fuel NISSAN PATROL 1998 Y61 / 5.G Maintenance Workshop Manual

MAINTENANCE
SECTION
MA
CONTENTS
PRECAUTIONS AND PREPARATION............................1
Supplemental Restraint System (SRS) ``AIR
BAG'' and ``SEAT BELT PRE-TENSIONER''...............1
Special Service Tools ..................................................1
PRE-DELIVERY INSPECTION ITEMS............................2
GENERAL MAINTENANCE............................................3
PERIODIC MAINTENANCE............................................4
Engine Oil & Minor Service .........................................4
Engine and Emission Control Service .........................5
Chassis and Body Services.........................................6
Maintenance Under Severe Driving Conditions ..........8
RECOMMENDED FLUIDS AND LUBRICANTS.............9
Fluids and Lubricants ..................................................9
SAE Viscosity Number ..............................................10
Anti-freeze Coolant Mixture Ratio ............................. 11
ENGINE MAINTENANCE..............................................12
Checking Tightening Torque ......................................12
Checking Drive Belt ...................................................12
Changing Engine Oil..................................................13
Changing Engine Oil Filter ........................................14
Changing Engine Coolant..........................................14
Checking Cooling System .........................................16
Checking and Replacing Fuel Filter and Draining
Water .........................................................................16
Checking Fuel Lines ..................................................17
Cleaning and Replacing Air Cleaner Filter ................18
Checking Injection Nozzle .........................................18
Checking Idle Speed .................................................19
Timing Belt Replacement...........................................19
CHASSIS AND BODY MAINTENANCE.......................20
Checking Exhaust System.........................................20
Checking Clutch Fluid Level and Leaks ....................20
Checking Clutch System ...........................................20Checking M/T Oil Level and Leaks ...........................20
Changing M/T Oil.......................................................20
Checking Water Entry ................................................21
Checking Transfer Fluid Level ...................................21
Changing Transfer Fluid ............................................21
Checking Propeller Shaft ...........................................21
Greasing Nipples of Propeller Shafts ........................21
Checking Differential Gear Oil ...................................22
Changing Differential Gear Oil ..................................22
Checking Front Wheel Bearing Grease ....................22
Repacking Front Wheel Bearing and Axle Joint
Grease .......................................................................23
Checking Free-running Hub Grease .........................23
Checking Water Entry in Knuckle Flange..................23
Checking Brake Fluid Level and Leaks.....................23
Checking Brake System ............................................24
Changing Brake Fluid ................................................24
Checking Brake Booster, Vacuum Hoses,
Connections and Check Valve ..................................24
Checking Disc Brake .................................................24
Balancing Wheels ......................................................25
Tire Rotation ..............................................................25
Checking Power Steering Fluid and Lines ................26
Checking Steering Damper .......................................26
Checking Steering Gear Box and Linkage ................26
Lubricating Locks, Hinges and Hood Latches...........27
Checking Seat Belts, Buckles, Retractors,
Anchors and Adjusters...............................................27
Checking Body Corrosion ..........................................28
SERVICE DATA AND SPECIFICATIONS (SDS)..........29
Engine Maintenance ..................................................29
Chassis and Body Maintenance ................................29
MA

Supplemental Restraint System (SRS) ``AIR
BAG'' and ``SEAT BELT PRE-TENSIONER''
The Supplemental Restraint System such as ``AIR BAG'' and ``SEAT BELT PRE-TENSIONER'' used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS composition which is available to NISSAN MODEL Y61 is as follows (The composition varies
according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag in¯ation, all maintenance must be performed
by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.
Special Service Tools
Tool number
Tool nameDescription
EG17650301
Radiator cap
tester adapter
NT564
Adapting radiator
cap tester to radiator
®ller neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
KV10113600
Fuel ®lter wrench
Oil ®lter wrench
NT553
Removing fuel ®lter
Removing oil ®lter
a: Max. 100 mm
(3.94 in) dia.
PRECAUTIONS AND PREPARATION
MA-1

Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for speci®cations.
UNDER HOOD Ð engine off
hRadiator coolant level and coolant hose connec-
tions for leaks
hBattery ¯uid level, speci®c gravity and condi-
tions of battery terminals
hDrive belts tension
hFuel ®lter for water or dusts, and fuel lines and
connections for leaks
hEngine oil level and oil leaks
hClutch and brake reservoir ¯uid level and ¯uid
lines for leaks
hWindshield and rear window washer and head-
lamp cleaner reservoir ¯uid level
hPower steering reservoir ¯uid level and hose
connections for leaks
ON INSIDE AND OUTSIDE
hXRemove front spring/strut spacer (If applicable)
hOperation of all instruments, gauges, lights and
accessories
hOperation of horn(s), wiper and washer
hSteering lock for operation
hCheck air conditioner for gas leaks
hFront and rear seats, and seat belts for opera-
tion
hAll moldings, trims and ®ttings for ®t and align-
ment
hAll windows for operation and alignment
hHood, trunk lid, door panels for ®t and alignment
hLatches, keys and locks for operation
hWeatherstrips for adhesion and ®t
hHeadlamp aiming
hTighten wheel nuts (Inc. inner nuts if applicable)
hTire pressure (Inc. spare tire)
hCheck front wheels for toe-in
hInstall clock/voltmeter/room lamp fuse (If appli-
cable)
h
XInstall deodorizing ®lter to air puri®er (If appli-
cable)
h
XRemove wiper blade protectors (If applicable)
UNDER BODY
hManual transmission/transaxle gear oil, transfer
¯uid and differential gear oil level
hBrake and fuel lines and oil/¯uid reservoirs for
leaks
hTighten bolts and nuts of steering linkage and
gear box, suspension, propeller shafts and drive
shafts
h
XTighten rear body bolts and nuts (Models with
wooden bed only)
ROAD TEST
hClutch operation
hParking brake operation
hService brake operation
hAutomatic transmission/transaxle shift timing
and kickdown
hSteering control and returnability
hEngine performance
hSqueaks and rattles
ENGINE OPERATING AND HOT
hAdjust idle mixture and speed (and ignition tim-
ing*1)
hAutomatic transmission/transaxle ¯uid level
hEngine idling and stop knob operation (Diesel
only)
FINAL INSPECTION
hInstall necessary parts (outside mirror, wheel
covers, seat belts, mat, carpet or mud ¯aps)
hInspect for interior and exterior metal and paint
damage
hCheck for spare tire, jack, tools (wheel chock),
and literature
hWash, clean interior and exterior
*1: Not required on models with a direct ignition system
h
X: Not applicable to this model.
PRE-DELIVERY INSPECTION ITEMS
MA-2

General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the
checks and inspections themselves or they can have their NISSAN dealers do them.
Item Reference pages
OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise
speci®ed.
TiresCheck the pressure with a gauge periodically when at a service station, including the
spare, and adjust to the speci®ed pressure if necessary. Check carefully for damage, cuts or
excessive wear.Ð
Windshield wiper bladesCheck for cracks or wear if they do not wipe properly. Ð
Doors and engine hoodCheck that all doors, the engine hood, the trunk lid and back door
operate properly. Also ensure that all latches lock securely. Lubricate hinges, latches, rollers and
links if necessary. Make sure that the secondary latch keeps the hood from opening when the
primary latch is released.
When driving in areas using road salt or other corrosive materials, check for lubrication fre-
quently.MA-27
Tire rotationTires should be rotated every 5,000 km (3,000 miles) for 4WD models. MA-25
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when per-
forming periodic maintenance, cleaning the vehicle, etc.
LightsMake sure that the headlights, stop lights, tail lights, turn signal lights, and other lights
are all operating properly and installed securely. Also check headlight aim.Ð
Warning lights and chimesMake sure that all warning lights and chimes are operating prop-
erly.Ð
Steering wheelCheck for change in the steering conditions, such as excessive free play, hard
steering or strange noises.
Free play: Less than 35 mm (1.38 in)Ð
Seat beltsCheck 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-27
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the
engine oil or refuel.
Windshield washer ¯uidCheck that there is adequate ¯uid in the tank. Ð
Engine coolant levelCheck the coolant level when the engine is cold. MA-14, 15
Engine oil levelCheck the level after parking the vehicle on a level spot and turning off the
engine.MA-13, 14
Brake and clutch ¯uid levelMake sure that the brake and clutch ¯uid levels are between the
``MAX'' and ``MIN'' lines on the reservoir.MA-20, 23
BatteryCheck the ¯uid level in each cell. It should be between the ``MAX'' and ``MIN'' lines. Ð
GENERAL MAINTENANCE
MA-3

Engine and Emission Control Service
Annual driving distance below 30,000 km (18,000 miles)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust. [ ]: At the speci®ed mileage only
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform either at number of kilometers (miles)
or months, whichever comes ®rst.km x 1,000 10 20 30 40 50 60 70 80 90
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)
Months 6 12 18 24 30 36 42 48 54
Underhood and under vehicle
Engine anti-freeze coolant (Ethylene glycol base, LLC) See NOTE (2) R MA-14
Cooling systemI I I MA-16
Fuel linesI I MA-17
Fuel ®lterR R MA-16
Air cleaner ®lter (Viscous paper type).R R MA-18
Intake & exhaust valve clearanceAAAA *1
Injection nozzles See NOTE (3)MA-18
Timing belts for camshaft and injection pump[R] *2
NOTE: (1) Maintenance items with ``.'' should be performed more frequently according to ``Maintenance Under Severe
Driving Conditions''.
(2) First replace at 80,000 km (48,000 miles) or 48 months, then every 60,000 km (36,000 miles) or 36 months.
(3) If engine power decreases, black smoke is emitted or engine noise increases, check and, if necessary, adjust
the fuel injection nozzle's starting pressure and the fuel spray pattern.
*1: ``VALVE CLEARANCE'', RD in EM section
*2: ``TIMING BELT'' RD in EM section
Annual driving distance over 30,000 km (18,000 miles)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page km x 1,000 10 20 30 40 50 60 70 80 90
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)
Underhood and under vehicle
Engine anti-freeze coolant (Ethylene glycol base, LLC) See NOTE (2) R MA-14
Cooling systemI I MA-16
Fuel linesI MA-17
Fuel ®lterR MA-16
Air cleaner ®lter (Viscous paper type).R MA-18
Intake & exhaust valve clearanceAAA*1
Injection nozzles See NOTE (3)MA-18
Timing belts for camshaft and injection pumpR*2
NOTE: (1) Maintenance items with ``.'' should be performed more frequently according to ``Maintenance Under Severe
Driving Conditions''.
(2) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles).
(3) If engine power decreases, black smoke is emitted or engine noise increases, check and, if necessary, adjust
the fuel injection nozzle's starting pressure and the fuel spray pattern.
*1: ``VALVE CLEARANCE'', RD in EM section
*2: ``TIMING BELT'', RD in EM section
PERIODIC MAINTENANCE
MA-5

Maintenance Under Severe Driving Conditions
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A Ð Driving under dusty conditions
B Ð Driving repeatedly short distances
C Ð Towing a trailer or caravan
D Ð Extensive idling
E Ð Driving in extremely adverse weather condi-
tions or in areas where ambient temperatures
are either extremely low or extremely high
F Ð Driving in high humidity areas or in mountain-
ous areasG Ð Driving in areas using salt or other corrosive
materials
H Ð Driving on rough and/or muddy roads or in
the desert
I Ð Driving with frequent use of braking or in
mountainous areas
J Ð Frequent driving in water
Maintenance operation: Check = Check and correct or replace as necessary.
Driving
conditionMaintenance
itemMaintenance
operationMaintenance
interval
Reference
page Annual driving distance
below 30,000 km
(18,000 miles)over 30,000 km
(18,000 miles)
ABCD......Engine oil & oil ®lter
ReplaceEvery 3 months or
5,000 km (3,000
miles)Every 5,000 km
(3,000 miles)MA-13, 14
A.........Aircleaner ®lter Viscous paper type
ReplaceEvery 30,000 km
(18,000 miles) or
18 monthsEvery 30,000 km
(18,000 miles)MA-18
A...E.....Fuel ®lter
ReplaceEvery 20,000 km
(12,000 miles) or
12 monthsEvery 30,000 km
(18,000 miles)MA-16
.....F....Brake ¯uid
ReplaceMA-24
..C....H..Limited slip differential (LSD) gear oil*3
ReplaceEvery 30,000 km
(18,000 miles) or
18 monthsEvery 30,000 km
(18,000 miles)MA-22
......GH..Steering gear & linkage, axle & suspension parts &
propeller shaft & exhaust systemCheck
Every 10,000 km
(6,000 miles) or 6
monthsEvery 15,000 km
(9,000 miles)MA-26, 21,
23 *1
......GH.JGreasing points of propeller shafts Lubricate MA-21
..C....H..Drive shafts & steering damper Check *1
A.C...GHI.Brake pads, discs & other brake components Check MA-24
.........JFront wheel bearing grease & free-running hub grease Check *2, MA-23
*1: ``Front Axle and Front Suspension Parts'' in FA section, ``Rear Axle and Rear Suspension'' in RA section
*2: ``Front Wheel Alignment'' in FA section
*3: Including differential gear with differential lock
Maintenance for off-road driving
Whenever you drive off-road through sand, mud or water as deep as the wheel hub, more frequent mainte-
nance may be required of the following items:
mBrake pads and discs
mBrake lining and drums
mBrake lines and hoses
mWheel bearing grease and free-running hub grease
mDifferential, transmission and transfer oil
mSteering linkage
mPropeller shafts and front drive shafts
mAir cleaner ®lter
mClutch housing (Check water entry. Refer to MA-21.)
PERIODIC MAINTENANCE
MA-8

Checking Cooling System
CHECKING HOSES AND CLAMPS
Check hoses and clamps for proper attachment, leaks, cracks,
damage, loose connections, cha®ng and deterioration.
CHECKING RADIATOR CAP
Apply pressure to radiator cap with cap tester to see if it is satis-
factory.
Radiator cap relief pressure:
78-98kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Pull the negative-pressure valve to open it. Check that it closes
completely when released.
CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system with cap tester to check for
leakage.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm
2, 14 psi)
CAUTION:
Use of higher pressure than the speci®ed value may cause
damage to radiator.
Checking and Replacing Fuel Filter and
Draining Water
Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.
CHECKING FUEL FILTER
Check fuel ®lter for fuel leakage, damage and other abnormal
signs.
REPLACING FUEL FILTER
1. Disconnect harness connector and drain fuel.
SLC613
SMA871B
SMA007D
SMA757B
ENGINE MAINTENANCE
MA-16

2. Remove fuel ®lter using band-type ®lter wrench.
Remove fuel ®lter and fuel ®lter sensor.
CAUTION:
Remove fuel ®lter without spilling fuel. If spilt, wipe off imme-
diately. Be specially careful not to spill fuel on engine mount
insulator.
3. Wipe clean fuel ®lter mounting surface on fuel ®lter bracket and
smear a little fuel on rubber seal of fuel ®lter.
4. Screw fuel ®lter on until a slight resistance is felt, then tighten
an additional more than 2/3 of a turn.
5. Install fuel ®lter sensor to new fuel ®lter.
6. Bleed air from fuel line.
Refer to Bleeding Fuel System in EC section.
7. Start engine and check for leaks.
DRAINING WATER
1. Drain water as follows.
Loosen drain cock and drain water.
Loosening drain cock 4 to 5 turns causes water to start drain-
ing. Do not remove drain cock by loosening it excessively.
If water does not drain properly, move the priming pump up and
down.
2. Bleed air.
Checking Fuel Lines
Check fuel lines and tank for proper attachment, leaks, cracks,
damage, loose connections, cha®ng and deterioration.
CAUTION:
Keep clean parts with compressed air when assembling.
SMA005D
SMA010
SMA825B
SMA803A
ENGINE MAINTENANCE
Checking and Replacing Fuel Filter and
Draining Water (Cont'd)
MA-17

Cleaning and Replacing Air Cleaner Filter
VISCOUS PAPER TYPE
The viscous paper type air cleaner ®lter does not require any clean-
ing operation between renewal.
Checking Injection Nozzle
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to come into contact with your hand or
body, and make sure that your eyes are properly protected.
1. Install nozzle to injection nozzle tester and bleed air from ¯are
nut.
2. Check initial injection pressure by pumping tester handle one
full stroke per second.
Initial injection pressure:
Used nozzle
More than 14,220 kPa
(142.2 bar, 145 kg/cm
2, 2,062 psi)
New nozzle
14,711 - 15,495 kPa
(147.1 - 155.0 bar, 150 - 158 kg/cm
2,
2,133 - 2,247 psi)
+Always check initial injection pressure before installing
new nozzle.
3. Check spray pattern by pumping tester handle one full stroke
per second.
a. If main spray angle is within 30 degrees as shown, injec-
tion nozzle is good.
b. It is still normal even if a thin stream of spray deviates from
main spray (pattern B).
4. If initial injection pressure or injection nozzle is not normal,
adjust or clean injection nozzle.
5. Test again. If it is not corrected, replace nozzle.
Refer to EC section for injection pressure adjustment, clean-
ing and replacement.
SMA006D
EF791A
SEF672A
SEF079S
ENGINE MAINTENANCE
MA-18

6. Install all injection nozzles with Tool and securely connect fuel
spill tube and delivery tubes.
7. Bleed air from fuel system and check for fuel leakage with
engine running.
Injection nozzle to cylinder head:
:59-69Nzm (6.0 - 7.0 kg-m, 43 - 51 ft-lb)
Spill tube nut:
:39-49Nzm (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Injection tube:
:20-25Nzm (2.2 - 2.5 kg-m, 16 - 18 ft-lb)
Checking Idle Speed
Inspection should be carried out with gears in ``Neutral'' and
with air conditioner and other electrical loads off.
1. Warm up engine until engine coolant temperature indicator
points to the middle of gauge.
2. Attach a diesel tachotester's pick-up to No. 1 fuel injection tube.
3. Race engine two or three times and check idle speed.
Idle speed:
Unit: rpm
MT 750+50
þ0
Timing Belt Replacement
Refer to EM section.
ENGINE MAINTENANCE
Checking Injection Nozzle (Cont'd)
MA-19