC

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

0 vacuum manifold Intake


Air chamber

Pressure Regulator
The pressure regulator maintains the fuel pressure at kPa ( kg/cm2, 43,4 psi). Since the injected fuel amount depends on injection pulse duration, it is necessary to maintain the pressure at the above value.

Fuel chamber To fuel tank Q

Fuel return from injector

SEF

Exhaust Gas Sensor


Louver

Holder

Connector Isolation bushing Contact plate


SECA

?:
;; '" 0> ~ 0
C.

The exhaust gas sensor, which is placed into the exhaust manifold, monitors the amount of oxygen in the exhaust gas. The sensor has a closed-end tube made of ceramic zirconia. The outer surface of the tube is exposed to exhaust gas, and the inner surface to atmosphere. The zirconia of the tube compares the oxygen density of exhaust gas with that of atmosphere, and generates electricity. In order to improve the generating power of the zirconia, its tube is coated with pratinum. The voltage is approximately 1V in a richer condition of the mixture ratio than the ideal air-fuel ratio, while approximately OV in leaner conditions. The radical change from 1V to OV occurs at around the ideal mixture ratio. In this way, the exhaust gas sensor detects the amount of oxygen in the exhaust gas and sends the signal of approximately 1V or OV to the E.C.U.

> :J

8 0I
Rich

~ I
Ideal ratio Mixture ratio --Lean SEFD

Outlet 0

Fuel Pump
Fuel damper

The fuel pump with a fuel damper is a submergible type, and are located in the fuel tank.

Motor

1) Inlet

SEFC

Power Transistor
The ignition signal from the E.C.U. is amplified by the power transistor, which turns the ignition coil primary circuit on and off, inducing the proper high voltage in the secondary circuit. The ignition coil is a small, molded type.

SEFH

EF & EC

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION Air Regulator


-

The air regulator provides an air by-pass when the engine is cold for a fast idle during warm-up. A bimetal, heater and rotary shutter are built into the air regulator. When the bimetal temperature is low, the air by-pass port opens. As the engine starts and electric current flows through a heater, the bimetal begins to turn the shutter to close the by-pass port. The air passage remains closed until the engine stops and the bimetal temperature drops.
SEFB

Idle Air Adjusting (I.A.A.) Unit


Idle adjusting screw

The I.A.A. unit is made up of the AA.C. valve, F.I.C.D. solenoid valve and idle adjust screw. It receives the signal from the E.C.U. and controls the idle speed at the preset value. The F.I.C.D. solenoid valve compensates for changes in idle speed caused by the operation of. the air compressor. A vaCl/um control valve is also installed in this unit to prevent an abnd'rmal rise in intake manifold vacuum pressure during deceleratton.
SEFH

Auxiliary Air Control (A.A. C.) Valve


The E.C.U. actuates the A.A.C. valve by an ON/OFF pulse. The longer that ON pulse is received, the larger the amount- of air that will flow through the A.A.C. valve.

Air SEFE

Power Steering Oil Pressure Switch


The power steering oil pressure switch is attached to the power steering high-pressure tube and detects the power steering load, sending the load signal to the E.C.U. The E.C.U. then sends the idle-up signal to the I.S.C. valve.

SEFH

Magnetic

line

Vehicle Speed Sensor


Reed
(sS
I
//

\ /'
~SWitch N S

Reed
N

N) switch M;;Qnetic \ I. me I

Fieldplate

0 : G

The vehicle speed sensor provides a vehicle speed signal to the E.C.U. The speed sensor consists of a reed switch, which is installed on the transmission unit and transforms vehicle speed into a pulse signal.

"{

t;\

y-/
SEFB

Fieldplate

EF & EC

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

E.G.R. Control Valve


The E.G.R. control valve controls the quantity of exhaust gas to. be led to the intake manifold through vertical movement of the taper valve connected to the diaphragm, to which vacuum is applied in response to the opening of the throttle valve.

SEFB

To E.G.A. control valve Air filter

B.P.T. Valve
Vacuum signal source

".'.1' ~~~'ff'

The B.P.T. valve monitors exhaust pressure to activate' the diaphragm, controlling throttle chamber vacuum applied to the E.G.R. control valve. In other words, recirculated exhaust gas is controlled in response to positioning of the E.G.R. control valve or to engine operation.

t
Exhaust pressure
ECA

Air Induction Valve (AJ.V.)


The air induction valve sends secondary air to the exhaust manifold, using a vacuum created by exhaust pulsation in the exhaust manifold. When the exhaust pressure is below atmospheric pressure (negative pressure), secondary air is sent to the exhaust manifold. When the exhaust pressure is above atmospheric pressure, the reed valves prevent secondary air from being sent back to the air cleaner.
SEFH

\.

EF & EC

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION A.I.V. Control Solenoid Valve
The A. LV. control solenoid valve cuts the intake manifold vacuum signal for A.I.V. control. It responses to the ON/OFF signal from the E.C.U: When the solenoid is off, the vacuum signal from the intake manifold is cut. When the control unit sends an ON signal, the coil pulls the plunger downward and feeds the vacuum signal to the A.I.V. control valve.

E.G.R. Control Solenoid Valve


SEFH

The E.G.R. system is controlled only by the E.C.U. At both lowand high-speed engine revolutions, the solenoid valve turns on and accordingly the E.G.R. valve cuts the exhaust gas leading to the intake manifold.

Pressure Regulator (P.R.) Control Solenoid Valve


The solenoid valve responds to the ON/OFF signal from the E.C.U. When it is off, a vacuum signal from the intake manifold is fed into the pressure regulator. When the control unit sends an ON signal, the coil pulls the plunger downward and cuts the

vacuum signal.

S.C.V. Control Solenoid Valve


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Nissan Sx Repair Manual Service

: Nissan NissanNissanSx-Repair-Manual nissannissansx-repair-manual nissan pdf

Open the PDF directly: View PDF PDF.
Page Count:

~.,,-, '. f \ , ~\ '.~«J.. , ,,"'.,. ".' ,- \~. \ , \ , "NI5SAN h \ ) SX - ,'. , / .. . , . t":"', V -~ .~ SERVICE< MANUAL " " \, ~ QUICK REFERENCE INDEX NISSAN j 24DSX MODEL - S13 SERIES . GENERALINFORMATION GI MAINTENANCE MA ENGINEMECHANICAL EM ENGINELUBRICATION & COOLING SYSTEMS- LC ENGINEFUEL& EMISSIONCONTROL SYSTEM- EF ENGINECONTROL, FUEL& EXHAUST SYSTEM- FE CLUTCH CL MANUALTRANSMISSION MT AUTOMATIC TRANSMISSION AT PROPELLER SHAFT& DIFFERENTIAL CARRIER- PD FRONTAXLE& FRONTSUSPENSION FA REARAXLE& REARSUSPENSION RA BRAKESYSTEM SR STEERING SYSTEM ST BODY SF HEATER & AIRCONDITIONER HA ELECTRICAL SYSTEM EL , cg NISSAN MOTOR CO., LTD. Printed in U.S.A. Not to be reproduced in who~e or in part without the prior written permission of Ni~n .. <"" Motor Company Ltd., Tokyo, Japan. &EC FOREWORD This manual contains maintenance and repair procedures for the Nissan SX. In order to assure your safety and the efficient functioning of the vehicle, this manusl should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at a~y time without notice. IMPORTANT SAFETYNOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, 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 jeopardiz~d by the service method selected. . NISSAN MOTORCo.,LTD. Overseas Service Department Tokyo, Japan . GENERAL INFORMATION I GI SECTION CONTENTS PRECAUTIONS GI- 2 HOW TO USE THIS MANUAL GI- 5 HOW TO READ WIRING DIAGRAMS ~ GI- 7 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES GI IDENTIFICATION INFORMATION GI """'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' LIFTING POINTS AND TOW TRUCK TOWING GI TIGHTENING TORQUE OF STANDARD BOLTS GI - PRECAUTIONS Observe the following precautions ~o ensure safe and proper servicing. 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 inflammable 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. SGI 2. Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. SGI 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. SGI 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. SGI GI-2 PRECAUTIONS 6. Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint. SGI 7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set. Arrange the disassembled parts in accordance with their assembled locations and sequence. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. Use only the lubricants specified in MA section. Use approved bonding agent, sealants or their equivalents when required. Use tools and recommended special tools where specified for safe and efficient service repairs. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. Precautions for E.F.I. or E.C.C.S. Engine SGI 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 eliminate danger. 3. Be careful not to jar components such as control unit and air flow meter. GI-3 PRECAUTIONS Precautions for Catalyst Clean floor SG 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 compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on inflammable material. Keep inflammable material off the exhaust pipe. Precautions for Fuel Unleaded gasoline of at least 87 AKI number (RON 91) GI-4 HOW TO USE THIS MANUAL 1. A QUICK REFERENCE INDEX, a black tab (arenaqq.us18) 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. 2. THE CONTENTS are listed on the first page of each section. 3. THE TITLE is indicated on the upper portion of each page and shows the part or system. 4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. "BR-5"). 5. THE lARGE IllUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. "Example" Pad retainer r;~'~ Torque member ~ ~ ~ ,/I J~ ~ 5~ ~ ~. ::;:; / . Pin boot r- Main pin IE! to sliding portion / Outer shim SBRA 6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary. 7. The followings SYMBOLS AND ABBREVIATIONS are used: ~ E1I ~ rJ ~ ~ EaI~ @> : "f:l : * S.O.S. L.H., R.H. . Tightening torque Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. Should be lubricated with oil. Sealing point Checking point Always replace after every disassembly. Apply petroleum jelly. Apply A.T.F. Select with proper thickness. Adjustment is required. Service Data and Specifications Left-Hand, Right-Hand GI-5 M/T A/T Tool L.H.D. R.H.D. A.T.F. 0, 02 03 D. 22 2, 12 1, Manual Transaxle/Transmission Automatic Transaxle/Transmission Special Service Tools Left-Hand Drive Right-Hand Drive Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear ",. HOW TO USE THIS MANUAL 8. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. "Example" Tightening torque: 59 - 78 Nom ( - kg-m, 43 - 58 ft-Ib) 9. TROUBLE DIAGNOSES are included in sections dealing with complicated components. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. . . . BOLD TYPED STATEMENTSexcept WARNING and CAUTIONgive you helpfulinformation. GI-6 HOW TO READ WIRING DIAGRAMS ""'= WIRING DIAGRAM Symbols used in WIRING DIAGRAM are shown below: Example CONNECTOR Th is shows that these con nectors white 6 terminal connectors. POWER SUPPLY -This shows the ignition switch position in which the system can be ope rated. - See POWER SUPPLY ROUTING in EL section for the detai led wiring diagram. are BRANCH M/T model n ~ . '-LAMP-! 1m lG~ . ~B~ A/T model ~ . ~ 2 ~~ ~~B-SCLG~ ~ : MfT model @ : AfT model > I I lyw IiliJ ~Whi"~ m G ~ LOCATION NUMBER This number shows where the connector is located. See HARNESS LAYOUT in EL section. The number is identical with the one in HARNESS LAYOUT. I t ABBREVIATIONS ~@! I: ~ l-l SWITCH .rn '""".~ '"" ~ SWITCH This shows that continuity exists between terminals CD and CID, when the switch is turned to ON position. Instrument harness g 'WIRE -b BODY D GROUN ~ COLOR CODING BR B -BI,,' OR W R G Y L P PU GY SB LG ~ ~ ~ ~~ White Red Green Blue Yellow . ~ ~ ~ ~ ~ ~ Brown Orange Pink Purple Gray Sky Blue ht Green ~ Llg . d the base is stripe, . When. the iven wire first, co orfollowe d by the stripe color as IS gshown below: Example: I L/W ~ Blue with Whtte Stripe M: Main harness S G SWITCH POSITIONS Normally open ~~ ~ Normally closed = , 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. .. . ~ SELE GI-7 HOW TO READ WIRING DIAGRAMS CONNECTOR SYMBOLS All connector symbols in wiring diagrams are shown from the terminal side. Example . Connector SG Example EE . M.~ te,m;nal . ~ Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams. G";d'-[~ Connector Connector symbol Female terminal Efj Guide Connector Connector symbol SG MULTIPLESWITCH The continuity of the multiple switch is identified in the switch chart in wiring diagrams. Example WIPER SWITCH Continuity circuit of wiper switch SWITCH POSITION -B/Y -R. -W/B -L/Y CONTINUITY CIRCUIT OFF B E C (f) 1 5 @ 2 -B. INT 3 - 4,5 - 6 LO HI WASH 1 -6 -yo Example: Wiper switch in LO position Continuity circuit: Red wire - @ terminal - CID terminal - Wiperswitch (@ - @: LO) - @ terminal - CD terminal - Black wire SG GI-8 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 STARTING SYSTEM Wiring Diagram W w SUPER MULTIPLE JUNCTION (S.M.J.) arenaqq.us g rnIJ ~ SYSTEM FF Dm3 A"angament Check 0 0 [ ,=fd:0CI~ crhKk 0 - '" ~ ], ,~ r- liJ 0 j ¥ := Super Multiple Junction (S.M.J.) y--R .S.M.J. L--S 't Refer to last page ( (Foldout page). J r-R~ ~B (Main harness) DO L +-+ BR~ (Instrument harness) r-B (Main harness) (Instrument harness) BRl. SELF GI-9 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES m" ( INSPECTION START) ~m -=- SG I iii ~ lu I iii CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". _MECT [ill rill ~ CHECK POWER SUPPLY. Check the following items. 1) Turn ignition switch "ON" .~ [ IN.G. 1) Harness continuity betWeen 2) Check voltage between crank angle sensor and battery. terminal @ and ground. 2) E.C.C.S. relay-1 (See page EF & T~Battery voltage should exist. EC) 3) "BR" fusible link O.K. 2 4) Power source for E.C.U. (See page EF & EC) 5) Ignition switch ~~ 00 2) Disconnect crank angle sensor harness connector. 3) Check resistance betWeen terminal @ and ground. Resistance: Approximately Check the following items. 1) Harness continu ity betWeen crank angle sensor and I N.G~ grou nd 2) Ground circuit for E.C.U. (See page EF & EC) on I SG O.K. NOTICE The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check" or the "Symptom Chart". 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pin Point Check. If you must perform circuit continuity between harness connectors more detail, such as in case of sub harness is used, refer to Wiring Diagram and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be "OFF" . 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as it was. GI HOW TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES HOW TO FOllOW ITJ m THIS FLOW CHART Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. I CHECK POWER SUPPLY. 1) Turn ignition switch "ON". 2) Check Check voltage between terminal @ and ground. Battery voltage should exist. item being performed. Procedure, measurement } steps or results O.K. I2J Measurement results Required results are indicated in bold type in the corresponding block, as shown below. These have the following meanings: Battery voltage ~ 11 14V or approximately 12V Voltage: Approximately OV ~ Less than 1V - ~ Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. For example, symbol m indicated in the left upper portion of each illustration corresponds with the symbol in the flowchart for easy identification. More precisely, the procedure under the "CHECK POWER SUPPLY" outlined previously is indicated by an illustration m . @] Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Example View from terminal side Connector symbol ~ Direction mark ~ View from harness side Connector Connector symbol ~ [it Direction 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. . . ~: View f,om lermlnel side n' r.s. All connector symbols shown from the terminal side are enclosed by a single line. ~: Viewf,omhernessside .n H.S. All connector symbols shown from the harness enclosed by a double line. mark SGI GI side are HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES Key to symbols signifying measurements or procedures Symbol Symbol explanation cT IV CONNECT £) @- 00 00 OOACC F Symbol Symbol explanation Check after disconnecting the connector to be measured. AIC switch Check after connecting the connector to be measured. AIC switch is "ON". Insert key into ignition switch. REC switch is "ON". Turn ignition switch to "OFF" position. REC switch is "OFF". Turn ignition switch to "ON" position. DEF switch is "ON". Turn ignition switch to "START" position. VENT switch is "ON". Turn ignition switch from "OFF" to "ACC" position. Fan switch is "ON". (At any position except for "OFF" position) Turn ignition switch from "ACC" to "OFF" position. Fan switch is "OFF". "cfi Turn ignition switch from "OFF" to "ON" position. OOF 0 trJ Apply battery voltage directly to components. 7 Turn ignition switch from "ON" to "OFF" position. Drive vehicle. Do not start engine,or check Disconnect battery negative cable. with engine stopped. Start engine. or check is "OFF". with engine Depress running. brake pedal. Apply parking brake. Release brake pedal. Release parking brake. Depress accelerator pedal. CffH Check after engine is warmed up sufficiently. Release accelerator pedal. l!V Voltage should be measured with a voltmeter. - La) II CIUIIT foi-- Circuit resistance should be measured with an ohmmeter. € II - Le1J Currentshould be measuredwith an ammeter. GI Pin terminal check for S.M.J. type arenaqq.us AIT control unit connectors. For details regarding the terminal arrangement, refer to the foldout page. ' IDENTIFICATION INFORMATION Model Variation Destination Model Body Transmission Engine Coupe HLS13FU Fastback RHLS13FU Coupe HLS13AU Fastback RHLS13AU Coupe HLS13FV Fastback RHLS13FV Coupe HLS13AV Fastback RHLS13AV Coupe HLS13FN Fastback RHLS13FN Coupe HLS13AN Fastback RHLS13AN Differential carrier FS5W71C Non-California RE4R01A FS5W71C California KA24E R RE4R01A FS5W71 C Canada RE4R01A Prefix and suffix designations: R 0: R : Coope Fastba~ H: KA24E engine L: L.H. drive H L S13 A N (R) L T (R) : With A.B.S. N : Canada V : California U: Non-California A : Automatic transmission F : 0 : means no indication. GI 5-speed manual transmission IDENTIFICATION INFORMATION Identification Number Vehicle identification plate Vehicle identification number (Chassis number) F.M.V certification Vehicle identification label number plate SGI VEHICLE IDENTIFICATION NUMBER ARRANGEMENT IN 1 H S 3 6 P X K W Manufacturer I IT IN 1: N issan passenger vehicle Engine type H: KA24E Vehicle serial number Manufacture plant W: Kyushu Model year K: year model . Vehicle line S: NISSAN SX Check digit (0 to 9 or XI The code for the check digit is determined by mathematical computation. Model change (0 to 91 Body type 4: Coupe 6: Fastback Restraint system S: Standard P: Automatic GI IDENTIFICATION INFORMATION Identification Number (Cont'd) IDENTIFICATION PLATE NISSAN MOTORCO.,LTD. JAPAN ~:it ~i:J ill 1 2 3 4 5 6 7 8 9 CHASSIS NO NO DE CHASIS MODEL .& MOOElO 0 I &" ",-COlOR TRiM f 'Jk COlOR GUMNICION ;,.0 '/;,.0 ENGIN[ MOTOR ;; ';~: ; ~ElE 0 ffi& && CC & & I tf; S jJt ~ ItJ :if[** :it ~ U A MADEINJAPAN Type Vehicle identification number (Chassis numbed Model Body color code Trim color code Engine model Engine displacement Transmission model Axle model SGI ENGINE SERIAL NUMBER KA24E engine TL M MANUAL TRANSMISSION NUMBER AUTOMATIC SGI TRANSMISSION NUMBER SGI GI IDENTIFICATION INFORMATION Dimensions Unit: mm (in) Coupe Fastback Overall length 4, () 4, () Overall width 1, () 1, () Overall height 1, () 1, () Front tread 1, () 1, () Rear tread 1, () 1, () Wheelbase 2, () 2, () Wheels and Tires Road wheel Steel 6-JJx 15 Aluminum 6-JJx 15 Offset Tire size mm (in) 40 () Conventional /60R 15 86H /60R 15 89H * Spare T/70D 15 *: Option GI LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand WARNING: Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat. . . Garage jack points SGI GI LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines. Sill ~ Put the sill in the slit of the lift pad to prevent the sill from deforming. If the pad does not have lift pad // the slit, prepare a suitable attachment with slit. Note: Lift-up points are the same as pantograph jack points. SGI 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. When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral (UN" position). NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated. 'i::ij,iiii.2ii;~1',,,';1tiii:.; -. SG GI LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont'd) TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (With rear wheels on ground) Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. TOWING POINT Alwayspull the cable straightout from the arenaqq.us pull on the hook at a sidewaysangle. Front Rear CE1 DD9M GI TIGHTENINGTORQUE OF STANDARD BOLTS Grade Bolt size Bolt dia- meter* mm Tightening torque (Without lubricant) Pitch mm Hexagon head bolt N.m 4T M6 M8 M10 M12 M14 M6 M8 7T M10 M12 9T 13 9 15 11 13 9 16 12 25 18 29 22 25 19 30 22 42 31 51 38 46 34 56 41 74 54 88 65 10 7 21 15 25 18 22 16 26 20 41 30 48 35 43 32 51 38 71 52 84 62 77 57 92 68 94 M6 12 9 15 11 M8 29 22 35 31 23 37 26 27 59 43 70 51 62 46 74 54 98 72 87 80 M12 M14 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. 4T 7T 9T kg-m M14 M10 Grade ft-Ib Hexagon flange bolt N.m ft-Ib kg-m *: Nominal diameter Mark 4 7 9 M 1 GI 6 """"L- Nominal diameter of bolt threads (Unit: mm) Metric screw threads '..~ MAINTENANCE MA .J SECTION I CONTENTS PERIODIC MAINTENANCE MA- 2 GENERAL MAINTENANCE. MA- 4 RECOMMENDED LUBRICANTS AND FLUIDS MA- 6 ENGINE MAINTENANCE MA- 8 "'"'''''''''''' CHASSIS AND BODY MAINTENANCE SERVICE DATA AND SPECIFICATIONS (S.D.S.) MA :" MA", l1li PERIODIC MAINTENANCE The following charts show the normal maintenance schedule. Under severe driving conditions, additional or more frequent maintenance will be required. Refer to "Maintenance under severe driving conditions". The periodic maintenance schedule is repeated beyond the last mileage and period shown by returning to the first 15, miles (24, km) or 12 months. EMISSION CONTROL SYSTEM MAINTENANCE MAINTENANCE. OPERATION Perform at number of miles, kilometers or months, whichever comes first. Drive belts MAINTENANCE 15 30 INTERVAL 45 60 Miles x 1, (km x 1,) (12) (24) (48) (72) (96) 6 12 24 36 48 1* Months See NOTE (1). Replace every 30, miles (48, km). 1* 1* 1* 1* Air cleaner filter Vapor lines Fuel lines Fuel filter See NOTE (2)*. R Engine coolant Egnine oil R Engine oil filter (Use Nissan PREMIUM R R Then replace every 7, . miles (12, km) or 6 months. Then replace every second oil change. type or equivalent.) Ignition wires MA-8 MA MA MA-9 MA MA-8 MA MA Replace every 30, miles (48, km). Inspect every 3 years. * Spark plugs Reference page MA MA CHASSIS AND BODY MAINTENANCE MAINTENANCE OPERATION Perform at number of miles, kilometers or months, whichever comes first. Miles x 1, 15 (km x 1,) (24) 12 Months Break lines & cables I I I Brake pads & discs Manual and automatic transmission & differential gear oil Steering gear & linkage, and axle & suspension parts Exhaust system MAINTENANCE INTERVAL 30 45 (48) 24 I I I I I (72) 36 I I I 60 Reference page (96) 48 I I I I I MA MA MA,15,16 MA, FA-4,RA-4 MA NOTE: (1) After 60, miles (96, km) or 48 months, inspect every 15, miles (24, km). (2) If vehicle is operated under extremely adverse weather conditions or in arees where ambient temperatures are either extremely low or extremely high, the filters might become clogged. In such an event, replace them immediately. (3) Maintenance items and intervals with "." are recommended by NISSANfor reliable vehicle operation. The owner need not perform such maintenance in order to ~aintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required. Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. MA-2 PERIODIC MAINTENANCE MAINTENANCE UNDER SEVERE DRIVING CONDITIONS The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance is required to. be performed on the following items as shown in the table. Severe driving conditions A - Repeated short trips less than 5 miles (8 km) and outside temperatures remain below freezing B - Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use C - Driving in dusty conditions D - Driving on rough, muddy, or salt spread roads E - Towinga trailer, usinga camper or a car-top carrier Driving condition C ABC A. . A. DE C D E . item Maintenance interval Reference More frequently' MA Engine oil & oil filter R Every 3, miles (5, km) or 3 months MA Every 7, miles (12, km) or 6 months MA Every 30, miles (48, km) or 24 months MA, 15, 16 Brake pads & discs D . Steering gear & linkage, and axle & suspension parts Maintenance operations: operation R Manual and automatic transmission & differential gear oil D E Maintenance Air cleaner filter D E CD. . Maintenance R page MA, FA-4, RA-4 Every 7, miles (12, km) or 6 months Steering linkage ball joints & front suspension ball joints Exhaust system MA,FA-4 MA I = Inspect. Correct or replace if necessary. R = Replace. 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 vehicl~isto continue operating properly. The owners can perform the checks and inspectionsthemselvesor they can have their NISSANdealers do them for a nominal charge. Item Reference page OUTSIDE THE VEHICLE The ma!ntenance 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 excessivewear. 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, km (7, miles.) MA Wheel alignment and balance If the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. MA FA-6 RA-6 Windshieldwiper blades Check for cracks or wear if they do not wipe properly. Doors and engine hood Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate 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 frequently. INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Lights Make sure that the headlights, stop lights, taillights, tUrn signal lights, and other lights are all operating properly and installed securely. Also check headlight aim. MA 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 excessivefree play, hard steering or strange noises. Free play: Lessthan 35 mm ( 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 restrains 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 folding-down rear seatbacks. . Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage. MA-4 MA GENERAL MAINTENANCE Item Reference page Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free travel. CL-5 Brakes Check that the brake does not pull the vehicle to one side when applied. 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. BR-7 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. BR 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.g. each time you check the engine oil or refuel). Windshieldwasher fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant levelwhen the engine is cold. MA-9 Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or loose connections. Brake and clutch fluid levels Makesure that the brake and clutch fluid levelsare between the "MAX" and "MIN" lines on the reservoir. MA,16 Engine drive belts Makesure that no belt is frayed, worn, cracked or oily. MA-8 Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine. MA Power steering fluid level and lines Check the level when the fluid is cold and the engine is turned off. Check the lines for proper attachment, leaks, cracks, etc. MA Automatic transmission fluid level Check the level on the dipstick after putting the selector lever in "P" with the engine idling. MA Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it. MA Underbody The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise 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, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. MA-5 RECOMMENDED LUBRICANTS AND FLUIDS Lubricants and Fluids Capacity (Approximate) Engine oil (Refill) With oil filter Without oil filter Cooling system (with reservoir tank) Reservoir tank Manual transmission Differential oil gear oil Automatic transmission fluid Power steering fluid Recommended lubricants and fluids US measure Imp measure Liter /4 qt /8 qt /8 qt /8 qt /8 qt /8 qt 3/4 qt 5/8 qt /8 pt /4 pt API GL-4*2 /4 pt /4 pt API GL-5*2 /4 qt /4 qt 1 qt 3/4 qt Genuine Nissan Motor Oil*1 or equivalent (Energy Conserving Oils of API SF or SG)*2, *3 Anti-freeze coolant (Ethylene glycol base) Genuine Nissan ATF*1 or equivalent Type DEXRON TM Type DEXRON TM Brake fluid Genuine Nissan Brake Fluid*1 or equivalent DOT 3 (US FMVSS No. ) Multi-purpose grease NLGI No.2 (Lithium soap base) *1: Available in mainland U.S.A. through you Nissan dealer. *2: For further details, see "SAE Viscosity Number". *3: Energy Conserving Oils These oils can be identified by such labels as energy conserving, energy saving, improved fuel economy, etc. MA-6 RECOMMENDED LUBRICANTS AND FLUIDS SAE Viscosity Number Outside Temperature Anticipated ENGINE Outside Temperature Range Anticipated Before Next Oil Change GEAROIL Range Before Next Oil Change OIL . °C",OF ++"'--++86 - +++ +32 +50 ~ -5W T T 10W is preferable if the ambient temperature is above °C (0° F). 20W and 20W are usable if the ambient temperature is above 10°C (50° F) for all seasons. MA-7 8OW is preferable if the ambient temperature is below 40°C (°F). ENGINE MAINTENANCE Power steering oil pump IAJ Water pump lAJQ' l:~:o, I Crank pulley T : Tension checking points IAJ: Adjusting bolts lAJA;,,ood;,;oo", Checking Drive Belts 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: Inspect drive belt deflections when engine is cold. compressor Unit: mm (in) 8MAOO2C Used belt deflection Set deflection of new belt Limit Adjusted deflection. Alternator 11 () ( - ) ( - ) Air conditioner compressor 12 () ( - ) ( Power steering oil pump 13 () ( - ) ( - ) Applied pushing force - ) 98 N (10 kg, 22 Ib) Changing Engine Coolant ~~~ [~O m ~ ~ m .- 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. 8M AOO3C 2. Open drain cock at the bottom of radiator, and remove radiator cap. MA-8 "'. ENGINE MAINTENANCE 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. to;J 44 N.m ( - kg-m, 25 - 33 ft-Ib) L . J - 5. Open air relief plug. . 6. 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. Repeat step 2 through step 9 until clear water begins to drain from radiator. Drain water. Open radiator cap and air relief plug. Fill rafdiator with coolant up to specified level. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity. (With reservoir tank) Q (/8 US qt, /8 Imp qt) Pour coolant through coolant filler neck slowly to allow air in system to escape. MAX. MIN. Close air relief plug. Remove reservoir tank, drain coolant, then clean reservoir tank. Install reservoir tank and fill it with coolant up to "MAX" level and then install radiator cap. Run engine and warm it up sufficiently. Race engine 2 or 3 times under no-load. Stop engine and cool it down, then add coolant as necesary. SMAB Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts. MA-9 ENGINE MAINTENANCE Checking Fuel Lines CAUTION: 3 mm in) , ~--,'-' . (Cont'd) Tightenhigh-pressurerubber hose clamp so that clamp end is 3 mm ( in) from hose end. Ensure that screw does not contact adjacent parts. , --T-+-+--J__J.-_J SMAA Changing Fuel Filter WARNING: Before removing fuel filter, release fuel pressure from fuel line. 1. Remove fuse for fuel pump. 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is 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 shop towel to absorb fuel. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. . . . Whentighteningfuel hose clamps, refer to "CheckingFuel Lines". Changing Air Cleaner Filter The viscous paper type filter does not need cleaning between renewals. MA ENGINE MAINTENANCE Changing Engine Oil WARNING: Be careful not to burn yourself, as the engine Is hot. 1. Warm up engine, and check for oil leakage from engine components. 2. Remove drain plug and oil filler cap. 3. Drain oil and refill with new engine oil. Refill oil capacity (Approximate): ~ Front SMAOO9C Unit: liter (US qt, Imp qt) With oil filter change (/4,/8) Without oil filter change (/8,/8) CAUTION: . Be sure to clean drain plug and Install with new washer. Drain plug: tOJ - 39 N.m . . ( - kg-m, 22 - 29 ft-Ib) Use recommended engine 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. SMAC Changing Oil Filter 1. Remove oil filter with a suitable tool. WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot. 2. Before installing new oil filter, clean the oil filter mounting surface on cylinder block, and coat the rubber seal of oil filter with a little engine oil. ~ SMA MA ENGINE MAINTENANCE Changing Oil Filter (Cont'd) 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. 2/3 of a turn SMAB Changing N.G. O.K. Spark Plugs 1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire. SMA 2. Remove spark plugs with spark plug wrench. Spark plug: Standard type ZFR5D Hot type ZFR4D Cold type ZFR6D R 16mmV1 'arenaqq.us~ SEMA Side electrode iii 3. Check plug gap of each new spark plug. Gap: - mm ( - 0~ in) 4. Install spark plugs. Reconnect ignition wires according to nos. indicated on them. Spark plug: ~ - 29 N.m ( - kg-m, 14 - 22 ft-Ib) SMA 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 kil .If it exceeds the limit, replace the ignition wire with a new one. ~ SMAA MA ENGINE MAINTENANCE Checking Vapor Lines 1. Visually inspect vapor lines for. improper 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 EF & EC section. /" " MA . CHASSIS AND BODY MAINTENANCE Checking Exhaust System . Check exhaust pipes, muffler and mounting for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. SMAA Checking Clutch Fluid Level and Leaks . Max. If fluid level is extremely low, check clutch system for leaks. Min. SMAB Checking M/T Oil 1. Check for oil leakage. , SMAA 2. If leakage is found, check oil level. Never start engine while checking oil level. Filler plug: ~: 25 - 34 N.m ( - kg-m, 18 - 25 ft-Ib) K SMA Changing 1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: Q (/8 US pt, /4 Imp pt) Drain plug: ~: 25 - 34 N.m ( - kg-m, 18 - 25 ft-Ib) ~~~ .,. M/T Oil ~.;. ~"~ SMAA MA CHASSIS AND BODY MAINTENANCE Checking AIT Fluid 1. Check for fluid leakage. . . SMAA . Front side Hot: 50 - aooc ( - °F) Add" 2. If leakage is found, check fluid level. Fluid level should be checked using "HOT" range on dipstick at fluid temperatures of 50 to 80°C ( to °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 °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 overfill. O.K. ~ 3. Check fluid condition. Check fluid for contamination. If fluid is very dark or smells burned, or contains frictional material (clutches, band, etc.), check operation of AlT. Refer to section AT for checking operation of AlT. Check fluid for contamination. SMAB Changing AIT Fluid 1. Drain fluid by removing oil pan. 2. Replace gasket with new one. 3. Refill with fluid and then check fluid level. Oil capacity (With torque converter): Q (/4 US qt, /4 Imp qt) ~ SMAB MA CHASSIS AND BODY MAINTENANCE Checking Differential Gear Oil 1. Check differential carrier for oil leakage. SMAC 2. If leakage is found, check oil level. Filler plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib) - - SMA A Changing ~~ Differential Gear Oil 1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: Q (/4 US pt, /4 Imp pt) Drain plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib) - 0,,;" PI~ - ~ SMAA Checking Brake Fluid Level and Leaks . = If fluid level is extremely low, check brake system for leaks. MAX = MIN Checking Brake Lines and Cables . Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc. SMAA MA CHASSIS AND BaDY MAINTENANCE Checking Disc Brake . Check condition of disc brake components. ROTOR . Check condition and thickness. Unit: mm (in) Front Rear CL22VB CL9H Standard thickness () () Minimum thickness () () Disc brake type SMAA CALIPER . Check operationand for leakage. SMAA PAD Check for wear or damage. . Unit: mm (in) Disc brake type Standard thickness Minimum thickness Front Rear CL22VB CL9H () () () SMAB Balancing . Wheels Adjust wheel balance using road wheel center. Wheel balance (Maximum allowable unbalance at rim flange): Refer to S.D.S. Tire balancing weight: Refer to S.D.S. MA CHASSIS AND BODY MAINTENANCE Tire Rotation FRONT ! 0 . Do not include the T-type spare tire when rotating the tires. Wheel nuts: ~: 98 - N.m ( - kg-m, 72 - 87 ft-Ib) A! 0 SMAB Checking Steering Gear and Linkage STEERING GEAR Check gear housing and boots for looseness, damage or grease leakage. Check connection with steering column for looseness. STEERING LINKAGE Check ball joint, dust cover and other component parts for looseness, wear, damage or grease leakage. . . . . Q : Check grease leakage : Check tightening torque SMA B Checking Power Steering Fluid and Lines SMAB . Check fluid level, when the fluid is cold. . Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. SSTB MA CHASSIS AND BODY MAINTENANCE LUBRICATING LOCKS, HINGES AND HOOD LATCHES Fastback lEI =~~ m m. SMAB CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS CAUTION: 1. AUseat bait arenaqq.us, including retractors and attaching hardwares such as guida rail set, etc" should ba inspacted after any collision. Nin recommends that aUseet bait amblies in use during a collision ba replaced unless the collision was minor and the baits show no damage and continue to operete properly. Seat bait assemblies not in use during a collision should allO ba inspacted and replaced if eithar damage or improper operation is noted. 2. If tha condition of any component of a seat bait is questionable, do not have seat bait repaired, but raplaced as a bait mbly. 3. If wabbing is cut, frayed, or damaged, replace bait assembly. 4. Do not spill drinks, oil, etc. on inner lap bait buckle. Never oil tongue and buckle. 5. Use a NISSAN genuine arenaqq.us bait assembly. ~ Anchor bolt N.m ( - kg-m, 17 - 23 ft-Ib) For automatic seat bait, refer to BF section. Rear seat belt Check function of buckles and tongues when buckled and released. Front seat belt MA SMAOO1C SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Maintenance Spark plug INSPECTION AND ADJUSTMENT Drive belt deflection Unit: mm (in) Used belt deflection Adjusted deflection Limit Alternator Set deflection of new belt 11 () ( - I ( - ) ( - I ( - ) Air conditioner compressor 12 () Power steering oil pump 13 ( 1() ( ) ZFR5D Hot type ZFR4D Cold type ZFR6D Plug gap - mm ( . in) Ignition wire Resistance kS1 TIGHTENING I Applied pushing force Standard type 98 N (10 kg, 22 Ib) N'm kg-m ft-Ib Spark plug 29 - 22 25 - 33 Oil capacity (Refill) Unit: 2 (US qt, Imp qt) (/4,/8) Without (/8,/8) oil filter Coolant capacity Unit: 2 (US qt, Imp qt) With reservoir tank TORQUE Unit Drain plug With oil filter Less than 30 (,/8) MA - Engine block 34 44 Oil pan SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance Brake INSPECTION AND ADJUSTMENT Clutch Unit: mm (in) Unit: mm (in) - () Pedal free height "H" Pedal free play" A" - ( ) Disc brake Pad Standard thickness CL22VB () CL9H () Minimum thickness CL22VB Front axle and front suspension(Unladen)* -1°30' Camber degree Caster degree Toe-in mm (in) to 0° () CL9H 6°00' . ~30' Rotor Standard th ickness CL22VB 0 - 2 (0 - ) (Total toe-in) degree 0' - 12' Kingpin inclination degree 12°30'- 14°00' () () CL9H Minimum thickness CL22VB Front wheel turning angle Full turn Inside/outside d () 39° egree ° /33° () CL9H *: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. () Pedal Free height M/T A/T Rear axle and rear suspension (Unladen)* Camber degree Toe-out mm (in) (Total arenaqq.us) degree -1°36' - ( - ) Free play 1 - 3 ( - ) to -0°36' Depressed hElight [under force of N (50 kg, Ib) with engine running] 0 - 5 (0 . ) 0' - 28' I - ( - ) *: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. () or more Parking brake Number of notches [at pulling force N (20 kg, 44 Ib)] Wheel bearing Wheel bearing axle end mm (in) play Wheel bearing lock nut Tightening torque N.m (kg-m, ft-Ib) Front Rear () or less () or less - - (15 22, (, ) ) Wheel balance Wheel balance (Maximum allowable unbalance at rim flange) g (OZ) Tire balance weight MA g (OZ) 10 () ( ) Spacing 5 () SERVICE DATA AND SPECIFICATI'ONS(S.D.S.) Chassis and Body Maintenance (Cont'd) TIGHTENING TORQUE Unit N'm Clutch Pedal stopper lock nut Clutch switch lock nut 16 22 - 15 - 12 - 16 12 - 9 - 11 Drain and filler plugs Final drive Drain plug 25 - 34 - 18 - 25 59 6 - 10 Filler plug Front axle and front 59 6 - 10 37 - 46 - 27 - 34 - 91 - Manual transmission suspension Tie-rod lock nut kg-m . - ft-Ib Camber adjusting pin Rear axle and rear suspension Toe adjusting pin 69 51 - 65 Camber adjusting pin 69 51 Brake system Air bleed valve - Brake lamp switch lock nut 12 - 15 - 9 - 11 Brake booster input rod lock nut 16 - 12 - 16 - 72 Wheel and tire Wheel nut 98 - MA ENGINEMECHANICAL EM SECTION EM CONTENTS PRECAUTION EM- 2 PREPARATION EM- 3 OUTER COMPONENT PARTS EM- 6 COMPRESSION PRESSURE EM- 7 OIL PAN EM- 8 TIMING CHAIN EM OIL SEAL REPLACEMENT EM CYLINDER HEAD EM ENGINE REMOVAL EM CYLINDER BLOCK EM SERVICE DATA AND SPECIFICATIONS (S.D.S.) """'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' EM PRECAUTION LIQUID GASKET APPLICATION ~~ Groove ' . . I~r Side Bolt hole SEMC PROCEDURE a. Before applying liquid gasket, remove all traces of old liquid gasket from mating surface using a scraper. b. Apply a continuous bead of liquid gasket to mating surface. (Use Genuine Liquid Gasket or equivalent.) c. Be sure liquid gasket is to mm ( to in) wide (for oil pan). Be sure liquid gasket is to mm ( to in) wide (in areas except oil pan). d. Apply liquid gasket to inner sealing surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) e. Wait at least 30 minutes before refilling engine oil and engine coolant. EM-2 PREPARATION SPECIAL SERVICE TOOLS Tool number (arenaqq.us No.) Tool name Description STS ( - Disassembling and assembling ) Engine stand assembly CD ST ( ) - Engine stand @ ST ( Base - ) ~ KV ) ( Engine attachment - KVSO ) ( Valve spring compressor - CD Disassembling and assembling valve components CI< KV - ( ) Compressor @KV ) ( Adapter - KVB ( ) Valve oil seal drift - ~ Installing valve oil seal ~ KV ( - Disassembling and assembling piston with connecting rod ) Piston pin press stand assembly CD KV ( ) Cap @ KV ( ) Spacer @ ST ( ) Press stand @ ST ( ) Spring @ KV ( ) Drift @ KV ( ) Center shaft 3 ~ ?~~ EM-3 PREPARATION Tool number (Kent-Moore No.) Tool name Description EM (J ) Piston ring compressor ~ Installing piston assembly into cylinder bore (J) Valveoil seal remover ~ Displacement valve oil seal KV ( - ) Seal cutter WS - ( ) Tube presser ST (J) Pilot bushing puller ~ T Removing oil pan Pressing the tube of liquid gasket ~ EM-4 PREPARATION COMMERCIAL SERVICE TOOLS Tool name Spark plug wrench Description c:Y Q 16mm ( in) Pulley holder r ~ -- Valve seat cutter set ~ \ ~~.- Valve guide drift installing Holding camshaft pulley while tightening or loosening camshaft bolt Finishing valve seat dimensions .- - ~ ~ Piston ring expander Removingand spark plug Removing and installing piston ring Removing and installing valve guide Diameter: A¥:~ mm (in) Intake Exhaust A () () B () () Reaming valve guide (CD) or hole for oversize valve guide (@) Valve guide reamer Diameter: ~- @ D. EM;.5 mm (in) Intake Exhaust 01 7 () 8 () Os () '() OUTER COMPONENT PARTS KA24E ENGINE ~ ~ - 16 21 (_,12 ) 16 ( , ) B.P.T. valve . I A A umt LI-I~~ I.-L ~ rA'.. (, ) ,r" Adjusting bar ~ ~~ (,7 - 9) ( , ) ~ : N.m (kg-m, ft-Ib) rJ : Apply liquid gasket. SEMC EM-6 COMPRESSION PRESSURE Measurement of Compression 1. 2. 3. 4. 5. Pressure Warm up engine. Turn ignition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable. Q) 6. Attach a compression tester to NO.1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution. Compression pressure: kPa (kg/cm2,. psi)/rpm Standard 1, (, )/ Minimum (10, )/ Difference limit between cylinders 98 (, 14)/ If cylinder compression in one or more cylinders is loyi. 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. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat Is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is I,akage past the gasket surface. If so, replace cylinder head gasket. . SEM B . . . EM-7 OIL PAN 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. @ 0 (jJ) 0 Q 2- Front 0 @ @ Loosen bolts in reverse order. @ SEMC 6. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. Do not insert screwdriver, or oil pan flange will be deformed. . . (2) Slide Tool by tapping its side with a hammer, and remove oil pan. SEMA 7. Pull out oil pan from front side. EM-8 OIL PAN Installation Scraper 1. Before installing oil pan, remove all traces of liquid gasket . from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block. SEMC 2. Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent. . SEMC Cut here. ~ Liquid gasket . Be sure liquid gasket is to mm ( to in) wide. :J SLC 7 mm in) --Lt-. 3. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. 4. Install oil pan. Wait at least 30 minutes before refilling engine oil. . . Inner side Groove Bolt hole SEMB EM-9 . TIMING CHAIN r ~ ~ Camshaft sprocket ' , - (1:~ain'tenSioner 08 5.' ( . , ~ ~ ~ ~ rJ ~ I L Qj Front cover .~ ., . Crankshaft sprocket ( , 9 . L. ~ : N.m (kg-m, ft-Ibl rJ : ApplV liquid gasket. SEMC . CAUTION: \ After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. EM TIMING CHAIN Removal 1. 2. 3. 4. .. . Disconnect battery terminal. Drain coolant from radiator. Remove radiator shroud and cooling fan. Remove the following belts. Power steering drive belt Compressor drive belt Alternator drive belt 5. Remove all spark plugs. 6. Set NO.1 piston,at T.D.C. on its compression stroke. Q Front SEMC 7. Remove the following parts. Power steering pump, idler pulley and power steering pump brackets Compressor idler pulley Crankshaft pulley Oil pump with pump drive spindle . .. .. Rocker SEMC SEMC EM-" cover . TIMING CHAIN Removal (Cont'd) 8. Remove oil pan. (Refer to OIL PAN.) 9. Remove front cover. SEMC Remove the following parts. . Chain tensioner . Chain guides . Timing chain and sprocket . Oil thrower, oil pump drive gear and crankshaft sprocket Crank~h3ft sprocket SEMC Inspection Check for cracks and excessivewear at roller links. Replace if necessary. Jf) ~ ,~ ' SEMC EM TIMING CHAIN crankShaft Crankshaft ~prOCket ~ ~ Installation 1. Install crankshaft sprocket, oil pump drive gear and oil thrower. . Make sure that mating marks of crankshaft sprocket face engine front. . "4~ . O;I:;:~~~'\ n ~ 0 Front. SEMC 2. Install camshaft sprocket. 3. Confirm that NO.1 piston is set at T.D.C. on its compression stroke. 4. Install timing chain. Set timing chain by arenaqq.us its mating marks with those of crankshaft sprocket and camshaft sprocket. ~~~ '/0 ~ (O@ . \ ~. '~ " ~ \\ II ~ Can ,",ocke< )) " ii ~r C"ok .p-" " e: Punchmark SEMC 5. Tighten camshaft sprocket bolt. 6. Install chain guide and chain tensioner. EM TIMING CHAIN Installation (Cont'd) 7. Apply liquid'gasket to front cover. ~ mm 8. Apply lithium grease to sealing lip of crankshaft oil seal. ( . inl die. 9. Install front cover. Be careful not to damage cylinder head gasket. Do not forget seal. .. SEMC Install rubber plug. (Refer to "Installation" HEAD.) Install oil pan. (Refer to Oil PAN.) of CYLINDER Install oil pump and distributor driving spindle with new gasket in front cover. (1) Assemble oil pump and driving spindle, aligning punchmark on driving spindle with oil hole. ~ Punchmark SEMC EM TIMING CHAIN Installation (Cont'd) (2) Make sure that driving spindle is set as shown in figure. Front Q SEMC Install distributor. Make sure that NO.1 piston is set at T.D.C. and that distributor rotor is set at NO.1 cylinder spark position. Q Front SEMC EM OIL SEAL REPLACEMENT VALVE OIL SEAL 1. Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove valve spring and valve oil seal with Tool or suitable tool. Piston concerned should be set at T.D.C. to prevent valve from falling. (J) KV ( - 4. Apply engine oil to new valve oil seal and install it with Tool. Before installing valve oil seal, install valve spring seat. ) () Valve spring seat Unit: mm (in) SEMC OIL SEAL INSTALLING DIRECTION Engine inside . Oil seal lip Engine outside Dust seal lip SEMA FRONT OIL SEAL 1. Remove radiator shroud and crankshaft pulley. 2. Remove front oil seal. Be careful not to damage crankshaft. EM 9i- SEAL REPLACEMENT 3. Apply engine oil to new oil seal and install it using suitable tool. SEMB REAR OIL SEAL 1. Remove flywheel or drive plate. 2. Remove rear oil seal retainer. 3. Remove traces of liquid gasket using scraper. 4. Remove rear oil seal from retainer. .J'I; l it 5. Apply engine oil to new oil seal and install it using suitable tool. Diameter of Iiqu id gasket: - mm ~ ( 6. Apply liquid gasket to rear oil seal retainer. - in) EM CYLINDER HEAD ~~-8 .,' , ' ' Valve rocker cover- Rocker cover gasket ~ 37 - 41 ( - , 27 - 30) Valve and spring Intake Spring retainer Valve '~w, ~ ,\;~ ~ ,\ ~J @ , ~~ E'M":~ Oilseal @ springseatA \\ V"Wg";..~~ Valve seat ~ . ~ ~ Cylinder head \J @<~ 'b@cg ~ Head bolt ~: N'm (kg-m, ft-Ib) SEMC EM CYLINDER HEAD CAUTION: When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. . When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts. . . O.K. Hydraulic valve lifters are installed in each rocker arm. If hydraulic valve lifter is kept on its side, even when installed in rocker arm, there is a possibility of air entering it. After removal, always set rocker arm straight up, or when laying it on its side, have it soak in new engine oil. Ii SEMB N.G. . . Do not disassemble hydraulic valve lifter. Attach tags to valve lifters so as not to mix them up. SEMB Removal 1. Drain coolant from radiator and drain plug of block. 2. Remove the following parts. Power steering drive belt Power steering pump, idler pulley and power steering brackets Vacuum hoses of S.C.v. and pressure control solenoid valve Accelerator wire bracket 3. Disconnect E.G.R. tube from exhaust manifold. 4. Remove bolts which hold intake manifold collector to intake manifold. 5. Remove bolts which hold intake manifold to cylinder head while raising collector upwards. 6. Remove rocker cover. When removing rocker cover, do not hit rocker cover against rocker arm. . . .. EM CYLINDER HEAD ~ Removal (Cont'd) 7. Set NO.1 piston at T.D.C. on its compression stroke. -5/0° 5° 10° 15° 20° Red painted / ~ Front SEMC 8. Loosen camshaft sprocket bolt. Support timing chain by using Tool as shown in figure. . SEMC 9. Remove camshaft sprocket. EM CYLINDER HEAD Removal (Cont'd) Remove front cover tightening bolts to cylinder head. SEM
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