engine NISSAN PICK-UP 1998 Repair Manual

Radiator (Aluminum type)
PREPARATION
1. Attach the spacer to the tip of the radiator plate pliers A.
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71
in) wide x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A are closed
dimension H¢¢is approx. 7.6 mm (0.299 in).
3. Adjust dimension H¢¢with the spacer, if necessary.
lIf the radiator core rims cannot be crimped as specified,
further modification of the radiator plate pliers A is
required. Refer to the Technical Bulletin LC 91-001.
DISASSEMBLY
1. Remove tank with Tool.
lGrip the crimped edge and bend it upwards so that Tool slips
off.
Do not bend excessively.
SLC142B
SLC655C
SLC903
SLC893
ENGINE COOLING SYSTEM
LC-28

lIn areas where Tool cannot be used, use a screwdriver to
bend the edge up.
Be careful not to damage tank.
2. Make sure the edge stands straight up.
ASSEMBLY
1. Clean contact portion of tank.
2. Install sealing rubber.
Push it in with fingers.
Be careful not to twist sealing rubber.
3. Caulk tank in specified sequence with Tool.
SLC930
SLC931
SLC932
SLC917A
SLC904
ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont'd)
LC-29

lUse pliers in the locations where Tool cannot be used.
4. Make sure that the rim is completely crimped down.
Standard height ``H'':
8.0 - 8.4 mm (0.315 - 0.331 in)
5. Confirm that there is no leakage.
Refer to Inspection.
INSPECTION
1. Apply pressure with Tool.
Specified pressure value:
157 kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
2. Check for leakage.
SLC896
SLC897
SLC554A
SLC933
SLC934
ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont'd)
LC-30

Overheating Cause Analysis
Symptom Check items
Cooling
system parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
Ð Thermostat stuck closed Ð
Damaged finsDust contamination or paper
clogging
Mechanical damage
Clogged radiator cooling tubeExcess foreign material (rust,
dirt, sand, etc.)
Reduced air flowCooling fan does not operate
ÐÐ Fan coupling does not operate
High resistance to fan rotation
Damaged fan blades
Damaged radiator shroud Ð Ð Ð
Improper coolant mixture ratio Ð Ð Ð
Poor coolant quality Ð Ð Ð
Insufficient coolantCoolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deteriora-
tion or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into cooling
systemCylinder head deterioration
Cylinder head gasket deteriora-
tion
Except
cooling
system parts
malfunctionÐ Overload on engineAbusive drivingHigh engine rpm under no load
Driving in low gear for extended
time
Driving at extremely high speed
Powertrain system malfunction
Ð Installed improper size wheels
and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air flowBlocked bumper Ð
Ð Blocked radiator grilleInstalled car brassiere
Mud contamination or paper
clogging
Blocked radiator Ð
Blocked condenser
Ð
Installed large fog lamp
ENGINE COOLING SYSTEM
LC-31

Engine Lubrication System (KA)
Oil pressure check
Engine speed
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed More than 78 (0.78, 0.8, 11)
3,000 412 - 481 (4.12 - 4.81, 4.2 - 4.9, 60 - 70)
Oil pump inspection
Unit: mm (in)
Rotor tip clearance Less than 0.12 (0.0047)
Outer rotor to body radial
clearance0.15 - 0.21 (0.0059 - 0.0083)
Side clearance (with gasket) 0.04 - 0.08 (0.0016 - 0.0031)
Engine Cooling System (KA)
Thermostat
Valve opening temperature ÉC (ÉF) 76.5 (170)
Valve lift mm/ÉC (in/ÉF) More than 8/90 (0.31/194)
Radiator
Unit: kPa (bar, kg/cm2, psi)
Cap relief
pressureStandard78-98
(0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit59-98
(0.59 - 0.98, 0.6 - 1.0,9-14)
Leakage test pressure 157 (1.57, 1.6, 23)
Engine Lubrication System (TD)
Oil pressure check
Engine speed
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed More than 78 (0.78, 0.8, 11)
3,000 294 - 392 (2.94 - 3.92, 3.0 - 4.0, 43 - 57)
Oil pump inspection
Unit: mm (in)
Gear side clearance Less than 0.13 (0.0051)
Gear backlash Less than 0.43 (0.0169)
Oil pump bushing clearance Less than 0.15 (0.0059)
Oil pump bushing inside diameter13.012 - 13.106
(0.5123 - 0.5160)
Drive gear shaft outside diameter12.974 - 12.992
(0.5108 - 0.5115)
Engine Cooling System (TD)
Radiator
Unit: kPa (bar, kg/cm2, psi)
Cap relief pressure78-98
(0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Leakage test pressure 157 (1.57, 1.6, 23)
Thermostat
Tropical type Standard type
Valve opening tem-
perature ÉC (ÉF)76.5 (170) 82 (180)
Valve lift
mm/ÉC (in/ÉF)More than 8/90
(0.31/194)More than 8/95
(0.31/203)
SERVICE DATA AND SPECIFICATIONS (SDS)
LC-32

MAINTENANCE
SECTION
MA
CONTENTS
PRECAUTIONS AND PREPARATION..................... 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models).............................................. 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models).............................................. 1
Special Service Tools ............................................ 2
Commercial Service Tools ..................................... 2
PRE-DELIVERY INSPECTION ITEMS...................... 3
GENERAL MAINTENANCE...................................... 4
PERIODIC MAINTENANCE...................................... 5
Basic Schedule for Gasoline Engine Models ........ 5
Basic Schedule for Diesel Engine Models ............ 8
Maintenance Under Severe Driving Conditions .. 10
RECOMMENDED FLUIDS AND LUBRICANTS..... 12
Fluids and Lubricants........................................... 12
SAE Viscosity Number......................................... 13
Anti-freeze Coolant Mixture Ratio........................ 14
KA
ENGINE MAINTENANCE........................................ 15
Checking Drive Belts ........................................... 15
Changing Engine Coolant .................................... 16
Checking Cooling System.................................... 17
Checking Fuel Lines ............................................ 18
Changing Fuel Filter ............................................ 18
Changing Air Cleaner Filter (Viscous paper
type) ..................................................................... 19
Changing Engine Oil ............................................ 19
Changing Oil Filter ............................................... 20
Checking and Changing Spark Plugs.................. 20
Checking Ignition Wires ....................................... 21Checking Positive Crankcase Ventilation
(PCV) System ...................................................... 21
Changing Positive Crankcase Ventilation
(PCV) Filter .......................................................... 21
Checking Vacuum Hoses and Connections ........ 22
Checking Vapor Lines.......................................... 22
Checking Heated Oxygen Sensor ....................... 22
TD
ENGINE MAINTENANCE........................................ 23
Checking Manifold Tightening Torque ................. 23
Adjusting Intake and Exhaust Valve Clearance .. 23
Checking Drive Belt ............................................. 23
Changing Engine Oil ............................................ 24
Changing Engine Oil Filter................................... 24
Changing Engine Coolant .................................... 25
Checking Cooling System.................................... 26
Checking and Replacing Fuel Filter and
Draining Water ..................................................... 27
Checking Fuel Lines ............................................ 28
Cleaning and Replacing Air Cleaner Filter .......... 29
Checking Injection Nozzle ................................... 29
Checking Idle Speed............................................ 30
CHASSIS AND BODY MAINTENANCE................. 32
Checking Exhaust System ................................... 32
Checking Clutch Fluid Level and Leaks .............. 32
Checking Clutch System...................................... 32
Checking M/T Oil ................................................. 32
Changing M/T Oil ................................................. 32
Checking Water Entry - For 4WD models ........... 33
MA

Checking Transfer Fluid....................................... 33
Changing Transfer Fluid ...................................... 33
Checking Propeller Shaft ..................................... 33
Greasing Propeller Shaft ..................................... 33
Checking Differential Gear Oil ............................. 34
Changing Differential Gear Oil............................. 34
Balancing Wheels ................................................ 34
Tire Rotation ........................................................ 35
Checking Brake Fluid Level and Leaks ............... 35
Checking Brake System ...................................... 35
Changing Brake Fluid .......................................... 35
Checking Brake Booster, Vacuum Hoses,
Connections and Check Valve ............................ 36Checking Disc Brake ........................................... 36
Checking Drum Brake.......................................... 36
Checking Steering Gear and Linkage ................. 37
Checking Power Steering Fluid and Lines .......... 37
Checking Steering Gear Oil Level and Leaks ..... 38
Lubricating Hood Latches, Locks and Hinges ..... 39
Checking Seat Belts, Buckles, Retractors,
Anchors and Adjusters......................................... 40
Checking Body Corrosion .................................... 41
SERVICE DATA AND SPECIFICATIONS (SDS)... 42
Engine Maintenance (KA) .................................... 42
Engine Maintenance (TD) .................................... 42
Chassis and Body Maintenance .......................... 42

Special Service Tools
Tool number
Tool nameDescriptionEngine application
KA TD
KV10106001
Oil filter wrenchRemoving oil
filter
ÐX
NT690
KV10105901
Oil filter cap wrench
NT689
XÐ
EG17650301
Radiator cap tester
adapter
NT564
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)XX
KV10113600
Fuel filter wrench
NT553
Removing fuel
filter
ÐX
a: Max. 100 mm
(3.94 in) dia.
Commercial Service Tools
Tool name DescriptionEngine application
KA TD
Spark plug wrench
NT047
Wrench with a
magnet to hold
spark plug
XÐ
PRECAUTIONS AND PREPARATION
MA-2

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 specifications.
UNDER HOOD Ð engine off
hRadiator coolant level and coolant hose con-
nections for leaks
hBattery fluid level, specific gravity and condi-
tions of battery terminals
hDrive belts tension
hFuel filter for water or dusts, and fuel lines and
connections for leaks
hEngine oil level and oil leaks
hClutch and brake reservoir fluid level and fluid
lines for leaks
hWindshield and rear window washer and head-
lamp cleaner reservoir fluid level
hPower steering reservoir fluid level and hose
connections for leaks
ON INSIDE AND OUTSIDE
hRemove 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 fittings for fit and align-
ment
hAll windows for operation and alignment
hHood, trunk lid, door panels for fit and align-
ment
hLatches, keys and locks for operation
hWeatherstrips for adhesion and fit
hHeadlamp aiming
hTighten wheel nuts (Inc. inner nuts if appli-
cable)
hTire pressure (Inc. spare tire)
hCheck front wheels for toe-in
hInstall clock/voltmeter/room lamp fuse (If appli-
cable)
UNDER BODY
hManual transmission/transaxle gear oil, trans-
fer fluid and differential gear oil level
hBrake and fuel lines and oil/fluid reservoirs for
leaks
hTighten bolts and nuts of steering linkage and
gear box, suspension, propeller shafts and
drive shafts
ROAD TEST
hClutch operation
hParking brake operation
hService brake operation
hSteering control and returnability
hEngine performance
hSqueaks and rattles
ENGINE OPERATING AND HOT
hAdjust idle mixture and speed (and ignition tim-
ing*1)
hEngine idling and stop knob operation (Diesel
only)
FINAL INSPECTION
hInstall necessary parts (outside mirror, wheel
covers, seat belts, mat, carpet or mud flaps)
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-3

General maintenance includes those items which should be checked during the normal day-to-day opera-
tion of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can per-
form the checks and inspections themselves or they can have their NISSAN dealers do them.
Item Reference pages
OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise
specified.
TiresCheck the pressure with a gauge periodically when at a service station, including the
spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or
excessive wear.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-39
Tire rotationTires should be rotated every 10,000 km (6,000 miles) for 2WD models and every
5,000 km (3,000 miles) for 4WD models.MA-35
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-40
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 fluidCheck that there is adequate fluid in the tank. Ð
Engine coolant levelCheck the coolant level when the engine is cold. MA-16, 25
Engine oil levelCheck the level after parking the vehicle on a level spot and turning off the
engine.MA-19, 24
Brake and clutch fluid levelMake sure that the brake and clutch fluid levels are between the
``MAX'' and ``MIN'' lines on the reservoir.MA-32, 35
BatteryCheck the fluid level in each cell. It should be between the ``MAX'' and ``MIN'' lines. Ð
GENERAL MAINTENANCE
MA-4