NISSAN SENTRA Model Bil Series FOREWORD This service manual has been prepared pri- marily for the purpose of assisting service personnel in providing effective service and maintenance of the 1982 NISSAN SENTRA. ‘This manual includes procedures for main- tenance, adjustments, removal and installa- tion, disassembly and assembly of com- ponents, and trouble-shooting. All information, illustrations and specifica- tions contained in this manual are based on the latest product information available at ‘the time of publication. If your DATSUN model differs from the specifications con- tained in this manual, consult your NISSAN/ DATSUN dealer for information. ‘The right is reserved to make changes in specifications and methods at any time with- out notice. NISSAN MOTOR CO., LTD. 1982 NISSAN MOTOR CO,, LTD. Printed in Japan [Not to be reproduced in whole or in part without the prior written permission of Nissan Motor Com pany Ltd, Tokyo, Japan, QUICK REFERENCE INDEX aa Dab Lh a aL ee ACSC ae a aU | aCe ta LC aed it TTD DU eae LN fl at OTL NLD a CLUS Aa Le NY ca eae aU Naa UL COC aL DTT IL TAA ct Ca eee tana ALA ch cl BR A tld iL aL> This Service Manual is designed as a guide for servicing cars. > This manual deals with the engine, chassis, body and the electrical system. A QUICK REFERENCE INDEX is provided on the first page. Refer to this index along with the index of the particular section you wish to consult. > The first page of each section lists the contents and gives the page numbers for the respective topics. D> SERVICE DATA AND SPECIFICATIONS are contained in each section. > TROUBLE DIAGNOSES AND CORRECTIONS are also included in each section. This feature of the ‘manual lists the likely causes of trouble and recommends the appropriate corrective actions to be taken. D> A list of SPECIAL SERVICE TOOLS is included in each section. The special service tools are designed to assist you in performing repair safely, accurately and quickly. For information concerning how to obtain special service tools, write to the following address: Kent-Moore Corporation Kent Moore of Canada, Ltd. 29786 Lite Mock ‘5486 Timberlea Biv, Unit 2 Roseville, Michigan 48068, Mississauga, Ontario (Cansda L4W 277 D> The measurements given in this manual are primarily expressed with the SI unit (International System of Unit), and alternately expressed in the metric system and in the yard/pound system. D> The back cover of the manual provides maintenance data for quick reference. D> In the text, the following abbreviations are used: SDS! Service ata and Speciistions LH RH: Gi Tntening Traue Mr air: > The captions CAUTION and WARNING warn you of steps that must be followed to prevent personal injury and/or damage to some part of the car. IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the mechanic and the efficient functioning of the car. The service methods in this Service Manual are described in such a manner that the service may be per- formed safely and accurately. Special service tools have been designed to permit safe and proper performance of service. Be sure to use them, Service varies with the procedures used, the skills of the mechanic 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 car's safety will be jeopardized by the service method selected.GENERAL VIEWS MODEL VARIATION IDENTIFICATION NUMBERS Engine serial number Manual transaxle number ‘Automatic transaxle number LIFTING POINTS AND TOWING .. GENERAL INFORMATION CONTENTS Gr2 Pantograph jack ........ G4 Garage jack and safety stan GI6 Towing Gié Tie-down Gl6 SPECIAL SERVICE TOOLS Gl6 ‘TIGHTENING TORQUE OF Gl7 “STANDARD BOLT G7 G7 G7 G7 Gis GisGENERAL VIEWS GENERAL VIEWS 1 = |< 1,395 (54.9) —o} L065 —+l 4,620 (63.8) 1 60 1167.9 —_______ Unit: mm (in) 2dloor Sedan 1,375 (5411 a | _ =e] 8 = ‘I + | Toa Las tsasr—l gp $0 5 sos cea) 1,620 (63.8)- “ “4,250 (167.3)- Unit: mm Gn)GENERAL VIEWS Hatchback Teal 1-10 40) oes ann conn at ca esi 1220 (608 szzo ier tit mo eae Wagon 4 i ao re hte then nl rath 18201633) aarstira2 Unis mam a) i GI-3MODEL VARIATION MODEL VARIATION oad wheel size Cass Model | Engine | Transaxle |. offset Tire size tm tind HLB1IRSFV 165-19/6.1513.4PR 2-door RSSFSOA fe HLBHTAFV HLBTIRAV RLIFOIA : 1555R13 2 paour [HLBTIEV RSSFIOA 3 HLBTIAV RLIFOTA é KHLBTIFV RS5F30A Hatchback 1 KHLBTAV RLIFOTA ees WHLBITEV ASF30A Wagon 155SR19 WHLBTIAV RLGFOIA HLBTIASFU 155.19/6,15.184R RSSF20A 185SR13 HusiiAseyy . 126/704" usa. HLBHTRU ANAFI0A | 41/2)x13 door 42 (1.65) HLBTIRFU nssraoa | 3 42(l Sedan meenirau | _, | RLSFOIA | 4ocisn 7 (Aluminum — | 155SR13 : HLBHIRYU reraon | £ HLBHU pepe 8 }4-door | HLB11FU_ RS5SF30A_ 15 (1.77) § HLBTIAU RLSFOIA KHLBTIU ANGFSOA Hatchback [KHLBTFU RSSFS0A 175/708R13 KHLBTIAU RLSFOIA WHLBIU ANGFQOA Wagon [WHLB11FU RS5F30A 165SR13 WHLBTIAU RLGFOIA HLBIIRSEN SSFI0A 185-19/6.15-13-40R 2edoor [HLBLIRSAN RL3FOWA Sedan HLBTTRAN HLBTIRFYN ae 155SR13 — edoo, [HEBITEN HLBITAN RLGFOIA Vowhpack [KHLBTIEN RSSFIOA ae KHLBTIAN RLSFOTA RSER: — WHLBITEN S5FA0A ee WHLBTTAN RLGFOIA *F Spare tre GI-4Prefix and suffix designation G: Sedan K : Hatchback W: Wagon Ht E15 engine L: LH drive MODEL VARIATION OHL BIRS FYN eo 7O Note: Cl means no indication. GI-5 > 70 < zea + Non-California models for U.S.A, + California models Canada models MP.G. models ' 4-speed manual transaxle S-speed manual transaxle Automatic transaxle + Deluxe model + Standard model + Except 2-door Sedan + 2edoor SedanIDENTIFICATION NUMBERS IDENTIFICATION NUMBERS Vehicle serial number ‘(Chasis number) ‘number pate scree ENGINE SERIAL NUMBER MANUAL TRANSAXLE AUTOMATIC TRANSAXLE ‘The engine serial number is stamped NUMBER NUMBER 4s shown in the illustration. ‘The manual transaxle serial number The automatic transaxle serial number label is attached on the clutch with- label is attached on the upper face of drawal lever. the transmission case. [sonra GI-6LIFTING POINTS AND TOWING LIFTING POINTS AND TOWING PANTOGRAPH JACK WARNING: 1a, Never got under the vehicle white it is supported only by the jack. ‘Always use safety stands to support frame when you have to get under the vehicle, b, Place whee! chocks st both front and back of the wheel diagonally ‘opposite the jack posi Apply the pantograph jack furnished with the vehicle to the position indi- cated in the figure in a safe manner. GARAGE JACK AND SAFETY STAND jedown hooks Front towing and ‘soni8s WARNING ‘a, When carrying out operations with ‘the garage jack, be sure to support ‘the vehiclo with safety stands. 'b, When jacking up the rear (front) of ‘the vehicle, place the chocks at the front (rear) of the front (rear) wheols to hold the CAUTION: Always place a wood block between safety stand and vehicle body when supporting body with safety stand. Apply the garage jack and safety stand to the position indicated in the figure in a safe manner. TOWING CAUTION: 1 It is necessary to use proper towing ‘equipment to avoid possible dam- age to the vehicle during a towing operation, ‘Towing is in accordance with Tow- ing Procedure Manual at dealer side. GI-7 . All applicable State or Provincial (in Canada) laws and local laws re- ding the towing operation must be obeyed. ©. Before towing, make sure that the ‘transaxle, steering system and pow- er train are in good order. If any unit is damaged, a dolley must be used. i. Never tow an automati ‘model with rear whoels front wheels on ground) as this may cause serious damage to the vehicle. If it is necessary to tow it with rear wheols raised, always use a towing dolly under the front wheels. If the tyansaxle is inoperative, tow the vehicle with the front wheels off the ground, . When the vehicle is towed with its front wheels on the ground, secure the steering wheel in a straight ahead position with the ignition key tuned in “OFF” position, 9. Release ‘the parking brake and set the gearshift lever in “Neutral” position befora starting to tow the vehicle. ‘h. When towing an automatic trans- axle model, try to restrict towing speed below 30 km/h (20 MPH) and towing distance less than 30 km (20 mites). With manual transaxle model, try to restrict towing km/h (50 MPH) and towing ‘tance lass than 80 km (60 mites). 1. Do not apply force to the towing hook in a lateral direction. TIE-DOWN ‘CAUTION: Do not tow the vehicle with the rear tie-down hooks.SPECIAL SERVICE TOOLS / TIGHTENING TORQUE OF STANDARD BOLT SPECIAL SERVICE TOOLS Special Service Tools play very im- portant role in the maintenance of cars. These are essential to the safe, accurate and speedy servicing. The working times listed in the col- umn under FLAT RATE TIME in FLAT RATE SCHEDULE are com- puted based on the use of Special Service Tools. ‘The identification code of mainte- nance tools is made up of 2 alphabeti- cal letters and 8-digital figures. ‘The heading two letters roughly classify tools or equipment as: '$T00000000: Special Service Tool KV00000000: Special Service Tool EMC0000000: Engine Overhauling Machine GG00000000: General Gauge LM00000000: Garage Tool 1700000000: Hand Tool TIGHTENING TORQUE OF STANDARD BOLT Tighten | : ening torque Grade Boltornutsize | Poor nutdiam | Pict mm : eter mm Nm kgm feb M6 60 10 3-4 125 e-i1 8 = . 10 e-i1 15 16-22 ar Mio 100 125 16-22 175 26 M12 120 oe 125 30-40 Mia 140 15 46-62 MG 60 10 6-7 125 14-18 Ma 80 10 14-18 15 : 7 mio 109 2535 125 26-36 175, 45-61 m2 120 125 50-68 Mia 140 18 76 103 MG 60 10 3-1 125 19-25 Ms 80 2 10 20-27 15 36-5 oT Mio 100 $80 1.25 39-51 | a 115 : 6-90 ; 2 65-88 | 6 48-65 125 72.97 | 73-99 | 53-72 Mia 140 1s 109-147_[i.1-15.0_| 60-108 1. Special parts ara excluded, 2. This standard is applicable to bolts having the following marks embossed on the bolt head, Grade Mark 4T 7 ow *: Nominal diameter M6 [coo GI-8 Nominal diameter of bolt threads (Unit: mm) Metric screw threadsMAINTENANCE SCHEDULE LUBRICATION CHART... RECOMMENDED FUEL AND LUBRICANTS Fuel Lubricants SAE viscosity number APPROXIMATE REFILL CAPACITIES ENGINE MAINTENANCE Before engine start After engine warm-up MINOR TROUBLE DIAGNOSES AND CORRECTIONS MAINTENANCE CONTENTS ..MA- 2 CHASSIS AND BODY .MA-5 MAINTENANCE Engine control, fuel and MA: 6 exhaust systems MA- 6 Clutch MA- 6 Manual transaxle MA. 6 ‘Automatic transaxle . Front axle and front suspension Rear axle and rear suspension Brake system Wheel and tire Steering system Body SERVICE DATA AND SPECIFICATIONS (S.0.S.) . Engine maintenance Chassis and body maintenance SPECIAL SERVICE TOOLS . MA-23 MA-23 - MA23 MA23 MA-24 MA24 MA-26 MA-27 MA-29 .. MA33 . MAS4 MA-35 MA-35 MAB MASTZV The following tables list the periodic maintenance servicing required to ensure good emission control performance, good engine performance and good mechani- cal condition in DATSUN. The first 1,600 km (1,000 miles) service is one of the most important services required to ensure the maximum emission control performance and optimum engine condition. Periodic maintanance beyond th last period shown in the tables requires similar maintenance. TMAINTENANGE OPERATION WAINTENANGE INTERVAL kilometers 1,000 a Create maintenance held performed ot numberof aie TDD) ‘or frst |r fer [er sr iors =[s [els [als [3s EMISSION CONTROL MAINTENANCE (U.S.A. and Ganada Zdoor Sedan MP.G. models) Ore bale 7 MAT Gerbera Gear iar Se noTer a MAT Ancona er (eet MEE. mada See NOTE) 7 MRT Choke mecha Ueton& ening of cake ia BT] ; MAS Poste Grankease Vetiation PCV.) ter SeenOTeT Ga WAS Vapor 7 mas Fuel nes igs, coneaions we 1 WAS Fast er Seno 7 Engine colt z MR Engine of of i Se nOTe TH wpe apa TATA] mas.10 Soar plus f ATO “anton wie 7 wa TAvtomats pers Sonal ATC a deer 1 MA inthe & Exh valve Saronee x x x awact Carburetor iim 7 7 fF Ma Eston get ersor OIP.G_ not Ga) cles 1 was Note:(1) If car is operated under severe conditions: short distance driving, extensive idling or ‘every 5,000 km (3,000 mites) or 3 months, whichever comes first. (2) More frequent maintenance is required under dusty driving conditions, (3) If car is operated under extreme adverse weather conditions or in areas where ambient temperatures are ei ight become clogged. In such an event, replace them immediately. tremely high, the filters (4) Maintenance items with ““*" are recommended by NISSAN MOTOR CO., LTD. Other maintenance items are required, Abbreviations: A = Adjust R = Replace 1 = Inspect, correct, replace if necessary. ving in dusty conditions, change engine oll er extremely low or ex- FINGSHOS JONVNALNIVIN 31NG3HOS SONVNSLNIVWe-VN MAINTENANCE OPERATION MAINTENANCE INTERVAL : xalomaters 1900 16 [12 | 24 | 6 | as | oo [2 ae Sa man tanel 1 [esi] 051 [ezsi] or [ears esy | eterenee Pome Month = [6 [2 [ie [x | 0 [38 EMISSION CONTROL MAINTENANCE (Canada models except 2-door Sedan M.P.G. models) Dee bar 1 WAT ‘Cerbretor a coer ar See NOTE: Ga ® WAT Tir ndaction vale fier See NOTE: 1) f WAT ‘Choke machaian choke pate & Ta 7 1 [maa Pov Cranks Venton (G3) far Se NOTE was "Vapor Tins 7 MAS Fuel ns (he, pining conneeins te] 1 MAS Ft iter SenoTe WAS Engine cool z MAS Eine ool Tr sonore A Tata peta a | waa.t0 Spark f R R[ WAT Slaniton wire 1 MAIO TAutaratie oboe NTO a ener i 1 [wait Toke oxhaue va lwrance x x x awa Taniton timing a a a Mat3- 48 Carbrator eer Beas aaron a a a A [ Masa mire a 1 1 1 Twas. NOTE: (1) If caris operated under severe conditions: short distance driving, extensive idling or driving in dusty conditi ‘engine oil every 5,000 km (3,000 miles) or 3 months, whichever comes first. (2) More frequent maintenance is required under dusty driving conditions. change (3) If caris operated under extremely adverse weather conditions or in areas whore ambient temperatures are either ex- ‘tremely low or extremely high, the filters might become clogged. In such an event, replace them immediately, (4) Maintenance items and and intervals are required. Abbreviations: A = R ' Adjust Roplaoe Inspect, correct, replace if necessary. are recommended by NISSAN MOTOR CO., LTD. Other maintenance items 31NG3HOS JONVNALNIVWvn MAINTENANCE OPERATION MAINTENANCE INTERVAL Foe eee siomunx1o00 [is Tz [ze TosTo Tota] ic maintenance should be performed at number of eference page Heche use cone (Miles x 1,000) (Hy [7.51 | 8) |225)) cor [7 5) sh Months = [Te [2 [re [2 |e fae] UNDERHOOD MAINTENANCE Brake 6 automatic wancaxo fd level & leaks ‘See NOTE: (1) T T T [was 27 Brake tid @ R | _Maa7 rake booster vacuum hoses, connections & heck va 7 MAT Power storing fluid ines t 0 Tass UNDER VEHICLE MAINTENANCE as rake, clutch, foal & ex ayant attachment, leaks, cracks, chafing, abrasion, ee eee ee ' 1 ' MA23, 28 ‘Manual transaxle gor of! ‘See NOTE! (1 7 o 1 [was ‘Steering geer, linkage & suspension parts Yor dameged, loowe & missing pare ‘See NOTE: (2) | 1 0 H 1 | MA-26, 26,38 ‘Underbody (lush & loan every 12 monthel H o n = Ey OUTSIDE AND INSIDE MAINTENANCE Rotate wheel position & inspect whol balance & wheel alignment TT To 1] MA26, 30,32 Dise brake pads & brake drums, linings & other Brake components for woor, , setariration & eaks @ ' ' Maze Front wheel bearing oreo T WARE SeonOTE: (3) c tL Tt) _ Mase 0 T 0 MASA Foot brake, parking brake & clutch for free ploy & operation t t r MA23, 25 NOTE: (1) When towing a trailer, change oil in transaxle every 48,000 km (30,000 miles) or 24 months, whichever comes first. {2} _Stocring linkage & front suspension ball joints inspection should be performed every 96,000 km (60,000 miles) or 4 years, whichever comes (3) fear months, whichover comes first ‘The above charts show the normal maintenance schedule. Abbreviation Depending upon weather and atmospheric conditions, varying road surfaces, individual driving habits and car usage, additional or more frequent ‘maintenance may be required. ‘operated in aroas using road salt or other corrosive materials, inspect avery 6,000 km (3,000 miles) or 3 L = Lubricate R = Replace 1 = Inspect, correct, replace ‘necestary 3NG3HOS JONVNALNIVWS-VIN FRONT WHEEL BEARINGS ==() GREASE YY MANUAL TRANSAXLE @)== =" AUTOMATIC @ ama. ‘TRANSAXLE BRAKE FLUI vezevns ® [it etices operates in oress ung oad ator ‘other corrosive materials, inepect every 5/000 km (3200 miles) or 3 months, whichever comes first. © [when towing a waiter, change oll in wansaxle every 48,000 km (30,000 miles or 24 months, whichover comes fet. LOCKS, HINGES & Hoo LATCH fue filter might become clogged. In such an event, ken imite on) CHANGE @ cuce @ woncare ENGINE i ANTLEREEZE COOLANT (ETHYLENE GLYCOL BASE) JDSHIELD AND REAR "WINDOW WASHER FLUID POWER STEERING FLUID © eNnaine on m= =@ Furs FiLTER = == ENGINE ONL FILTER © [rar is operated under severe conditions: short distance ering, exter Gusty conditions, cheng on (3,000 mites) or 3 months, whi LYVHO NOILVOINENT 4YVHO NOILVOINENTRECOMMENDED FUEL AND LUBRICANTS/APPROXIMATE REFILL CAPACITIES RECOMMENDED FUEL AND LUBRICANTS FUEL Gasoline octane number (minimum) SAE VISCOSITY Gasoline RON. (Re M2 * USA. and Canada Unleaded MPG. models o 37 Toes RAS Canada models ex- | Unleaded Tt cept MP.G, models | or leaded ct a) ‘*7 The fuel filler opening is designed for use with an unleaded fuel gun [nozzle ~ hea iameter less than 21.3 mm (0.84 in)] only. coma LUBRICANTS Lubricant ‘Specifiations Remarks ca Gasoline engine oil APL SE Further details, refer to ided SAE ce Manual transaxle and recommen ‘manual stering ger oi API GL4 viscosity chart. i ‘Automatic transaxle and = power steering uid Type DEXRON a 5 Multi-purpose grease NLGI No.2 | Lithium soap base = TOF Brake fluid DOTS US FMVSS No. 116 SEES ES “Antifreeze . Ethylene glycol base =a APPROXIMATE REFILL CAPACITIES Liter ‘US measure Imp measure Fuel tank 30 13.1/4 gl ial | ae 47 Sat 41/84 aT 33 55/84 45/84 Engine coolant oo 41 43/8 qt 35/8 qt AIT 47 Sat +18 qt Reservoir tank 7 3i4at s/8at Engine ot With ol filter 39) 41/8 qt 33/8 qt ‘Without ol iter 34 35/8 qt 3qt Manual “peed 23 4718 pt 4pt Transaxle S-speed 27 5.3/4 pt 43/4 pt ‘Automatic 60 63/8 qt Sia qt ‘Windshield washer tank 1s 15/8 at 13/8 at Pore v9 Taal Tat | ‘Airconditioning Compressor oi os 5. flor 53 flex system Refrigerant 08 -10kg 18-2.21b 18-22 1b MA-6ENGINE MAINTENANCE ENGINE MAINTENANCE BEFORE ENGINE 2. Check drive belt deflections by START ‘Pushing midway between pulleys. ‘Adjust if necessary. CHECKING DRIVE BELTS 1. Inspect for cracks and wear. Replace if necessary. ‘Adjust deflection Set deflection ee of used belt of new belt ‘| mm (in) Alternator 13-17 (051 -0.67) 10-14 (0.39 -0.55) force — N(kg,Ib) Air conditioner 9-11 (0.35 -0.43) 7-9 (0:28-0:38) Power steering 7-9 (0.28 -0.38) 65 -8.5 (0.256 -0.335) eee ae 98 (10,22) Water pump pulley Tales pulley. [ler pulley lock nut: Power steering pump. Adjusting bolt Lock tlt aan 2-430, aan fee Compressor Double nuts Adjusting bolt ‘sMazo9a Alternator bolt 1. Loosen the upper and loweralter- nator securing bolts until the alterna- tor can be moved slightly. 2. Move the alternator with a prying bar until the belt deflection is within the specified range. Then tighten the bolts securely. Air conditioner belt 1. Loosen the idler pulley lock nut and adjusting bolt double nuts for the belt being adjusted. 2. Adjust the adjusting bolt until the belt deflection is within the specified range. 3. Tighten the adjusting bolt double nuts and idler pulley lock nut secure- ly. MA-7 Power steoring helt 1, Loosen the power steering oil pump adjusting lock bolt and its secur- {ng bolt for the belt being adjusted. 2. Adjust the adjusting bolt until the belt deflection is within the specified range. 3, Tighten the adjusting bolt lock bolt and oil pump securing bolt secure- y. REPLACING AIR CLEANER FILTER Air cleaner filter is @ viscous paper ‘type and does not require cleaning. 1, Remove air cleaner cover and re- move air cleaner filter. 2. Install new air cleaner filter and install air leaner cover. REPLACING AIR INDUCTION VALVE FILTER ‘Stop engine and remove air induc- tion valve case, and remove filter.ENGINE MAINTENANCE (CHECKING CHOKE MECHANISM (Lubrication and cleaning of choke plate and linkage) U.S.A.) 1. Check choke valve and linkage for free operation, and clean choke valve or lubricate choke linkage if necessary. 2. Before starting engine, fully open throttle valve and ensure that choke valve closes properly. CHECKING CHOKE MECHANISM (Choke plate and linkage) (Canada) 1. Check choke valve and mecha- nism for free operation, and clean or replace if necessary, Binding can result from petroleum gum formation on choke shaft or from damage. 2. Before starting engine, fully open throttle valve and ensure that choke valve closes properly. 3. Push choke valve with your finger, and check for binding. 4. Check to be sure that bimetal cover index mark is set at the center of choke housing index mark as shown below. Do not set bimotal cover index mark at any position except the conter of choke housing index mark, saa01a| CHECKING VAPOR LINES 1. Check all hoses and fuel tank filler cap. 2. Disconnect vapor vent line con- necting carbon canister to fuel tank. 3. Connect 3-way connector, mano- meter and cock (or equivalent 3-vay charge cock) to end of vent line. 4. Slowly supply fresh air into vapor vent line through cock until pressure teaches 3.923 kPa (400 mmH,0, 15.75 inll,0). 5. Shut cock completely. 6. After 21/2 minutes, measure height of liquid in manometer. 7. Variation in height should remain 0.245 kPa (25 mmH,0, 0.98 inll,0). 8. When filler cap does not close completely, height should soon drop to zero. 9. If height does not soon drop to zero when filler cap is removed, the cause is a clogged hose. If vent tine is clogged, breathing in fual tank is poor, thus causing insuf- ficient delivery of fuel to engine oF vapor lock. It must, therefore, be ropaired or roplaced. 3.923 kPa (400 mmH20, 16.75 inktz0) REPLACING P.C.V. FILTER Remove air cleaner cover, and re- place filter. CHECKING FUEL LINES (Hoses, piping, connections, etc.) Check fuel lines for loose connec- tions, cracks and deterioration. Re- tighten loose connections and replace any damaged or deformed parts. MA-8ENGINE MAINTENANCE REPLACING FUEL FILTER Disconnect battery cable. 1, Disconnect fuel hoses from fuel filter and replace it, 2. Check filter for contamination and water deposit. Plug open of fuel hove immediately after fuel hose has been removed from fuol filtor, suasit CHANGING ENGINE COOLANT [wanmnc: To avoid being scalded, never change the coolant when the engine shot. ‘© When replacing engine coolant, set heater “TEMP” control lever to fully “HOT position. 1. To flush system, open drain cock at bottom of radiator. Then thorough- ly flush until clear water comes out. cs00s| 2. Close drain cock. 3. Fill radiator with coolant up to specified level, Follow instructions at- tached to anti-freeze container for ‘mixing ratio of anti-freeze to water. Coolant capacity: Liter (USat.impad MIT AIT with “7 53 heater (5,4-1/8) _ | (5-5/8, 4-5/8) Witt | 41 47 heater |(43/8, 38/6] 6, 44/6 ae 0.7 0/4, 5/8) 4. Rum engine for a few minutes, and then check coolant level. If necessary add coolant. 5. Install radiator cap, 6. Fill reservoir tank with coolant up to “MAX” level. 7. Run engine for a few minutes, and ‘check drain cock for any sign of leak- age. CHANGING ENGINE OIL AND REPLACING OIL FILTER 1, Start engine and warm it up until water temperature indicator points to riddle of gauge, then turn off engine. 2. Remove oil filler cap and oil pan drain plug, and allow oil to drain. WARNIN' Use care as hot, MA-9 A milky oil indicates the presence ‘of cooling water. Isolate the cause ‘and take corrective messuro. ‘© An oil with extremely low viscosity indicates dilution with gasoline. 3. Using oil filter wrench, remove oil filter. 4. After draining engine oil, wipe oil pan drain hole with a clean rag. $. Clean and install oll pan drain plug with washer. il pan drain plug 35-47 Nm (3.6 -48 kg-m, 26-35 ftib) 6. Wipe oil filter mounting surface with a clean rag. 7. Smear a little engine ofl on rubber seal of new oil filter. smaoio| 8. Install new oil filter by hand, Do not use oil filter wrench to tighten the fittor, 9. Refill engine with the appropriate new engine oil by referring to Recom- ‘mended Lubricants. ‘Check oil level with dipstick.ENGINE MAINTENANCE Oil capacity: With oil filter 3.9 liters (4-1/8 US gt, 3.3/8 Imp qt Without oit filtor 3.4 liters (3-5/8 US qt, 3 Imp qt) SMAI60 10. Install oll filler cap and start en- sine. 11. Check area around drain plug and cil filter for any sign of oil leakage. If leakage is evident, retighten or replace. 12, Run engine until water tempera- ture indicator points to middle of gauge. Then tum off engine and wait several minutes. Check oll level with cil level gauge. If necessary, add en- gine oil When checking oil level, park car REPLACING SPARK PLUG 1, , Remove air cleaner. 2. Disconnect spark plug wire at boot. Do not pull on the wires. Ox. NG. K SM A0370 © Shake the wire while measuring re- sistance to ckeck for intermittent brakes. 3, Remove spark plugs with spark plug wrench. 4, Install new spark plugs are recon- rect high tension cables. ‘Spark plug type: Standard | BPRSES.1} BPRAES.1 BPRGESA 10-14 (0039- 0.083) "7 Not including Canada MG. model D: Spark plug 20-28.-m (2.0-3.0 kom, 14-22 feb) CHECKING IGNITION WIRES 1. Visually check wiring for eracks, and damaged and burned terminals. 2. Using an ohmmeter, measure the resistance between cable terminal on the spark plug side and corresponding ‘electrode inside cap. MA-10 suaor CHECKING ENGINE COMPRESSION PRESSURE 1. Warm up engine until water tem- perature indicator points to middle of gauge. 2. Remove air cleaner and all spark plugs. 3. Disconnect anti valve connector. 4. Properly attach a compression tester to spark plug hole in cylinder being tested. ling solenoid 5. Depress accelerator pedal to fully ‘open throttle and choke valve. 6. Crank engine and read gauge indi- cation. Run engine at about 350 rpm. © Engine compression measurement should be made as quickly as possi- ble. Compression pressure: kPa tg/om?, pil/at rpm Standard 1,245 (12.7, 181/350 Minimum 981 (10.0, 142)/350ENGINE MAINTENANCE 7. If cylinder compression in one or more cylinders is low, pour a small amount of engine oll'into cylinders through the spark plug holes and retest compression. ‘© If adding oil holes the compression pressure, chances are that piston rings are worn or damaged. ‘© If pressure stays low, valve may be sticking or seating improperly. © If cylinder compression in any two adjacent cylinders is low, and if adding oll does not help the com- prossion, there is leakage past the gasketed surface, il and water in combustion cham- bers can result from this problem. CHECKING AUTOMATIC TEMPERATURE CONTROL (A.T.C.) AIR CLEANER 1. Check that vacuum hoses (Intake manifold to temperature sensor, idle compensator and vacuum motor) are securely connected in correct position. 2. Check each hose for cracks or dis tortion. 3. Check A-T.C, system for function by proceeding as follows: Confirm that engine is cold before starting test. With engine turned off, check posi- tion of air control valve by hand or mirror. Air control valve is in correct posi- tion if its cold ar inlet is open and hot air inlet is closed. 4. Start engine and keep idling, Immediately after starting engine, air control valve is in correct position if its cold air inlet is closed and hot air inlet is open. 5. Check that air control valve gradually opens to cold air inlet side as engine warms up. When environmental ‘temperature around, temperature sen- sor is low, allow more time for engine ‘warming up to facilitate smooth opera- tion of air control valve. If the above test reveals any prob- Jem in the operation of air control valve, carry out the further inspection described in Section EF. AFTER ENGINE WARM-UP ADJUSTING INTAKE ‘AND EXHAUST VALVE CLEARANCE Adjustmont should be made while engine is warm but not running. 1, Start engine and warm it up until ‘water temperature indicator points to middle of gauge. Then turn off engine. 2. Remove air cleaner securing bolts 3. Remove valve rocker cover. 4. Rotate crankshaft. 3. Set No. 1 cylinder in top dead center on its compression stroke, and adjust valve clearance ©, @, @ and ©. 6. Set No. 4 cylinder in top dead center on its compression stroke and adjust valve clearance ©, @, @ and ® MA-11 \Volve clearance (Hot): Intake and exhaust 0.28 mm (0.011 in) (2) Loosen; valve rocker adjusting screw lock! nut and tum adjusting screw until specified clearance is obtained. (2) After adjustment, tighten lock nut and recheck clearance. © : Adjusting serew lock nut 16-21Nm (16-21 kgm, 12-15 feb) [smaos7aADJUSTING IDLE RPM (U.S.A. and Canada M.P.G. models) Preparation 1, Connect engine tachometer in its proper position. 2. On air conditioner equipped models, the sir conditioner system should be “OFF”, 3. Apply parking brake and block both front and rear wheels with hocks. WARNING: ‘a, Inspections should be carried ‘out while shift lever is in “D"” position on automatic transaxle equipped models and in “Neu- tral” on manual transaxle equip- ped models. ‘On automatic transaxle et ped models, racing the engine should be carried out wt lever “N" or “P’ position and brake pedal should be depressed, After adjustment has been made, shift the lever to “N” or “P” ENGINE MAINTENANCE Maintenance procedure Cart) + ‘Start engine and warm it up until water tempera ture indicator points to middle of gauge and en- sue that engine speed is below 1,000 rpm. ‘Run engine at idle speed for 2 minutes. ¥ Race engine (2,000 - 3,000 rpm) 2 oF 3 times under no-load, and run engine at idle speed. | IDLE SPEED Excopt MP.G. model \Sanooon “Throttle adjusting serew MA-12ENGINE MAINTENANCE ADJUSTING IDLE RPM, ADJUSTING IGNITION TIMING AND CHECKING MIXTURE RATIO (Canada model except M.P.G.) should be “OFF”. Preparation 1, Make sure that the following parts are in good order. © Ignition system ‘© Engine oil and coolant levels. Valve clearance Maintenance procedure ‘Air induction hose 2. Connect engine tachometer and timing light in their proper positions. 3. On air conditioner equipped ‘models, the air conditioner system WARNING: a Inspections should he carried out while shift lever is in “D” Position on automatic transaxle ‘equipped models and ‘tral” on manual transax! 4. Apply parking brake and block both front and rear wheels with hocks. ‘ped models, ing “CO” b. On automatic transaxle 5. When measuring “CO” percent: fol alan ee age, insert probe more than 40 em (15.7 in) into tail pipe. auld fe cost it lever is in “Nor “Pp and brake pedal should be depressed «, After adjustment has been made, shift the lever to “N"” or “P” ‘START ‘Start engine and warm It up until water tempera- ‘ure indicator points to middle of gauge and ensure that engine speed is below 1,000 rpm. T “Tum off engine and open engine hood. v ‘Disconnect ar induction hose from air pipe and install cp on air pipe. ‘Start engine and run tat ile speed for ? minutes. y 1s this maintenance interval 1,600 km 4,000 miles? serazaa| No { { ‘Race engine (2,000- 3,000 rpm) 2 or 3 times under no-oad and run engine at idle speed. ‘Check ignition timing. IGNITION TIMING (A.7.0.C.) yt: 422 AIT: 682° (in “0” position) ‘Adjust ignition timing by turing distributor, loosening distributor securing bolt, MA-13ENGINE MAINTENANCE Race engine (2,000 - 3,000 rpm) 2or 3 times under nodoad, and run engine at idle speed, ‘Race engine (2,000 3,000 rpm) 2 or 3 times ‘under nodoad, and run engine at idle speed. y ate [SEFS390 WwLe “co"% Mr: 281 AIT: 221 (in "D" postion) ‘Adjust idle “COM by turning idle adjusting screw. Refer to NOTE for ile limiter ap ‘A Mota ido limitar cep has boon adopted, 80 adjust idlo adjusting screw with idle ‘dusting screwdriver. “Turn off engine and connect air induction hose to air pipe Kv10108300 v ‘Start engine Race engine (2,000 3,000 rpm) 2 or 3 times under nooad and run engine at idle speed. IDLE SPEED MIT: 750850 rpm ‘AIT: 600850 rpm (in “D postion) SMA1904, ‘Adjust ile speed by turning throttle adjusting MA-14ENGINE MAINTENANCE CHECKING EXHAUST GAS SENSOR Preparation bd lated e 1 Ignition system ° When checking exhaust gus sensor, Engine oll and coolant levels . cap and oil lvel gauge imeke sure that the following parts are} Fuses 4 Valve clearance, engine compres in good order. © £.C.6, component parts, sion Maintenance procedure |e [ety ttn mer BS inspection is disconnected. 2 Ox. Tre — ae mte LV t —— € ‘Start engine and warm up engine unt water tempera indator punto the mile orere sersrea T ‘Run engine at about 000 rp for about, S minutes under nod —+ | FT Verify that alarm lamp on instrument panel. [N.G. f | isnot tured on. —_. OKT ‘Connect harness connector for EGG. inspection. q Make suze that alarm lamp on instrument CLI pia ges on od oft mote han 5 tines swazoen Alarm amp ning 10 sesame TN ‘iswonnet hares connector for EC. ‘heck and ajar should be made by inspection. ‘Sern to Dagon Procedsres for ELC. Engine of Section EF & EC. aS i 48,000 km (30,000 mites) '24 Months Service Exhaust gas sensor should be check: ed after 48,000 km (30,000 miles) of 24 months of operation ‘After car has been operated for 48,000 km (30,000 miles), exhaust gas sensor warning lamp will come on to indicate that sensor should be inspected. ‘warning lamp suas0sa| If sensor should be checked on the ‘After inspection, disconnect warn- 24th month before 48,000. km ing lamp harness connector $0 that (30,000 miles) of operation, also dis- ‘warning lamp will not come on there- connect warning lamp harness con- after nector. MA-15,MINOR TROUBLE DIAGNOSES AND CORRECTIONS MINOR TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action CANNOT CRANK — | Improper grade oil. Replace with proper grade oil. ENGINE OR SLOW | Discharged batt Charge battery. CRANKING ce semans Faulty battery. Replace. Loose alternator belt. Adjust. Malfunction in charging system. Inspect. Wiring connection loose in starting circuit. Conect. Faulty ignition switch. Repair or replace. Faulty starter motor. Repair or replace. (Troubleshooting procedure on starting circuit) Switch on the starter motor with light “ON’ ‘When light goes off or dims considerably, 1. Check battery. ». Check connection and cable. ©. Check starter motor, ‘When light stays bright, 4. Check wiring connection between battery and starter motor. ». Check ignition switch, ©. Check starter motor. ENGINE WILL CRANK NORMALLY BUT WILL NOT START In this case, the following trouble causes may exist, but in many cases ignition system or fuel system is in trouble. Ignition system in trouble Fuel system in trouble Valve mechanism does not work properly Low compression (Troubleshooting procedure) Check spark plug firs by following procedure, Disconnect high tension cable from one spark plug and hold it about 10 mm (0.39 in) from the engine metal part and crank the engine. Good spark occurs. 1. Check spark plog. ». Check ignition timing. . Check fuel system. 4, Check cylinder compression, No spark occurs, ‘Check the current flow in primary circuit. Very high current. Inspect primary circuit for short. Low or no current. Check for loose terminal disconnection in primary circuit. MA-16MINOR TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action Ignition system out of order Ful system out of ‘order Low compression Leak at rotor cap and rotor. Faulty spark plug. Improper ignition timing. Faulty ignition coil, Disconnection of high tension cable. Loose connection or disconnection in primary circuit Lack of fuel. Dirty fuel filter. Dirty or clogged fuel pipe. Fuel pump will not work properly. Carburetor choke will not work properly. Improper adjustment of float level Improper idling. Dirty or clogged carburetor. Clogged breather pipe of fuel tank. Malfunctioning anti-dieseling solenoid valve. Malfunction of fuel shut-off system, Incorrect spark plug tightening or faulty gasket. Improper grade engine oll or low viscosity. Incorrect valve clearance, ‘Compression leak from valve seat. Sticky valve stem. Weak or damaged valve springs. Compression leak at cylinder head gasket. ‘Sticking or damaged piston ring. Wom piston ring or cylinder. (Trouble shooting procedure) Pour the engine oil from plug hole, and then measure cylinder compression. Compression increases. Compression does not change. Clean or replace Clean, adjust plug gap or replace. Adjust. Replace. Replace. Repair or replace. Supply Replace. Clean, Replace. Check and adjust. Correct. Adjust. Disassemble.and clean. Repair and clean. Check for loose terminal or wire harness. Check for loose vacuum hose and harness connections, Adjust or replace if necessary. Tighten to normal torque or replace gasket. Replace with proper grade oil Adjust. Remove cylinder head and lap valves. Correct or replace valve and valve guide. Replace valve springs. Replace gasket. Replace piston rings. Overhaul engine. Malfunctioning cylinder or piston ring. Compression leaks from valve, cylinder head or head gasket. MA-17MINOR TROUBLE DIAGNOSES AND CORRECT z Condition Probable cause Corrective action IMPROPER ENGINE IDLING Fuol system out of (Clogged or damaged carburetor jets. Clean or replace. oe Incorrect idle adjustment. Adjust. Clogged air cleaner filter. Replace element, Low compression Others High engine idle speed Damaged manifold gaskets or carburetor insulator. Improper float level. Loose air hoses or air-fuel mixture hoses of carburetor. ‘Malfunctioning carburetor choke. Malfunctioning A.B. valve, ‘Malfunctioning automatic temperature con- trol air cleaner. In operative idle compensator. Carbon canister purge line hose damaged or disconnected. Incorrect valve clearance. Extremely low revolution. Malfunction of the ignition system (spark plug, high tension cable, ignition coil, etc.) Incorrect basic ignition timing. Malfunction of choke valve or linkage. Malfunction of vacuum motor, sensor or hoses of air cleaner. Incorrect idle adjustment. (Clogged air cleaner filter. Malfunction of idle compensator of air cleaner. Malfunction of E.G.R. control valve. ‘Loose manifold and cylinder head bolts. Dragged accelerator Linkage. Incorrect idle adjustment. Malfunction of throttle opener. Malfunction of speed switch and harness, Replace gasket or insulator. Adjust. Check for loose connections. Check and adjust or replace. ‘Check for loose connection of vacuum hose. Check air temperature sensor and vacuum motor. Check for connection of idle compensator hose or replace idle compensator. Connect or replace. Previously mentioned. Adjust Adjust. Replace. Adjust. Lubticate or clean, Check for loose hoses. Replace system com- ponents if necessary. Adjust idle speed. Replace. Replace. Clean or replace, Retighten bolts. (Check and correct accelerator linkage. Adjust idle speed. Check for loose vacuum hose and harness ‘connections. Adjust, replace if necessary. ‘Check for loose connection. Repair or re- place if necessary. MA-18MINOR TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action ENGINE POWER NOT UP TO NORMAL ‘Low compression Ignition system out of order Fuol system out of order Air intake system out of order Emission control Overheating Overeooting Others Incorrect ignition timing. Damaged spark plugs. Worn distributor points. Malfunction of T.C.S. Malfunction of V.D.V. Malfunction of choke system. Clogged fuel pipe or floating valve, Dirty or clogged fuel filter. Fuel pump will not work properly. Clogged carburetor jets. Malfunction of altitude compensator, Malfunction of A.T.C. air cleaner. Malfunction of air-fuel ratio solenoid valve, Clogged air cleaner. Air inhaling from manifold gasket or carbu- retor gasket. Malfunction of E.G.R. valve. Malfunction of V.V.T. valve. Malfunction of air-fuel mixture ratio control system, Insufficient coolant. Loose alternator belt. Wom or oiled alternator belt. Inoperative thermostat. Wom water pump. Clogged or leaky radiator. ‘Worn radiator filler cap. Air in cooling system. Improper engine oil grade. Incorrect ignition timing. Clogged carburetor (lean mixture), Inoperative thermostat. Improper octane fuel. Improper tire pressure. Dragging brake. Clutch slipping. Previously mentioned. Adjust. Clean, adjust or replace plugs. Dress or replace points. Also check con- denser. Check and correct. (Check and replace. Adjust or replace. Clean. Replace, Replace. Disassemble and clean. Check or replace, Check or replace. Check or replace. Replace element. Replace gasket. ‘Check and replace. Repair or replace. Check and replace. Replenish. ‘Adjust fan belt. Replace. Replace. Replace, Flush, repair or replace. Replace. Retighten each part of cooling system. Replace with proper grade oil. Adjust Overhaul carburetor. Replace. Replace with specified octane fuel. Inflate to specified pressure. Adjust. Adjust or replace. MA-19MINOR TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action NOISY ENGINE Car knocking Overloaded engine. Use right gear in driving. Carbon knocking. Disassemble cylinder head and remove car- bon. ‘Timing knocking, : ‘Adjust ignition timing, Fuel knocking. Use specified octane fuel. Preignition (misusing of spark plug). Use specified spark plug. ‘Mechanical knocking Crankshaft bearing knocking Connecting rod bearing knocking Piston cylinder noise Piston pin noise ‘Water pump noise This strong dull noise increases when engine is accelerated. To locate the place, cause a misfit in each cylinder. If the noise stops ‘by the misfire, this cylinder generates the noise. This is a little higher-pitched noise than the crankshaft knocking, and also increases ‘when engine is accelerated. Cause a misfire in each cylinder and if the noise diminishes almost completely, this crankshaft bearing ‘generates the noise When you hear an overlapping metallic noise which increases its magnitude with the revolution of engine and which decreases as ‘engine is warmed up, this noise is caused by piston and cylinder. To locate the place, cause a misfire in each cylinder. This noise is heard at each highest and lowest dead end of piston. To locate the place, cause a misfire in each cylinder. This noise may be caused by worn or dam- aged bearings, or by the uneven surface of sliding pars. ‘An improper adjustment of valve clearance, ‘An excessive end-play on crankshaft. Surging A-T.C. air cleaner vacuum motor. ‘This is caused by worn or damaged bearings, or unevenly worn crankshaft. Renew bear- ‘ngs and adjust or change crankshaft. Check lubrication system. Same as the case of crankshaft bearings. This may cause an abnormal wearing of cylinder and lower compression which in tum will cause a lower out-put power and excessive consumption of oil Overhaul engine. ‘This may cause a wear on piston pin, or piston pin hole. Renew piston and piston pin assembly. Replace water pump with a new one. Adjust. Adjust. Repair or replace. MA-20MINOR TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action ABNORMAL ‘COMBUSTION (Backfire, afterfire, run-on, etc.) Improper ignition Improper ignition timing, Adjust igntion timing, Improper heat range of spark plugs. Use specified spark plugs. Fuel system out of Damaged carburetor or manifold gasket. Replace them with new parts. order (backfire, afterfire) Faulty cylinder head, te. Clogged carburetor jet. Improper function of the float. Uneven idling. Improperly adjusted throttle opener. Malfunction of anti-dieseling solenoid valve. Malfunction of auto-choke, Improperty adjusted valve clearance. Excess carbon in combustion chamber. Damaged valve spring (backfire, afterfire). Disassemble carburetor and check it. ‘Adjust the level, and check needle valve Adjust. Adjust. Check or replace. ‘Adjust or replace. Adjust. Remove head and get rid of carbon, Replace it with a new one. Others: Malfunction of A.T.C. air cleaner. ‘Check for loose vacuum hoses. Replace if necessary. Inoperative A.B. valve, Replace EXCESSIVE OIL CONSUMPTION Oil leakage Loose oil drain plug. Tighten it. Loose or damaged oil pan gasket. Renew gasket or tighten it. [Loose or damaged chain cover gasket. Renew gasket or tighten it ‘Worn oil seal in front and rear of crankshaft. Renew oil seal. Loose or damaged rocker cover gasket. Renew gasket or tighten it (but not too such). Improper tightening of oil filter. ‘Renew gasket and tighten it with the proper torque. Loose or damaged ol pressure switch. Renew oi pressure switch or tighten it. Excnsive oi Cylinder and piston wear. Overhaul cylinder and renew piston. ‘consumption Improper location of piston ring gap or | Remount piston rings. reversely asiembled piston ring. Damaged piston rings. Renew rings. Repair or renew piston and cylinder. Wom piston ring groove and ring. Renew piston and piston ring. Fatigue of valve oll ip seal Replace lip sel with anew one. ‘Worn valve stem. Renew valve or guide. MA-21MINOR TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action Others Inadequate quality of engine oil. Use the designated oil Engine overheat. Previously mentioned. POOR FUEL ECONOMY ‘See the explanation of the power decrease Others Exceeding idling revolution ‘Adjust it to the designated rpm, Inoperative acceleration recovery. Adjust it. Fuel leakage. Repair or tighten the connection of fuel Pipes. Malfunction of throttle opener. Adjust. Malfunction of A.T.C. ar leaner. ‘Check and replace. PROBLEMS IN OTHER FUNCTIONS Decreesed oil pressure | Inadequate oil quality. Use the designated oil. Overheat. Previously mentioned. Worn oil pump regulator valve. Disassemble oil pump and repair or renew it Excessive waar on the sliding parts ‘Scutfing of siding parts Functional deterioration of oil pump. Blocked oil filter. Increased clearance in various sliding parts. Blocked oil strainer. ‘Malfunctioning oil gauge pressure switch. Oil pressure decreases. Improper quality or contamination of oil. Damaged air cleaner Overheat or overcool. Improper fuel mixture, Decrease of cl pressure. Insufficient clearances. Overheat. Improper fuel mixture. MA-22 Repair or replace it with a new one. Renew it. Disassemble and replace the worn parts with new ones, Clean it. Replace it with a new one, Previously mentioned. Exchange the oil with proper one and change element. ‘Change element. Previously mentioned. (Check the fuel system. Previously mentioned. Readjust to the designated clearance. Previously mentioned, Check the fuel system,CHASSIS AND BODY MAINTENANCE CHASSIS AND BODY MAINTENANCE ENGINE CONTROL, FUEL AND EXHAUST SYSTEMS CHECKING FUEL AND EXHAUST SYSTEMS Check fuel and exhaust systems for condition, connections and leaks. ee Np swars0a| Fuel system A OS Exhaust system suaarial CLUTCH CHECKING CLUTCH SYSTEM Check clutch system for proper at- tachment, chafing, abrasion, deteriora- tion, ete. CHECKING CLUTCH PEDAL HEIGHT AND FREE TRAVEL Check clutch pedal height and free travel. Adjust if necessary. SMANAZA SMAIISA Pedal height “H": 201 - 207 mm (7.91 -8.15 in) Padal froe travel “A’ 11-21 mm (0.43 -0.83 in) 1. Adjust pedal height with pedal stopper. Then tighten lock nut, 2. Adjust withdrawal lever play “B” at lever tip end with adjusting nut. Withdrawal lever play “t 2- 4mm (0.08 - 0.16 in) @: Lock nut 19-25Nm (1.9-2.6 kam, 14-19 ft-lb) MA-23 3. Depress and release clutch pedal several times, then recheck play “B”. Readjust if necessary. 4, Asa final check, measure pedal free travel “A” at center of pedal pad. Depress and release clutch pedal over its entire stroke to ensure that the clutch linkage operates smooth- Wy without squeak noise, inter- ference and binding. MANUAL TRANSAXLE CHECKING MANUAL TRANSAXLE OIL LEVEL Never start engine while checking il level. SMATAGA CHECKING MANUAL TRANSAXLE OIL, 1. Drain oil completely. IN ont —_ SMAN454CHASSIS AND BODY MAINTENANCE 2. Refill transaxle and check oil level. sMatagn AUTOMATIC TRANSAXLE CHECKING AUTOMATIC TRANSAXLE FLUID LEVEL 1. Check under following conditions. (A) Place selector lever in “P” (PARK) position and idle engine. (2) Maintain fluid temperature at 50 to 80°C (122 to 176°F). 2. Add fluid, if necessary. Use only automatic transmission fluid having “DEXRON” identifica- tons in automatic transaxlo, oo Ade OK transaxle, If fluid is very dark or smells burned, the frictional material (clutches, band, etc.) may need re- placement. (Check Muid for contamination. 40) BS ce Retighten all loose nuts and bolts to the specified torque. Refer to Sec- tion FA for tightening torque. Replace all worn parts as described under Front Suspension (Section FA). Se Ms FRONT AXLE AND FRONT SUSPENSION CHECKING FRONT AXLE AND SUSPENSION PARTS 1. Block rear wheels with chocks and raise front of vehicle, and then support it with safety stand. Refer to Section Gu. 2. Shake each front wheel by hold- ing upper and lower surfaces of tires as shown. 3. Check strut (Shock absorber) for oil leakage or damage. « SMANA7A CHECKING AUTOMATIC TRANSAXLE FLUID CONDITION Check fluid for contamination to determine condition of automatic sMANY Check suspension parts for loose- ness, wear, or damage. MA-24 4. Check suspension ball joint for ‘grease leakage and ball joint dust cover for damage.CHASSIS AND BODY MAINTENANCE 5. Remove wheel and tire assembly. 6. Check front axle parts for crack or damage. Replace wom parts. Refer to Front Axle (Section FA). 7. Remove brake pads. Refer to section BR. 8. Check wheel bearing. If there is any axial end play or if ‘wheel bearing does not smoothly turn, adjust bearing to specifications. Replace wom or damaged bearings. Refer to Front Axle (Section FA). SMAIGEA Camber and caster Camber and caster are preset at factory and cannot be adjusted, ‘The vehicle requires only toe-in and vehicle posture adjustment. If camber or caster alignment is ‘not within specifications, chock as- sociated parts. Repair or replace as ‘necessary. ‘Camber, Caster and Kingpin inclination Refer to S.0.S, Toe-in Measure toe-n, and make necessary adjustments. Use’ the following pro- cedure when making adjustments. 1. Raise front of vehicle and mark a baseline across the tread of left and right wheels. CHECKING WHEEL ALIGNMENT Before checking front wheel align- ment, be sure to make a preliminary inspection of all front end parts, © Tire prossure (© Whoo! bearing axial play © Suspension ball joint ‘© Stooring gear housing looseness at frame ‘© Steoring linkage and connections © ‘Shock absorber oper © Repair or replace the damaged Portion or parts, “Unladen” © Fuel tank, radiator and engine oil tank all ful. © Spare tire, jack, hand tools, mats in position. © All tires inflated to specified pres- sure. © All accumulation of mud, dist and road deposits removed from chassis and underbody. 2. Set wheels in a straight-ahead position, and then lower front of vehicle, After lowering front of vehicle, move it up and down to eliminate friction. 3. Measure toein and make neces- sary adjustments. ines paral to Tocin=A-B centerline of bods Toein can be adjusted by varying the length of steering side rods. Toein: 3-5 mm (0.12- 0.20 in) 9°- 15° (On both sides) If side rods have been disassembled, set the distance between lock nuts to the specified value “A” prior to re sembling. “A dimension: Power steering model 178.9 mm (6.93 in) Manual steering model 175.9 mm (6.93 in) FAB06 4. After correct toe-in has been ob- tained, tighten side rod lock nuts. @ : Side rod outer socket lock nuts 37-46 Nem (38-4.7 kgm, 27-34 feb) ‘Side rod innor socket lock nuts 78-98 Nm {8-10 kgm, 58-72 feb)CHASSIS AND BODY MAINTENANCE Front wheel turning angle 1, Set wheels in straight ahead posi- tion and then move-vehicle foward ‘until front wheels rest on turning radius gauge properly. 2. Rotate steering wheel all the way right and left; measure turning angle on inner wheel. If it is not within specification, ‘check rack stroke. ‘Turning angle: Refer to 8.0.8. Rack stroke "" (both sides): Power steering model 73.5 mm (2.804 in) ‘Manual steering model 73.5 mm (2.894 in) sMaa07 CHECKING FRONT WHEEL BEARING GREASE 1. Block rear wheel with chocks and raise front of car, and then support it with safety stands, Refer to Lifting Points and Towing (Section GI). 2. Remove wheel and tire. 3. Check for grease leakage from front wheel bearing grease seals by observing the area around them. Re- place wom or damaged grease seal. Refer to Front Axle (Section FA). 4. Check wheel bearing. If there is any axial end play or if Wheel bearing does not tum smoothly, adjust bearing to specifications. Replace worn or damaged bearings. Refer to Front Axle (Section FA). MA-26 REAR AXLE AND REAR SUSPENSION CHECKING REAR AXLE AND SUSPENSION PARTS Check rear axle and suspension parts for looseness, wear or damage. Retighten all loose nuts and bolts to the specified torque. Refer to Sec- tion RA for tightening torque. Replace all wom parts as instructed under Rear Suspension (Section RA). 'SMA320A ADJUSTING WHEEL BEARING PRELOAD ‘Aftor wheel bearing has been ro- placed or rear axle has beon reas- sembled, be sure to adjust wheel bear- ing preload as described below. 1. Before adjustment, thoroughly clean all parts to prevent possible en- try of dirt,CHASSIS AND BODY MAINTENANCE 2. Apply recommended multi-pur- pose grease sparingly to the following parts. '# Threaded portion of spindle. © Contact surface between wheel bearing washer and outer wheel bearing. ‘© Hub, hub cap and O-ring. ‘© Grease seal ip. Multi-purpose srease point SRA326 3. Tighten wheel bearing nut, @ 39-44N-m kam, 29-93 fb) A059 4. Turn wheel hub several times in oth directions to seat wheel bearing correctly ‘5. Again tighten wheel bearing nut. 6. ‘Tum back wheel bearing nut 90°, RA )) Turn back A: 90° candi Install adjusting cap and align any of its slots with hole in spindle, If the above procedure fails to align hole and slot together, then tighten lock nut as much as 15 degrees until hole in spindle is aligned with any slot, ruts, as this can cause wheel bearing seizure. 7. Tum hub in both directions two ‘or three times, measuring its turning torque and axial play to see if they are within the specified ranges. If they are not, adjust. ‘Axial play: O mm (0 in) Wheel bearing starting torque: With now grease seal Less than 08 N-m (8 kg-cm, 6.9 in-tb) ‘As measured at wheel hub bolt Loss than 13.7 N (1.4 keg, 3.1 1b) With used grease seal Less than 0.4 N-m (4 kg-em, 3.5 intb) ‘As measured at whoo! hub bolt Less than 69 N (0.7 kg, 1.5 Ib) Repeat above procedures until cor- rect starting torque is obtained, 4. Correctly measure rotation starting force toward tangential direction against hub bolt. 'b, Above figures do not include “dragging” resistance. When meas- turing wheel bearing starting torque, be sure to confirm no “dragging” resistance exists, ©. Any slightest wheel bearing axial play cannot be tolerated. 8, Spread cotter pin. 9. Install hub cap with new O-ring. BRAKE SYSTEM CHECKING BRAKE FLUID LEVEL AND LEAKS ‘Aad to MAX". level same If fluid level is extremely tow, ‘check brake system for leaks. CHANGING BRAKE FLUID 1. Change brake fluid. Use same procedure as in air bleed- ing to change brake fluid in system. ‘This operation should be done for one wheel ata time. Refer to Section BR.CHASSIS AND BODY MAINTENANCE CAUTION: Never reuse brake fluid because its characteristic is changed by oxidiza- tion as well as contains the foreign ‘material and dirt, CHECKING BRAKE SYSTEM Check brake system for proper at- tachment, leaks, chafing, abrasion, de- terioration, etc. SMAISBA (07-09 Kem, 51-65 Hb) Refll until new Auld appears [suarce 2. Check brake fluid level. 3. Check for leaks. CHECKING BRAKE BOOSTER VACUUM HOSES, CONNECTIONS AND CHECK VALVE 1, Check condition of vacuum hoses ‘and connections. 2. Check vacuum hoses and check valve for air tightness. ‘SMAIS7A Check condition of disc brake components. ‘SMAI594 1 Check condition and thickness of 2. Check caliper operation and Inspect fr leaks 3. Chock pads for wear Pad wear limit Rotor repair limit SMAI96 CHECKING DRUM BRAKE Check condition of drum brake ‘components, smagaia 1 Check tinings for wear oF damage 2. Check springs and pin 3. Check operation of pistons and inspect for leakage Lining wear limit aaa A pate Pa wear limit (A): 2.0 mm (0.079 in) ‘sMA135 Lining wear Hitt): 115 mm (0.059 in) ‘sMaige Refer to Section BR for pad re- placement. MA-28 Rofer to Section BR for shoe re- placement.CHASSIS AND BODY MAINTENANCE ‘Check condition of inner surface of drum ‘Drum repair Hit (Inner diameter) 181.0 mm (7-13 in} SMata9| CHECKING FOOT BRAKE Check brake pedal free height and free play. Adjust if necessary. XG: ment] sMasz20 Pedal free height Refer to$.D.S. Clearance “C” between pedal stopper rubber and threaded end of brake lamp switch: 0- 1mm (0 - 0.04 in) (2) Adjust pedal free eight with brake booster input rod. Then tighten Tock mut. @) Adjust clearance “C” with brake lamp switch. Then tighten lock mut. Make sure that no depressing force con brake booster input rod and that brake lamp is off when pedal is re- leased, Check brake pedal depressed height. ‘More than 85 mm (3.35 in) swarey If depressed height is below the specified value, check brake system for leaks, accumulation of air or any ab- ‘normality regarding component parts (master cylinder, adjuster, ete.), and make the necessary repairs. CHECKING PARKING BRAKE 1. Pull lever with specified amount of force. Measure lever stroke in a straight line at center of grip. Puiting force: ON TA 1388 20, a4) enz24a 3. Bend hand brake warning lamp switch plate down so that brake warn- ing light comes on when ratchet at hhand brake lever is moved back one notch and goes out when returned to its original position. MA-29 WHEEL AND TIRE CHECKING TIRE CONDITION Tire condition 1, Tires are provided with “tread wear indicator” at six places around tire circumference, indicating 1.6 mm (1/16 in) tread depth. When tires wear and then marks appear, replace them with new ones. 2. Remove pebbles, glass or any other foreign material embedded in tire treads. 3. Check tread and side walls for cracks, holes, separation or damage. 4. Check tire valves for air leakage. Tire Inflation 1. Check tire pressure. If necessary, adjust it to the specified value indi cated in the label attached to the car, also found in Owner's Manual or Tite pressure should be measured when tire is cold. 2. After inflating tires, valves should bbe checked for leakage. Whenever pressure is checked, be sure to tighten valve caps firmly by hand to keep dust and water out.Abnormal tire wear CHASSIS AND BODY MAINTENANCE Bias and Bias Belted Tires Correct abnormal tire wear ac- Right front Right rear, cording to the chart shown below. o-oo Condition Probable cause Corrective action © Underinflation (both | @ Measure and adjust eSs— ides wear) pressure Lett front Letter «Incorrect wheel camber | Repair, or replace 4 WHEELS Coe wen) ast end soremion | | neon nate parts. © Hard cornering ‘© Reduce speed ca—-e © Lack of rotation © Rotate tires, NN WZ ca—c> ! © Overinflation ‘© Measure and adjust a pressure, Lack of rotation @ Rotate tires, SWHEELS Radial Tire Right front Right cer ao=ca "Incorrect toe ‘Adjust toein, = “4 WHEELS Right font Right reat = ~=. pa a= font Left rear © Incorrect camber or | « Repair, or replace aor caster axle and suspension suaase parts. © Malfunctioning suspen- | ¢ Repair, replace or, if sion necessary, einstal, | THRE REPLACEMENT © Unbalanced wheel Balance or replace. AUTH # Outofoundbrake | Corrector replace. Diferent types ‘of irs, suchas bias, drum tres, ey bias belted and radial ties, must not 1 Other mechanical condi- } Correct or replace. be miced under any sheamatnacee Atelier! aerate Mixed use of different types of tires # Lack of rotation # Rotate ties. tan ativaly effect voici handling TIRE ROTATION 1. Tires tend to wear unevenly and become unbalanced after a certain running distance. Uneven tire wear often results in tire noise. which is attributed to rear axle gears, bearing, ‘saat ete. Front tires also tend to wear un- evenly because of improperly aligned front wheels. 2. Accordingly, to equalize tire wear, it is necessary to rotate tires period cally. MA-30 and may cause driver to lose control. 2, When replacing a worn or damaged tire, use a replacement tire of the same size and load carrying capaci- ty as that with which the car was equipped when manufactured. The ‘use of different size and/or load capacity tires will not only shorten tire service life but may also result ina serious accident,CHASSIS AND BODY MAINTENANCE b, Do not use tires and wheels other ‘than those recommended, and do rot mix tires of different brands or tread patterns. The use of tires and wheels other than those recommended or the mixed uso of tires of different brands or tread patterns can ad- versely affect the ride, braking, handling, ground clearance, body- to-tire clearance, and speedometer calibration, ¢, It is recommended that new tires be installed in pairs on the same a When replacing only one ti should be paired with the most tread, to eqialize d, When replacing ori ‘those tires of an optional recom- ‘mended size and of different diam- ter, the speedometer must be re- calibrated. fe. When tire is installed, refer to the procedure 7 described in TIRE RE- PAIR. 1. To replace a tire with a jack in a safe manner, refer to Lifting Points (Section GI) for jacking up. WARNING: Never get under vehicle while itis supported only by jack. Always use safety stands to support side member of body construction when you must get beneath vehicle, ey 2. To install wheel, tighten wheel nuts in criss-cross fashion. sMA0s9 Screw nut onto hub bolt ‘sMao70. 2. Slightly pull the wheel back to properly align the nuts with bolt holes in the wheel, and tighten the nuts as ‘much as possible with your fingers. Align nuts with bolt holes in wheel and evenly tighten nuts each one a litle ata time, 3. Tighten wheel nuts evenly with a wheel wrench in eris-cross fashion. Be sure to check the wheel nuts for tightness, after the aluminum wheel ‘has been run for the first 1,000 km {600 miles) (also in case of repairing ‘lat tires, tire rotation, etc.). Replace if necessary. Wheel nut Aluminum wheel To install an aluminum wheel, pro- ceed as follows: 1. Snugly tighten four nuts after the wheel is positioned. CAUTION: Two types of wheel nuts are used; one is designed for use with steel wheel and the other for use with aluminum wheel. Do not mix different types of wheel nuts. MA-31 For aluminum ‘wheels only For steel ‘wheats only © 78-98Nm (@0-1.0kem, 58-72 fib) smao72| Be careful not to smear thread- ed portion of bolt and nut, and seat of nut with oil or grease. TIRE REPAIR Inspect tire, following the proce- dure shown below. If any defect is pre- sent, repair or replace as necessary. 1. Apply soapy solution or submerge tire and wheel or tube in water after inflating it to specified pressure. 2. Inspect for leaks. 3. Specially inspect for leaks around valve or wheel rim and along tread. 4, Note bead and rim where leakage ‘occurs. Wipe water away from any area which leaks air bubbles and then mark place with chalk. 5. Remove object which caused puncture and seal the point. ‘a, When repairing a puncture, use 2 tire repair kit furnished by any tire dealer, following instructions pro- Vided with kit. ‘If 2 puncture is too large or there is some damage to tire fabric, repair should be carried out by authorized tire dealer. 6. Discard when any of the following problems occurs: ‘© Broken or damaged bead wire. © Ply or tread separation. ‘e Wor fabric damage on tubeless © Cracked or damaged side wall. © Tires with tread wear indicator showing, ete. CAUTION When replacing tire, take extra care fot to damage tire bead, rimflange and bead seat.CHASSIS AND BODY MAINTENANCE Do not use tira irons to force beads away from wheal rimlango; that is, always use tire replacament devi ‘whenever tire is removed. 7. Install tre, noting the following items: 4. Install valve core and inflate to proper pressure. Check the locating rings of the tire to be sure they show around the rim flanges on both sides. b, Check valves for leakage after in: ‘lating tires. ‘c. Be sure to tighten valve caps by hand. mly WARNING: When, while tire is being inflated, bbead ‘snaps over safety hump, it ‘might break. Thus, to avoid serious personal injury, never stand over tire when inflating it. Never inflate to a pressure greater than 40 psi (275 kPa). If beads fail to seat at that pressure, deflate the tre, lubri- cate it again, and then reinflate it. If the tire is overinflated, the bead ‘might break, possibly resulting serious personal injury. WHEEL INSPECTION Inspect wheel, taking care of the following points, in order to ensure satisfactory steering condition as well as maximum tire life. If any defect is present, repair or replace as necessary 1. Check wheel rim, especially rim flange and bead seat, for rust, distor- tion, cracks or other faults which might cause sir leaks. Function of tubeless tire depends on a good seal between tire bead and wheel rim. 2. Thoroughly remove must, dust, oxidized rubber or sand ftom wheel Rim bead seats should be cleaned with the fol Steol wheel: Wire brush, coarse stool wool, etc. ‘Aluminum wheel Neutral detergent, cloth, etc. 3. Examine wheel rim for lateral and radial runout, using dial gauge. smao7a| Lateral runout (A) and radial runout (B): ‘Steal whoa. Less than To'mm (0.039 in) ‘Aluminum wheel. Less than ‘05 mm (0.020 in} DDifforonce borwoon right and lot atoral Stool wheal. Less than {5 em (0.020 in} ‘Aluriqum whoo! Loss than 10.2 mi (0.008 in} 4, Replace wheel when any of the following problems occurs, Cause Wheel static unbalance © Bent, dented or heavily rusted © Elongated bolt holes ‘© Excessive lateral or radial runout © Air leaks through welds (© Wheel nuts will not stay tight Wheel balance Inspect wheel and tire for wheel balance and correct it if unbalance is Present, taking the following points into consideration. 1. Correct unbalance when the symptom of unbalance appears as wheel tramps and wheel shimmy. 2. Balance wheel and tire both statically and dynamically. ncing wheels WARNING: When balancing wheel and tire on the vehicle, he sure to observe the equipment manufacturers. instruc- tions carefully, Wheel dynamic unbalance ‘Symptom MA-32 Wheel tramp of Ses Wheel shimmy unbalance — Corrective Balance statically Balance dynamically action Pace balance weights here Whee shimmy Whee shimmyCHAS AND BODY MAINTENANCE Balance weights a. Be sure to place correct balance ‘weights on inner edge of rim. b. Do not put more than two weights on each side, ¢. Two types of belance weights are used; one is designed for use with stool wheol and the other for use with aluminum wheel. Do not mix different types of balance weights. . Properly rebalance the wheel and tire whenever puncture is repaired. STEERING SYSTEM CHECKING STEERING LINKAGE © Check parts for looseness, wear or damage. “Retighten if neccessary. Refer to Section ST for tightening torque. @ Check for any missing parts (cotter pins, washer, etc). ‘© Check ball joints for grease leakage, Ma77t CHECKING POWER STEERING SYSTEM FLUID AND LINES 1. Check the fluid level in reservoir by observing the dipstick when the fluid is cold. Add fluid as necessary to bring the level into the proper range on dipstick. CAUTION: ‘Do not overfill 2. Inspect line condition and check for leaks. suasz3A MA-33CHASSIS AND BODY MAINTENANCE BODY LUBRICATING LOCKS, HINGES AND HOOD LATCH Hatchback oS SMAI268 CHECKING SEAT BELTS, BUCKLES, ANCHORS AND ADJUSTER Check anchors for loose mounting. cauTiON: 1 IF th while etidd ot eve lap tat Buel. Rover tenga kl 45 Usa a AISSAN gain sat belt = D Anchor bolt 24-31 Nem (24-32 komm, 17-23 Hb) ‘Check buckles and tongues for function when buckled and released. eS smooth operon, sao MA-34SERVICE DATA AND SPECIFICATIONS (S.D.S.) SERVICE DATA AND SPECIFICATIONS (S.D.S.) ENGINE MAINTENANCE INSPECTION AND ADJUSTMENT Basic mechanical system Ignition timing, idle speed and idle “CO"% (For U.S.A.) Except MP. MPS. Manvel | Automatic | Manual 078 0011) tition sn! vazy | sexy | zz (0.28 (0.011) (7.0.6. degree/rpm) | 750880 | 650860 | 700:60 072 (0000) cormartaesoecs | Semin se preset an 02 (0000) re aa aaa Ignition timing, idle speed and idle ““CO"% (For Canada) awonee mmin | ost. | fae: a Len temtnra | MPG cia anv [Autorate | Mew Atettione mutes | ‘oas- | ba oe oat | ose Too wr | ay | ener 78 Er (7.0.6. degree/rpm) | 750880 | 60060 | 70060 tower sering mmiin) | (02s. | tease: a et ass! ce mice Poahing tore Nk) we toz2) C0" ee ped a fecend a sare Erin comprein sremure tr. ie al fad at * Nese wih diibior wesum hoe deooeced and ewe to liad nme eer 00, 42) "1 After checking veve clearance while engine i cold, alo check it when engine is hot tose it cmains within the specific range. IH ftdoes not readjust it. "2 Aust deflection of used belt *3 Set detection of now belt Ignition and fue! system Emission control system Unit: KPa (mmH,0, inH,0) ‘Supplied pressure | 3.923 (400, 15.75) Vapor tine leakage test Pressure variation | _ Less than 0.286 (25, 0.98) Spark pgs Desti- Tyee Gap ation | standard Hot Cold mm (in) TIGHTENING TORQUE testa nie we [= |e uaa. | arseos| sats] oma] gd tla] [2 Seca eee eneeett 16-21 16-21 12-15 Cons ‘BPRSES | BPR4ES | BPREES batho oe (oast 0098) Sere 28-35 igh rion eb reine * ‘ebm oe ‘Spark plug. (20-29 14-22 MA-35