service_manual_datsun_200sx_1980 z20e.pdf

8/11/2019 Service_Manual_Datsun_200SX_1980 Z20E.pdf

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v

I

DATSUN

I

o

98

DATSUN

2

SX

r

SERVICE

MANUAL

A

J

I

I

h

t

fi

t

t

i

C

o

IIV

INI55ANI

HUMOco


2/571

QUICK

REFERENCE

INDEX

GENERAl

INFORMATION

G

DATSUN

2 SX

MAINTENANCE

M

ENGINE

MECHANICAL

E

Model

S

J

JO

Series

ENGINE

LUBRICATION

COOLING

SYSTEMS L C

ENGINE

FUEL

iF

FOREWORD

EMISSION

C O N T R O L

SYSTEM

E

This

service

manual

has

been

prepared

pri

marily

for the

purpose

of

assisting

service

personnel

in

providing

effective service and

maintenance

ofthe

98

DATSUN

2 SX

ENGINE

REMOVAL INSTALLATION

E

ENGINE

CONTROl

FUEL

EXHAUST SYSTEMS

F

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

specif ications

con

tained in

thismanual

consult

your

NISSANI

DATSUN dealer for

information

CLUTCH

C

MANUAL TRANSMISSION

M

AUTOMATIC

TRANSMISSION

A

PROPE LLER SHAF T

DIFFERENTIAL

CARRIER

P

FRONT AXlE

FRONT SUSPENSION F

The

right

is reserved to

make

changes

in

specif ications

andmethods

at

any

time

with

out

notice

REAR A X L E

REAR

SUSPENSION

R

BRAKE

SYSTEM

B

STEERI N G

SYSTEM

S

NISSAN MOTOR CO

LTD

BODY

B

HEATER

AIR

CONDITIONER

H

@

t

979

NISSAN

MOTOR CO

LTD

Printed

in

Japan

Not

to be

reproduced

in

wholeorn

part

without

the

prior

written permission

of NissanMotor

Com

pany

Ltd

Tokyo

Japan

ELECTRICAL SYSTEM

E


3/571

HOW

TO

USE

THIS

MANUAL

This Service

Manual

is

designed

as a

guide

for

servicing

cars

This

manual

is divided into

9

sections

The

first

half

of

the

manual

presents

sections

which

concern

the

engine

and thesecond

half

presents

sections

which

deal

with

thechassis

and

body

AQUICK

REFERENCE

INDEX is

provided

on

the

first

page

Refer tothis

index

along

with

the

indexof the

particular

section

you

wish to

consult

The first

page

oeach

section lists the

contents

and

gives

the

page

numbers for the

respective topics

SE

RVICr

ATAANDSPECIFICATIONSare

contained

in

each

section

TROUBLE

DIAGNOSES

AND

CpRRECT IONS

arealso included in each section This

featureothe

manual

lists

the

likely

causeso

trouble

and recommends the

appropriate

corrective

actions

to

be

taken

A

ist of

SPECIAL

SERVICE

TOOLS is included

in

each section

The

special

service

tools

are

designed

to

assist

you

in

performing repair

safely

accurlltely

and

quickly

For

information

concerning

howto

obtain

special

service tools writetothe

following

address

K e n to o r e

Corporation

K e n to o r e

o

Canada

Ltd

29784Lttle ack 2395

Cawthra

RO

eville

Michigan

48 66

Mississauga

Ontario

CanadaL5A3P2

Themeasurements

given

in this

manual

are

primarily

expressed

with

the

Sl unit International

System

o

Unit

and

alternately

expressed

in

the

metric

system

and in the

yard pound

system

The

back

coveof

themanual

provides

maintenance

data for

quick

reference

In

thetext the

following

abbreviations

ae

used

so ServiceData nd

Specifications

L

H

R

H

let

Hand Right Hand

f

Tightening TorQue M O r r AiT Manual

Transmission Automatic Transmission

The

captions

CAUTION

and

WARNING

warn

you

o

steps

that

must

be followed to

prevent

personal

injury

and

or

damage

to

somepart

othe

car

N

IMPORTANT

SAFETY

NOTICE

I

The

proper

performance

o

service

is

essential for both

the

safetY

othe

mechanic and

theefficient

functioning

o

thecar

The

service

methods in this

Service

Manual

are

described

in

such

a

manne

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

themechanic

and

the

tools and

parts

available

Accordingly

anyone

using

service

procedures

tools

or

parts

which

are

no

specifically

recommended

by

NISSAN

must first

completely

satisfy

himself

that

neither

his

safety

nor

thecars

safety

will

be

jeopardized

by

the

service method

selected


4/571

DATSUN

2 SX

Model SIlO

Series

SECTIONGI

GI

GENERAL

INFORMATION

CONTENTS

GENERAL

VIE

WS

MODEL VARATION

IDENTIFICATION

NUMBER

LIFTING

POINTS

AND

TOWING

PANTOGRAPH

JACK

GARAGE

JACK AND

SAFETY

STAND

GI 2

GI 3

GI4

GI

5

GI 5

GI

5

TIE

DOWN

TOWING

SPECIAL

SERVICE TOOLS

TIGHTENING

TORQUE

OF

STANDARD

BOLT

GI 5

GI 5

GI 6

GI 6


5/571

Genetal

Vews

GENERAL

INFORMATION

Hardtop

I

r

I

O

II

JI

P o

dI

V

Ll

34S S3

68

66

l l

r

U

I

hF

o i

LI

345

53

O

J

68

66

Unit

mm

in

Hatchback

t

iq

L

345

53

68

66

Unit

mm

in

GI

2

GENERAL

VIEWS

J

c

f

r

L

m

4

f

g

t

I

ll

t

X

99 39

2 4

94

5

9 42

9

48

7 64

SGIOO2

f T

d

r

I i

r

b

t

I

J

I

t

i L

L

J J

I

J

J

t

u J J

IY

T

2 4

94 5 t

9

42 9

4

48

t

764

99 39

5GI 3


6/571

GENERAL

INFORMATION

Model

Variation

MODEL VARATION

Desti

Differential

Road

wheel

nation

Class

Model Engine Transmission

carrier

Size

Offset

Tire

size

mm

in

PII I O F E V

FS5W7 B

Hardtop

PLSIIOAEV

I

3N7 B

California

KPLSIlOFEV

I

5J

4

25

85

FS5W7 B

Hatchback

98

7

SR

4

KPLSllOAEV

I

3N7 B

U

S

A

PLSIl

OFEU

I

FS5W7 B

Hardtop

I

I

P L S l l O A JU

3N7 B

5

2JJ

4

25 85

Z2 E

HI65B

KPLSllOFEU

I

FS5W7 B

98

7

SR 4

Hatchback

Non

I

KPLSIIOAEU

I

3N7 B

California

I

PLSllOFEN

I

FS5W7 B

Hard

top

I I

2

PLSllOAEN

3N7 B

4

T

x

6

35

T 35

Canada

I

KPLSllOFEN

I

FS5W7IB

8 7 D 6

2

Hatchback

I

KPLSllOAEN

I

3N7 B

Prefix

and

suffix

designations

K

o

P

L

Hatchback

I

Hardtop

J

Z2

engine

Left

handdrive

K

P

L

SIlO

J

I

PST

LT

means no

indication

I

Aluminumwheel

Option

2

Spare

tire

Sun

roof

Glass

Sport Luxury

model

Power

steering

Sun

roof Steel

Rear window

wiper

Air

conditioner

N o na l i f o r n i a model

for

U

S

A

V

California

model

N Canada

model

E E

Fl

F

Manual transmission

S

P

R

L

C

U

A

Automatic

transmission

GI

3


7/571

IdentificationNiJmber

GENERAL INFORMATION

CARSERAL

NUMBER

PLATE

CARSERIAL

NUMBER

Hatchback

Z2

engine

Model

ENGINE

SERIAL

NUMBER

The

engine

seria

number

is

stamp

ed on

the

left side

of

the

cylinder

block

I

Q

SGIOO6

GI4

IDENTIFICATION NUMBER

EMISSION CONTROL

INFORMATION LABEL

K

P

SlID

r

x

X X X X X

I

MANUAL TRANSMISSION

NUMBER

The

transmission

seria

number

is

stamped

on

thefront

upper

face of

the

transmission

case

TM235

SGI 4

Car serial number

AUTOMATIC

TRANSMISSION

NUMBER

The

transmission

serial

number

plate

is

attachedon

the

right

hand side

of

the

transmission

case

AT344


8/571

GENERAL

INFORMATION

UftingPointsand

Towing

LIFTING

POINTS

AND TOWING

Towing

hook

UL

IW

I

@

A

@

Il

Towing

hook

Jack

up

point

for

pantograph jack

Jack

up

point

for

garage

jack

Supportable point

for

safety

stand

PANTOGRAPH JACK

WARNING

a Never

get

under

the car

while it

is

supported only

by

the

jack

Always

use

safety

stands

to

support

framewhen

you

have to

get

under the

car

b Place

wheel chocks

at both front

and back

of

thewheel

diagonally

opposite

the

jack position

Apply

the

pantograph

jack

fur

nished

wth

the

car

to the

position

indicated

below in a

safe manner

t

GARAGE

JACK

AND

SAFETY

STAND

WARNING

a

When

carrying

out

operations

with the

garage

jack

be

sure

to

support

the

car

with

safety

stands

b

When

jacking

up

the

rear front

of

the

car

place

the

chocks

at

the

front rear of

the

front

rear

wheels

to

hold

them

CAUTION

Always

place

a

wood block

between

safety

stand

and car

body

when

supporting body

with

safety

stand

Apply

the

garage

jack

and

safety

stand to the

position

indicated

below

in

a

safe

manne

TIEDOWN

FRONT SIDE

Use

front

towing

hooks

for tie

down

REAR

SIDE

Use rear

towing

hooks

for

tie down

TOWING

CAUTION

a

It

s

necessary

to use

proper

towing

equipment

to

avoid

possible

dam

age

to

the car

during

a

towing

operation

Towing

is in accordance with Tow

ing

Procedure

Manual

at

dealer

side

Towing

hook

7

r

J

@

II

I

6

Towing

hook

SG

7

b All

applicable

State

or

Provincial

in

Canada

laws

and local laws

regarding

the

towing

operation

must be

obeyed

c Before

towing

make

sure

that

the

transmission

axles

steering

system

and

power

train are in

good

order

If

any

unit

is

damaged

a

dolley

must

be used

d

If

the

transmission is

inoperative

tow

the

carwith

the rear

wheels

off

the

ground

or with

the

propeller

shaft

removed

e When thecar

s

towed

with its front

wheels

on

the

ground

secure

the

steering

wheel

in

a

straight

ahead

position

with

the

ignition

ke y

turned in

OFF

position

f

When

towing

an

automatic

trans

mission model on its rear

wheels

do

not exceed 3

k m

h2

MPH

and

a

distance of

3

km 2 miles

g

Release

the

parking

brake and

set

the

gearshift

lever in

Neutral

position

before

starting

to tow

the

car

GI

5


9/571

Specia Service

Too

s

Tightening

TO

u e o f S t a n d a r d B o l t

GENERAL

INFORMATION

SPECIAL

SERVICE

TOOLS

Special

Tools

play very important

role

in

the

maintenance

of

cars These

are

essential

to

the safe

accurate

and

speedy

servicing

The

working

times

listed

in the

column under

FLAT

RATE TIME

in

FLAT

RATE

SCHEDULE

are com

puted

based on the

use

of

Special

Tools

The

identification

code

of

mainte

nancetools

is

made

up

of

2

alphabeli

calletteISand

8

i g i t a l

figures

The

heading

two

letters

roughly

classify

toolsor

equipment

as

STOOOOOOOO

Special

Tool

KVOOOOOOOO

Special

Tool

EMOOOOOOOO

Engine

Overhaul

ing

Machine

General

Gauge

Garage

Tool

Hand Tool

GGOOOOOOOO

LMOOOOOOOO

HTOOOOOOOO

TIGHTENING TORQUE OF

STANDARD

BOLT

Grade Boltornut size

M6

M8

4T

MIO

MI2

MI4

M6

M8

7T

MIO

MI2

M4

M6

M8

9T

MIO

MI2

M4

Specialpam

re

excluded

2

This

standard

is

applicable

to

bou

having

the

following

marks

embossed

on

thebolt head

Grade

Mark

4T

7T

9T

GI

6

Bolt

ornut diam

eter

mm

Pitch mm

6

5

5

75

5

25

5

75

5

5

5

5

5

8

2

4

6

8

2

4

6

8

2

4

Nominal diameter

4

7

9

M6

T T

Tightening

torque

Nm

kg

m

ft

Ib

29 3

9 3

4 2 2 2 9

78

8

8

L

5

8

8

7

8

8 8 L

5

8 8

6

22

2 2 2 6

6 22

2 2 2 6

26

36

27

3

7

2

27

3 4

3

4

22 3

46 62 4

7 63

34 46

5

9 6 9

6

7

43

5

I

4

8

4

8 3

I

4

84

8

3

I

25

35

2

6

3

6

9 26

I

26 36

2 7

3

7

2

27

I

45 6

4

6

6

2

33

45

I

5 68 5

6 9 37

5

L

76

3

77

5

56 76

I

78

8

O

8 8

I

9

25

25

4 8

I

2

27

2

2

8

4

2

I

36 5

37

5

27

37

I

39

5 4

5 29 38

I

65 88

6 6

9

48

65

I

72 97

73

9

9

53 72

I

9

47

5

8 8

Nominal diameter

of

bolt threads

Unit

mm

Metric

screw threads


10/571

DATSUN

2 SX

Model

S J

J

Series

II

MAINTENANCE

CONTENTS

MAINTENANCE SCHEDULE

MA

2

MANUAL

TRANSMISSION

MA

23

LUBRICATION CHART

MA

4

AUTOMATIC

TRANSMISSION

MA 24

RECOMMENDED

FUEL AND

PROPELLER SHAFT

AND

LUBRCANTS

MA

5

DIFFERENTIAL

CARRER

MA 24

FUEL

MA

5

FRONT AXLE AND

LUBRCANTS

MA

5

FRONT SUSPENSION

MA

24

SAE

VISCOSITY

NUMBER

MA

5

REAR AXLE

AND

APPROXIMATE

REFILL

REAR SUSPENSION

MA

27

CAPACITIES

MA

5

BRAKE

SYSTEM

MA

28

ENGINE

MAINTENANCE

MA

6

WHEEL AND TIRE

fVlA 29

BASIC

MECHANICAL

SYSTEM

MA

6

STEERING

SYSTEM

MA33

IGNITION

AND FUEL

SYSTEM

MA

9

BODY

MA

35

EMISSION

CONTROL

SYSTEM

MA

4

HEATER

AND

AIR

CONDITIONER

MA36

MINORTROUBLE

DIAGNOSES

SERVICE

DATA

AND

AND

CORRECTIONS

MA

5

SPECIFICATIONS

MA

39

CHASSIS

AND

BODY

ENGINE

MAINTENANCE

MA

39

MAINTENANCE

MA

23

CHASSIS

AND

BODY

ENGINE

CONTROl

FUEL

MAINTENANCE

MA

39

AND EXHAUST

SYSTEMS MA 23

SPECIAL

SERVICE TOOL

M A

CLUTCH

MA

23


11/571

Maintenance Schedule

MAINTENANCE

MAINTENANCE

SCHEDULE

The

following

tabels list

the

periodic

maintenance

servicing

required

toensure

good

emission

control

performance

good

engine

performance

and

good

mechanicalcondition inDATSUN

Thefint

6 km

miles service isone

o

the

most

important

services

uired

to

nsurw

the

maximum mission

control

perfonnlnce

and

optimuin

engine

con

ition

MAINTENANCE

OPERATION

MAINTENANCE

INTERVAL

Periodicmaintenanceshould

be

performed

Kilometers

x

t2

24 36 48 6

72

a

numberokilometers milesormonths

Ref

rence

whichever

comes

first

Mlesx

7

5

t5

22

5

3 37

5

45

page

Months 6

t2 t8

24

3D

36

Intake exhaust valve clearance

Drive

belts

E n

in e

oil oil

filte

Engine

coolant

Idle

rpm

Fuel filte

Fuel

lines

hoses

piping

connections

ec

Air

cleaner

filte

Spark

plugs

EMISSION

CONTROL MAINTENANCE

@

CALIFORNIA

@ @

j

So NOTE

R

RO

R

R

RO

@

So NOTE

3

I

Soo

NOTE

2

@

@

Ignitionwiring

Ar

induction

v8lv filte

Vapor

lines

NOTE

III

2

3

4

So NOTE

2

R

@

MA

6

MA

6

MA 7

MA

8

MA

2

MA

3

MA

3

MA

4

MA

9

MA9

MA t4

MA t4

RO

Abbreviations A

Adjust A

Replace

I I

nspect

correct replace

if

necessary

If

nhcas

under

seve conditions

short

distance

driving

extensive

idling

o

driving

in

dusty

conditions

change

engine

oil

every

5 km

3 miles

o

months whichever

comes

first

More

frequent

maintenance

is

required

und

dustydriving

conditions

Ifhevehice is

operated

underexremeadverseweather

conditions

o

in

as

whereambient

temperaturas

are

either

extremely

low

o

extremely

high

the

filte

might

become

clogged

Insuchan

event replace

the filt

mmmiatefy

D @

an

@

arethemaintenance intervals

required

by

California

Regulations @

limits thewarranty

COYItohesere

placement

InterYals and

R

the

uired

mainUNInce

intervals

Other

maintenance

itemsand intervalsarerecommended

by

NISSAN

MOTORCO

L

TO

EMISSION CONTROL MAINTENANCE

NO NA L l F O R N I A

A A

I

R R

R

A

Intake

exhaust valveclearance

Drjve

bel

s

Engine

oil oil filte

Engine

coolant

Idle

rpm

mixture

ratio

Fuel

filter

Fuel lines

hoses

piping

connections

e tc

J

Air cleaner

filte

Ignition

timing

Spark

plugS

So NOTE

5

R

R R

Idle

rpm

A A

Mixture

raio

Soo

NOTE

7

So NOTE

6

R

A

R

I

R

A

Ignitionwiring

Arinduction valve

filte

except

Canada

Vapor

lines

A

2

Soo

NOTE

6

A MA

6

MA

6

MA

7

MA 8

MA

l

MA

l

MA

3

MA

3

MAt4

MA l

MA 9

MA 9

MA 4

MA

4

R

A

A

5

6

7

8

Abbreviations

A

Adjust

R

Replace

I

Inspect

correct

replace

if

necessary

Ifvehicle is

operated

under

senre

conditions short

distance

driving

extensive

idling

ordriving

in

dusty

conditions

chenge

engine

oil

every 5

km 3

miles

o

3

months whchne

comes

fitst

Mor

frequent

maintenance

is

required

undar

dusty

driving

conditions

Ifhevehicle is

opemed

under

extreme

adverse

weather

conditionso

n

aeas

whereambient

temperatures

are

either

extremely

low

or

extremely

high

the

filte

might

become

dow

l

n such

IIn

event

replace

the

filter

immeduty

Maintenance

items

wth

are

recommended

by

NISSAN

MOTORCO LTO

Other

maintenanceitemsIfll

required


12/571

MAINTENANCE

Maintenance

Schedule

Periodic

maintenance

should

be

performed

a

number

okilometers

miles

o

months

whichevercomes

first

MAINTENANCE INTERVAL

Kilometers

x

t2

24 36 48 6

72

Reference

Mles

x

III

7 5 It5 22 5 3 37 5

45

page

Months

6

t2 t8

24 3

36

MAINTENANCE OPERATION

UNDERHDOD

MAINTENANCE

Brake fluid

Brake booster

vacuum

hoses

connections

check valve

Air

conditioning system

hoses

connections

refrigerant

leaks

Power

steering

fluid

lines

R

MA23 24

28 33

R R

MA

28

MA

28

M A

7

I

I

MA

33

Brake

clutch

steering

gear

automatic

transmission fluido

cillevel

leaks

UNDER

VEHICLE

MAINTENANCE

Brake

clutch

fuel

exhaust

systems

for

proper

attachment leaks cracks

chafing

abrasion deterioration

ec

MA

23 28

Manual transmission

differential

gear

oil

SeeNOTE

9

MA

23

24

MA

24 27

34

Steering

gear

box linkage

suspension

parts propeller

588 NOTE

shaft

for

damaged

loose

missing

parts

Underbody

flush

and

clean

every

2

months

OUTSIDE

AND INSIDE MAINTENANCE

Rotate

wheel

position

nspect

wheel balance

wheel

alignment

MA26 3

32

y

Disc brake pads

other

brake

components

for

wea

deterioration leaks

See

NOTE

MA

28

Frontwheel

bearing

MA25

Locks

hinges

hood

latch

Seat

betts

buckles

reractorsanchors

adjuster

Foot

brake

parking

brake

clutch

for

stroke free

play

operation

SeeNOTE

L

L L MA

35

MA35

MA

23 28

Abbreviations

R

I

Replace

L

Lubricate

Inspect

correct replace

if

necessary

NOTE

9

When

towing

arailer

change

oil

in differential

gear

every

48

km 3

miles

o

4

months whichever

comes

first

Steering linkage

front

suspension

ball

joint

inspection

shouldbe

performed every

96

km

6

miles

o

years

whichever

comes

first

If

vehicle

is

operated

in

areas

using

road

salt

o

other

corrosivematerials

inspect every

5

km

3 milesl

o

months

whichevercomes

first

The

abovecharts show

thenormal maintenance

schedule

Depending

upon

weather and

atmospheric

conditions

varying

road

surfaces

individual

driving

habits

and

vehicle

usage

additional

o

ore

frequent

maintenance

may

be

required

MA

3


13/571

j

f

i S l

C H A N G E

l

C H E C K

L U B R I C T E

Q I Q

G R E S E

U P

E N G I N E

N T I F R E E Z E

C O O L N T

n

F R O N T

W H E E L

B E R I N G n

C L U T C H

F L U I O

B R A K E

F L U I O

6

S T E E R I N G

G E A R

O IL

L O C K S

H I N G E S

8

@

H O O D

L A T C H

D I F F E R E N T I L

G E A R

O I L @

@

If

v e h i c l e

is

o p e r a t e d

in

e r e a i

u

in g

r o a d

s a l t

o r

o t h e r

c o r r o s i v e

m a t e r i a l

i n s p e c t

e v e r y

6

k m

3

m i l e

o r

3

m o n t h

w h i c h e v e r

c o r n e l

fil

t

il a

M o n t h

E V E R Y

4

@

E V E R Y

2 4

5

@

L

@

W h e n

t o w i n g

t r a i l e r

c h a n g e

in

d i f f e r e n t i a l

g e a r

e v e r y

4 8

k m

3

m i l e s

o r

2 4

o n t h

w h i c h e v e r

c o r n e l

fll

t

f

th e

v e h i c l e

o p e r a t e d

u n d e r

e x t r e m e

a d v e r s e

w h e a t h e r

c o n d i t o n

o r

in

erel

w h e r e

a m b i e n t

t e m p e r a t u r e

l I r e

e i t h e r

e x t r e m e l y

lo w

o r

e x t r e m e

IV

h i g h

th e

f i l t e r

m i g h t

b e c o m e

c l o g g l t d

In

s u c h

a n

e v e n t

r e p l I C e

t h e

f i l t e r

I m m e d i a t e l v

T T E R Y

E L E C T R O L Y T E

W I N D S H I E L D

A N D

R E A R

W I N D O W

W A S H E R

F L U I D

@

F U E L

F I L T E R

P O W E R

S T E E R I N G

G E A R

O I L

O I L F I L T E R

E N G I N E O I L

M A N U A L

T R N S M I S S I O N

U T O M T I C

T R N S M I S S I O N

@

If

v e h i c l e

o p e r a t e d

u n d e r

s e v a r e

c o n d i t i o n s

s h o r t

d l u a n c e

d r i v i n g

e x t e n s i v e

i d l i n g

o r

d r i V i n g

d u s t y

c o n d i t i o n s

c h a n g e

e n g i n e

o il

e v e r y

6

k m

3

m i l e s

o r

3

m o n t h s

w h i c h e v e r

c o m e s

t

I

m

J ob o 5

ctg

3

ZlZzn

2


14/571

Recommended

Fuel

and Lubricsnts

MAINTENANCE Approximate

Refill

Capacities

RECOMMENDED FUEL

AND

LUBRICANTS

FUEL

Use

an

unleaded

gasoline

only

ofat least 9 research

octanenumber

Anti

knock

index

87

Under no

circumstances should

a

leaded

fuel

be

used ince

this

will

damage

the catalytic

convete

LUBRICANTS

SAE

VISCOSITY

NUMBER

Lubricant Specifications

Remarks

Gear

oil

Transmission

and

steering

API

GL4

Further

details refer

to

recommended SAE

viscosity

chart

ENCEOL

I I I

I

ICM

2

JGIIf4

o

asoline

engine

oil

APISE

Anti freeze Ethylene

glycol

base

I I

I

o

vJ

ri

I

I

I r I I I

I

r

I

4

I

I

II

T

c

nII

OI

l l 4 O l l l C l l l l l l l F

T Jl

Nu

O

C

Differential

API

GL

5

Automatic

T Mand

power

steering

fluid

Type

DEXRON

Muti

purpose

grease

NLGI

No

2

lithium

soap

base

Brake

and clutch

fluid

DOT

3

US FMVSS

No 6

APPROXIMATE

REFILL

CAPACITIES

liter

usmeasure

Imp

measure

Fuel tank

Hardtop

53

4gal

II5

8

gal

Hatchback 6

5 7

8

gal

3

4

gal

Coolant With

heater

9

5

IOqt

8

3

8qt

Without

heater

88 9

4qt

7

3 4

ql

Engine

Wth

oil filter

4 4

3

8

qt

3

5

8qt

Without

oil

filter

3

9

4

8

qt

3

3

8

ql

Transmission

MT

2

4

4

pt

3

2

pt

A

T 5

5

78

qt

47

8

qt

Differential carrier

2 3 8

pi

2

pt

Power

steering

system

2

4ql

I

8

ql

Steering

gear

8

5

8

pt

2

pt

Windshield

washer

tank

2

2

8

ql

3

4qt

Rear

window washer

tank

8

qt

7

8

qt

Air

conditioning

system Compressor

oil 7

9

f

Z

9

oz 9f

Z

9 oz

Refrigerant

9

kg

2

2

lb 2 2

4 b

MA5


15/571

Engine

Maintenance

MAINTENANCE

BASIC

MECHANiCAL

SYSTEM

ADJUSTING INTAKE

AND

EXHAUST

VALVE

a

ARANCE

Adjustment

should

be made

while

engine

is hot

I

Start

engine

and

warm

upengine

until

water

temperature

indicator

points

to

themiddle of

gauge

then

stop engine

Valve clearance

adjustment

canno

be made

while

engine

is in

operation

2

Remove

valve rocker

cove

3

Set

so

that

high

point

of No I

cam

lobe

points

down

No

earn

lobe

SMA 5

When

turning

crankshaft

with

starte

remove

high

tension

cable

from

ignition

coil

then

turn

it

Adjust

clearance

o

half

of

the

valves

Adjust

only

C D

@ @

and

j

alves

C D 4

Front

o

lJf

Dt

D F J

SMA 49

MAS

ENGINE

MAINTENANCE

Valve clearance

Hod

Intake

C D

@

3 mm

2 in

Exhaust

@

j

3 mm

2

i

n

I

Using

feeler

gauge

measureclear

ance between valve

stem

end

and

rocker

arm

screw

Feeler

gauge

should move with

a

very slight drag

8M

AQSO

2

Ifthe

clearance

is

notwithin

spec

ified

value loosen

rocker

armnut

and

turn rocker

ann

screw

to

provide pro

per

clearance

3 Hold

rocker arm

screw and

tighten

rocker arm

nut

SMA 5

dl

Rocker

arm

nut

6 22 N

m

6

2

2

kg

m

2

6

ftb

4

Recheck

clearance

4

Turn

crankshaft

and set so that

high

point

of

No I

cam

lobe

points

above

No

earn lobe

SMA

Adjust

ID

ID

@

and

@

valves

using

same

procedure

as

for

Step

3

@ @

Front

kGD

tDf

O O

D

SMA 52

Valve

clearance

Hod

Intake

@ @

3

mm

2 in

Exhaust

ID ID

3

mm

2 in

5

Install valve rocker

cove

CHECKING AND

ADJUSTING DRIVE BELTS

I

Visually inspect

for

cracks or

damage

Th belts should

no

touch the

bottom

of the

pulley

groove

2

Checkbell

tension

by

pushing

The

belts

shoulddeflect

by

the

spe

cified

amount

Drive

belt

deflection

8 2

mm

3

47

in

Applied prening

forc

98

N

kg

22b


16/571

Loosen to

adjust

I

f

r

Checking

point

odrive

belt

deflection

3

Adjust

belt tension

as

follows

Fan and

atenaorbelt

I

Loosen

the

upper

and lower alter

nator

securing

bolts until

the alterna

tor

can be moved

slightly

2 Move

the

alternator

with

a

prying

bar

until

the

belt tension iswithin the

specified

range

Then

tighten

the bolts

securely

Ar

conditioner

compressor

and

power

steering

pump

belts

Loosen

the

idler

pulley

lock nut

2

Adjust

the

adjusting

bolt until

the

belt tension

is

within the

specif ied

amount

3

Tighten

the

idler

puUey

lock

nut

securely

MAINTENANCE Engine

Maintenance

Alternator

t

ilJ

Idler

puUey

LoCknu

Adjust

Loosen

Compressor

pulley

Crank

pulley

Idler

pulley

Adjusting

bolt

Adjust

8M

A 53

CHANGING ENGINE OIL

AND

OIL

FILTER

Start

engine

and warm

up

engine

until water

temperature

indicator

points

to

the

middle of

gauge

then

stop

engine

2 Remove

oil

pan

drain

plug

and oil

fiUer

cap

and

allowoil

to drain

A

milky

oil

indicates

the

presence

of

cooling

wae Isolate

the

cause

and take corrective

measure

An oilwth

extremely

low

viscosity

indicatesdilutionwth

gasoline

3 Cean

and

install

oil

pan

drain

plug

with

washer

WARNING

Be

careful not to burn

yourself

as

the

engine

oil

may

behot

IiJ

Oil

pan

drain

plug

2 29

N

m

2 3

kg

m

4 22 ftlb

4

Using

Tool remove

oil

fIlter

E 36

SLC 28

MA

7


17/571

Engine

Maintenance

MAINTENANCE

5

Wipe

oil

fIlter

mounting

surface

with

a

clean

rag

6

Smear

a

little

engine

oil

on

rubber

gasket

o

newfIlter

SMA

7

Install new

oil

fIlter

Hand

tighten

ONLY DO NOT

use a

wrench

to

tighten

thefilte

8

Refill

engine

with new recom

mended

engine

oil

referring

to

RE

COMMENDED

LUBRCANTS

Check oil levelwith

dipstick

Oil

Capacity

With oil filte

4

lite

3

8

US

qt

35

8

mp

qt

Without oil filte

3 9

lite

48S

qt

3

8

Impqt

E 38

9 Start

engine

Check

area around

drain

plug

and oil

fIlter for

any

sign

of

oil

leakage

If

any

leakage

is evident

these

parts

have not been

properly

installed

Run

engine

until

it

reaches

oper

ating temperature

Then turn

it

of

and

wait several

minutes

Check oil

levelIf

necessary

add

engine

oil

M A

8

When

checking

on

level

park

the

ear

on

a

level surface

v

SMA 63

CHANGING

ENGINE

COOLANT

WARNING

To

BVoid

the

danger

of

being

scalded never

attempt

to

change

the

coolant

when

the

engine

is hot

When

changing

engine

coolant

on

heater

equipped

model

se heater

TEMP

control

lever

a

fully

HOT

position

I

Open

drain

cock

at

bottom of

radiator

and

removeradiator

cap

r l

ild

x r C

l

rli

I

v

t

III

4

i l

I

ll

LOOSEN

CS 5

2

Remove

cylinder

block

drain

plug

located

at left

rearof

cylinder

block

W

F

O

3

Drain coolant

completely

Then

flush

cooling system

4

Close

drain

cock and

plug

5

Fll radiator with

coolant

up

to

fIller

opening

observing

instructions

attached to

anti

freeze

container for

mixing

ratio

of

anti

freeze

towater

Cooling

wae

capacity

95

lite

US

qt

83

8

mp

qtl

6

Run

engine

for

a

few

minutes If

necessary

add

coolant

7

Fll

reservoir tank

with

coolant

up

to

MAX level

I

t

S 2

8

Install

radiator

cap

Check

drain

valve

and

plug

for

any

sign

ofleakage

CHECKING

DiGINE

COMPRESSION

PRESSURE

I Warm

up

engine

untilwater

tem

perature

indicator

points

to

the

middle

of

gauge


18/571

2 Remove

au

spark plugs

on

one

side

forCalifornia

models

3

Disconnect

all harness

connectors

at

injector

4

Properly

attach

a

compression

tester to

spark

plug

hole

in

cylinder

being

tested

8MA 42

S

Depress

accelerator

pedal

to

open

throttlevalve

fully

6

Crank

engine

and

read

gauge

indi

cation

Run

engine

at about

35

rpm

Engine

compression

measurement

should be

made

as

quickly

as

possi

ble

Compression pressure

kPa

kg

em

ps

a

rpm

Standard

77 2

7 35

Minimum

883

9 28

35

7

Cylinder

compression

in

cylinders

should not

be

less

than

8

of

the

highest reading

If

cylinder

compression

in

one

or

more

cylinders

is

low

pour

a

small

quantity

of

engine

oil

into

cylinders

through

the

spark plug

holes

and

retest

compression

If

adding

oil

helps

the

compres

sion

pressure

chances

are

that

piston

rings

are

worn

or

damaged

If

pressure

stays

low

valve

may

be

sticking

orseating

improperly

If

cylinder

compression

in

any

two

adjacent

cylinders

i

low

and

if

adding

oil doe no

help

the

com

pression

there

is

leakage

past

the

gasketed

surface

Ol and water

in

combustioncham

bers

can

result

from this

problem

IGNITION

AND

FUEL

SYSTEM

REPLACING

SPARK

PLUGS

I Disconnect

spark

plug

wire at

boot

Do

not

pull

o

the

wires

O

K

N

G

SMAO

7

2

Remove

spark plugs

wth

spark

plug

wrench

3

Using

feeler

gauge

check new

spark plug

gap

If

t

is

not

within

specif ied

range

set

gap by

bending

side

ele

trode

Side electrode

if

Gap

8 9

mm

3t

35

SMA 9

MAINTENANCE Engine

Maintenance

SPARK

PLUG

Re

sistor

Standard

built

iJl

type

Standard

BP6ES BPR6ES

type

Hot

type

BPSES

BPRSES

Cold

type

BP7

ES BPR7ES

4

Install new

spark

plugs

and re

connect

high

tension

cables

Al

cable aremarked to

identify

their

original

locations

iY J

Spark

plug

5 2

N

m

5

2

kg

m

4ft

Ibl

CHECKING

IGNITION

WIRING

I

Visually

check

wiring

for

cracks

damaged

andburned

terminals

2

Using

an

ohmmeter

measure

the

resistance between

cable

tenninal

on

the

spark

plug

side

and

corresponding

electrode

inside cap

Resistance

Less than3

ohms

SMA

66

Shake

thewire

while

measuring

re

sistanee

to check

for

intermittent

brake

3

If

he

resistance

ismorethan

the

limt remove

cable from

cap

and

check

the

cable

resistance

only

If

resistance is still more

than the

limit

replace

cable

assembly

MA

9


19/571

EngineMaintenance

MAINTENANCE

ADJUSTlNGIDLERPM

ADJUSTING

IGNITION

TIMING

AND

CHECKING

MIXTURE RATIO

Non

California

models

Preparation

Makosure

thauhofollowing

parts

are

in

good

order

Battery

Ignition system

Maintenance

procaclure

MA

l

El

ilrness

cOriectiri

Vacuum

hoses

Ar

intako

system

Oil

fille

cap

oil

level

gauge

etc

2

Connect

engine

tacho

ter

and

timing

light

in

dieir

proper

pOsitions

3

On

air

conditioner

equipped

mode s

checks

should

be

carried

out

whilo

thooi conditioner

is

OFF

4 On automatic

transmiuion

equip

peel

modols

checks should be

carried

out

while

s

ift

lever is in

O

position

START

Start

engine

and

wann

upengine

until

water

temperature

indicator

points

to

the

middle

I

f

gauge

Open engine

hood

Run

engine

at about

2

rpm

for abou

2

undet

no

load

WARNING

a

WIlen selector

lever

is

shifted

to

position apply

parking

brake and block

both front

and

reanvheels

with

chocks

b When

racing engine

on

auto

matic

transmission

equipped

modelsimake

ure

that

shift

lever is in

N

or

P

position

and

depress

brake

pedal

to

pre

vent

forward

SUI8

fcar

c After

tha

adjustment

has been

made

shift thelever

to

the

N

or

P

position

and

remove

wheel chocks

E

un

engine

at idle

speed

For

Canada

For

U

S

A

I

Di nnecthose fromair induction pipe

and amtall

proper

cap

on

air

induction pipe

t

Race

engine

two

orthree times

under

no

load

Thenrun

engine

forone

minute

at idle

speed

Check

idle

speed

M nuai lransmiRon

7o o

t

tpm

A u t o m

w

c

Transmission

7

rpm in

D

position

OK

j

N

G

I

Adjust

idle

SPeed

by turning

idle

opeed

adjusting

screw

j

b

this

maintenance

operation

at

6 km

I

miles

serviceor

rechecking

idle

CO

I N O

@

YES

I

I

b

g

@


20/571

r

Note

a

When

measuring

CO

iniert

probe

I

into

tail pipe

morethan

m

6

in

J

b

Use CO

meter

alter

engine

is

fully

warmed

up

e

When

adjusting

idle CO

at

high

altitude

adjust

toobtain

following

valua

Altitude

Unt

m

ft

f d t e

2

7

t

2

2

4

2 8

4

6

Above

8

6

3 8

5

L J

N

G

I

Adjust ignition

timin

gby

turn

g

dri

u

fter

loosening

bolts

which

secure

distributor

i

o

Check

ignition

ti

ing

wth

irin g

t

8

f2

B

T DC

O

K

I

Race

erigine

two

o

three

times

under

I

load thenrun

engine

at

idle

speed

Check

CO

wth

CO meter

3

t

O

K

I

Turn

of

engine

and

connectair induction

r h o s e

to air

induction

pipe

i

Start

engine

Race

engine

twoorthree timesunder

no

load then

run

engine

at idle

speed

I

Check

idle

speed

M

nu

Transmission

7

t

rpm

AutomaticTrnsmission

7

rpm

in

position

OK

I

NG

END

MAINTENANCE

Engine

Maintenance

@@

f

SMA 59

If

SMA 6

Adjust

CO by turning

air

by pass

screw

onair flow

meter

When

adjusting

CO

remove

blind

plug

fromair

by

pass

screw

After

adjustment

install

the

plug

on

air

flow

meter

r

r

SMA263

I

Adjust

idle

speed by

turning

ide

speed

ad

justing

screw

L

l

MA

ll


21/571

i

tIine

M

tit ance

MAINTENANCE

ADJUSTING

IDLE

RPM

California modes

Preparation

On air conditioner

equiPPed

mod

els checks

should

be carried

out

whiletheairconditioner

is

OFF

2

On

automatic

transmission

equip

ped

models

checks

should be

carried

outwhile

shift lever is inOu

position

Intenailce

procedure

MA

2

WARNING

a When

selector lever is

shifted to

position apply

parking

brake

and

block both

front

and

fear wheelswith

chocks

b Whe

racing engine

on

auto

matic transmission

equipped

models

make

sure

that

shift

lever

is

in

N

or

P

position

and

depress

brake

pedal

to

pre

vent forward

surge

of

car

c

After

the

adj lUt rDent

has been

made

shift the

lever to

the N

or

P

position

and

remove

wheel

chockS

START

Start

engine

andwarm

up

engine

until water

temperature

indicatQfpoints

to

themiddle

of

gauge

j

Open engine

hood

Run

engine

about

2

rpm

for

about

2 minutes

undeJ

no

oad

Run

eDsine

at

Idle

speed

Check

idle

speed

Ma

aT

n s m i a i o n

7

rpm

Automatic Transmission

7

f

rpm

Un D

position

f

K

tG

8

MA 2

SMA 22

SMA263

I

dj

stidle

speed by

turning

idle

speed

ad

I

u s t JJg

screw

END


22/571

CHECKING

FUEL

LINES

Hoses

piping

connections

ec

I Check

fuel

line

for

leaks

particu

larly

around

connection

of fuel

pipe

and fuel hose

2

Retighten

loose

connections

and

replace

any

damaged

or

defonned

parts

SMA 34

CAUTION

a

not

reuse

fuel hose

clamp

after

loosening

b

Tighten high

pressure

rubber

hose

clamp

so

that

clamp

end

is

3

mm

2 in from

hose

end

or

screw

position

wider

than

other

portions

of

clamp

is

flushWith hose end

Tightening

torque specif ications

are

the

S a m e

for all rubber h o s e

clamps

When

tightening

ose

clamp

8n ure

thatscrewdoes notcomeinto

con

tactwith

adjacent

parts

REPLACING

FUEL

FILTER

The

fuel

fIlter

is

designed

especially

for

use

with the EFI

systerri

It

should

be

replaced

as

an

assembly

I Follow

the

procedure

below

to re

duce

fuel

pressure

to

zeo

CAUTION

Before

disconnecting

fuel

hose release

fuel

pressure

from fuel

line to

elimi

nate

danger

I

Start

the engine

MAINTENANCE Engine

Maintenance

Fuel return

pipe

l

To

ueltan

rbm

f

l tank

rFue

pipe

Fuel

damper

t

Fuel

pump

r

Fuel

pipe

tr

btor

J

J

Jf

Injector

W W

W

J

Fuel

hose

clamps

5N

m

5

kg

m

7

ft

bl

E

F976

2

Disconnect fuel

pump

relay

2har

ness

connectorwith

engine

runnin

Relay

bracket

SEF 3

SMA 62

3mmlo 2inl

fl

f

I

E

F336A

3

After

engine

stall

crank

the

engine

twice

or

three

times

4

Turn ignition

switch

of

and

con

nect

fuel

pump

relay

2

hamess

connec

tor

2 Unfasten

clamps

securing

fuel

hoses to

the

outlet

and

inlet

sides

of

fuel

fIlter

and disconnect

fuel

hoses

Be

careful

no to

spill

fuel over

engine

c o m P

r t m e n t

Place

a

rag

to

ab

so

b fue

MA

3


23/571

EngineMaintenanpe

MAINTENANCE

3

Remove

fuel

mter

I

V

tJl

SMA264

4 To

instaIl fuel

mter reverse

the

order of removal

REPLACING

AIR

CLEANER

FILTER

The viscous

paper type

air cleaner

filte does no

require

any deaning

operation

between renewal

Disengage

air

duct

I

SMA 63

2

Disengage

EAt Exhaust

Air

Induction

System

hose

from air

in

duction

pipe

r

J

MA

4

3

Remove

air

cleaner cover

and

remove

air

cleaner

ftIter

SMA 65

4

InstaIl

air

cleaner

mter

with UP

mark

facing

upward

SMA 39

EMISSION

CONTROL

S

YSTEM

REPLACING

AIR

INDUCTION

VALVE

FILTER

SMA 36

Ar

induction

valve

case

2

Air

induction

valve

3 Air

induction valve

rdter

4

Air

cleaner

Remove

air

induction

valve

case

from

air

cleaner

and

take

out

air in

duction

valve

fIlter

Then

instaIl

new

air

induction valve filter

When

replacing

pay

strict

attention

to

which

direction

the valve i

facing

sothat

exhaust

gas

wll

no

flow back

ward

J

CHECKING

VAPOR

LINES

Check all hoses

and

fuel

tank filler

cap

for

leaks

I

Dsiconnect

the

vapor

vent

line

connecting

carbon

canister to

fuel

tank

2

Connect

a

3

way

connector

a

manometer and

a

cock

or

an

equiva

lent

3

way

carge

cock

to

the

end

of

the

vent

line

3

Supply pressure

into

the

vapor

vent

line

tIuough

the

cock

little

by

little until

pressure

becomes to

the

below

Leakage

test

pressure

3

923

kPa

4

mmll2

5

75

in

H2

4

Shut

the

cock

completely

and

leave it unattended

5 After 2

minutes measure

the

height

of

the

liquid

in

manometer

Pressure variation

Less then

245

kPe

25

mmH2

98

inH2


24/571

MAINTENANCE

Minor Trouble

Diagnoses

andCorrections

I

When

filler

cap

does not close

completely

the

height

should

drop

to

zeo

in

a

short

time

2

Ifthe

height

does

not

drop

to

zeo

in

a

short

time

when iller

cap

is

removed

it

is the

cause of

a

staCfy

hose

AII

@

In

case

the

vent line

is

stuffy

the

breathing

in

fuel tank

isno

thorough

ly

made

thus

causing

insufficient

delivery

of

fuel

to

engine

or

vapor

lock

It

must

therefore

be

repaired

or

replaced

Carbon canister

3

923

kPII

4

mmH2

575

i nH2

Manometer

Check

valve

Fuel

filler

cap

EC 9 A

MINOR

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Condition

Probable

cause

CANNOT

CRANK

ENGINE

OR

SLOW

CRANKING

Improper grade

oil

Partially

discharged

battery

Malfunctioning battery

Loose

fan

belt

Trouble

in

charging

system

Wiring

connection

trouble

in

starting

crcut

Malfunctioning

ignition

switch

Malfunctioning starting

motor

Corrective

action

Replace

with

proper grade

oil

Charge

battery

Replace

Adjust

Inspect

Correct

Repair

or

replace

Repair

or

r e p l a c e

Trouble shooting procedure

on

starting

circuit

Switch

onthe

starting

motorwith head

l ights

ON

When

head

l ights

go

off

ordim

considerably

a Check

battery

b

Check

connection

and

cable

c Check

starting

motor

Whenhead

l ights

stay bright

a

Check

wiring

connection

between

battery

and

starting

motor

b Check

ignition

switch

c

Check

starting

motor

MA 5


25/571

Mnor

TrrJUbleDiagnoses

end

Correctiops

MAINTENANCE

Condition

ENGINE WILL

CRANK

NORMALLY BUT WILL NOT

START

Probable

cause

Corrective

action

In

this

case the

following

trouble causes

may

exist

butin

many

cases

ignition

system

orfuel

system

i

in trouble

Ignition system

in

trouble

Fuel

system

in

troubk

Valve

mecluznismdoes

no

work

properly

Low

compression

T r o u b l e

h o o t i n g

procedure

Check

spark

plug

fIrstly

by following procedure

Disconnect

high

tension

cable

from

one

spark

plug

and

hold

it

about

mm

9 in

from

the

engine

metal

part

and

crank the

engine

ENGINE

CRANKS

NORMALLY BUT

WI L OT

5

ART

Ignition

system

in

trouble

Fuel

system

malfunction

MA

6

Good

spark

occurs

a Check

spark plug

b

Check

ignition timing

c Check

fuel

system

d Check

revolution

trigger

signal

e

Check

cylinder compression

Very high

current

Check

the

current

flow

in

primary

circuit

Inspect primary

circuit for short

Check

distributor

pick

up

coil

operation

Check IC

ignition system

No

spark

occurs

Low

or

no

cunenL

Malfunctioning

distributor

pick

upcoil

Improper

air

gap

Leak

at

rotor

cap

and roor

Malfunctiflning

spark plug

Improper

ignition

timing

Malfunctioning

ignition

coil

Disconnection

of

high

tension cable

Loose

connection

or disconnection

4

primary

crcut

Irregnlar

revolution

trigger

pulse

Malfunctioning

IC

ignition

unit

Lackof

fuel

Damaged

electronic

fuel

injection

harnessor

relay

Malfunctioning

fuel

pumpUsten

to

opera

ting

sound

Damaged

control

unit

Seized

injector

Usten

to

operating

sound

Malfunctioning

air

flow

meter

Damaged

water

temp

sensor

Check for

loose

terminalordisconnectionin

primary

crcut

Check for

burned

points

Replace

Adjust

Clean

or

replace

Clean

adjust plug

gap

or

replace

Adjust

Replace

Replace

Repair

or

replace

Replace

IC

ignition

unit

Replace

Supply

Replace

Replace

Replace

Replace

Replace

Repl

ce

For

inspection

procedures

for

electronic

fuel

injection sys

tern

components

refer

to

Engine

Fuel

section


26/571

Condition

Fuel

system

malfunction

Lowco

prellion

UNSTABLE

ENGINE

IDLING

Ignition

system

in trouble

Engine

mechanical

system

in trouble

Fuel

system

malfunction

MAINTENANCE

Minor Trouble

Diagnoses

and

Corrections

Probable cause

Malfunctioning

pressure

regulator

Dirty

fuel

f lter

Dirty

or

clogged

fuel

pipe

Clogged

fuel

tank

breather

pipe

Incorrect

spark

plug

tightening

or

damaged

gasket

Improper

grade engine

oil

or

low

viscosity

Incorrect

valve

clearance

Compression

leakfrom valve

seat

Sticky

valve

stem

Weak

or

damaged

valve

springs

Compression

leak

at

cylinder

head

gasket

Sticking

or

defective

piston

ring

Worn

piston ring

or

cylinder

Trouble

shooting

procedure

Pour

the

engine

oil from

plug

hole and thenmeasure

cylinder

compression

Compression

increases

Compression

does not

change

Malfunctioning ignition system

spark

plug

high

tension cable

distributor IC

ignition

unit

ignition

coil

etc

Incorrect

basic

ignition timing

Loose

manifold

and

cylinder

headbolts

Incorrect

valve

clearance

Clogged

air

cleaner

f lter

Incorrect

idle

adjustme

nt

Damaged

manifold

gaskets

Intake air

leakage

at

following

points

Dipstick

Ol

filler

cap

Blow by

hoses

Intake

air

duct

air

flow

meter to throttle

chamber etc

Corrective

action

Replace

Replace

Clean

Repair

and clean

Tightef l

to

normal

torque

or

replace gasket

Replace

with

proper grade

oil

Adjust

Lap

valves

Corrector

replace

valve

and

valve

guide

Replace

valve

springs

Replace gasket

Replace

piston rings

Overhaul

engine

Trouble

in

cylinder

or

piston

ring

Compression

leaks from valve

cylinder

head

or

head

gasket

Replace

Adjust

Retighten

bolts

Adjust

Replace

f lte

Adjust

Replace gasket

Repair

or

replace

MA

7


27/571

Minor

Trouble

DiagnolJt

s

and

Correctiom

MAINTE ANCE

Condition

Fuel

system

malfunction

Low

compression

Others

HIGH ENGINE

IDLE

SPEED

Fuel

system

malfunction

Others

ENGINE

POWER

BELOWNORMAL

Low

compression

Ignitionsystem

in

trouble

Fuel

system

malfunction

MA

8

Probable

cause

Damaged

electronic

fuel

injection

harness

Seized

injector

Usten

to

operating

sound

Malfunctioning

air

regulator

During

warm

up

driving

only

Damaged

control

unt

Damaged

water

and

air

temp

sensor

Malfunctioning

throttlevalve switch

Irregular

fuel

pressure

Malfunctioning

P

C V valve

Malfunctioning

E GR

control

system

Incorrect

adjustment

of idle

speed

adjusting

screw

Malfunctioning

air

regulator

Throttle

valve

is

opened

excessively

at

idle

Malfunctioning

F

I

D

Dragged

accelerator

l inkage

Malfunctioning

Vacuum Control Valve

V

C

V

Incorrect

ignition

timing

Malfunctioning spark

plugs

Malfunctioning

distributor

pick up

coil

Throttle

valve

does not

open

fully

Damaged

electronic

fuel

injection

harness

Seized

injector

Usten

to

operating

sound

Malfunctioning

air

flow

meter

Malfunctioning

throttle

valve switch

Irregular

fuel

pressure

Clogged

fuel

pipe

Dirtyor

clogged

fuel

ftIter

Fuel

pwnp

will not

work

properly

Corrective

action

Replace

Replace

Replace

For

inspection

procedures

for

electronic

fuel

injection sys

tern

compo

nents refer

to

Engine Fuel

Section

Replace

Replace

Repair

or

replace

Replace pressure

regulator

Previously

mentioned

Checkor

replace

COrrect

or

replace

Correct

Replace

For

inspection procedures

for

air

regulator

refer

to

Engine

Fuel

section

Replace

throttlechamber

Replace

Check

and correct accelerator

l inkage

Check

or

replace

if

necessary

Previously

mentioned

Adjust

Clean

adjust

or

replace

plugs

Replace

Adjust

Replace

Replace

Replace

Repair

or

replace

Replace pressure

regulator

if

necessary

Replace

if

necessary

Replace

Replace

For

inspection

proce

dures for

electronic

fuel

injection

system

components

refer

to

Engine

Fuel Section


28/571

Condition

Arintake

system

malfunction

Overheating

Othe

NOISY

ENGINE

Car

knocking

Mechanical

knocking

Crankshaft

bearing

knocking

MAINTENANCE

Minor Trouble

Diagnosessnd

Corrections

Probable cause

Clogged

air

cleaner

filter

Ar

leaking

from

manifold

gasket

Intake air

leakage

at

following

points

Dipstick

Ol

ftller

cap

Blow

by

hoses

Intake air

duct

air flowmeter

to

throttle

chamber

etc

Insufficient coolant

Loose

fari belt

Wornor

damaged

fan

belt

Malfunctioning

thermostat

Malfunctioning

water

pump

Clogged

or

leaky

radiator

Malfunctioning

radiator

ftller

cap

Arin

cooling

system

Improper

engine

oil

grade

Incorrect

ignition timing

Malfunctioning

thermostat

Improper

octane

fuel

Improper

tire

pressure

Dragging

brake

Cutch

slipping

Malfunctioning

E

G

R

control

system

Overloaded

engine

Carbon

knocking

Timing

knocking

Fuel

knocking

Preignition misusing

of

spark

plug

This strong

dull

noise increases when

engine

is

accelerated

To

locate

the

place

cause

a

misfire

on

each

cylinder

If

the

noise

stops

by

the misfire

this

cylinder generates

the

noise

Corrective

action

Replace

filter

Replace gasket

Repair

or

replace

Replenish

Adjust

fan belt

Replace

Replace

Replace

Flush

repair

or

replace

Replace

Retighten

each

part

of

cooling

system

Replace

with

proper grade

ol

Adjust

Replace

Replace

with

specif ied

octane fuel

Inflate

to

specified

pressure

Adjust

Adjust

Correct

or

replace

Use

right

gear

in

driving

Disassemble

cylinder

head

and

clean car

bon

Adjust

ignition timing

Use

specif ied

octane fuel

Use

speci fi ed spar k p lug

This

is caused

by

worn

or

damaged

bearings

or

unevenly

worD

crankshaft

Renew

bear

ings

and

adjust

or

change

crankshaft

Check

lubrication

system

MA

9


29/571

Mnor

Trouble

Diagnoseund

Corrections

MAINTENANCE

Condition

Connecting

rod

bearing knocking

Piston

and

cylinder

noise

Piston

pin

noise

Water

pump

noise

Others

Others

ABNORMAL

COMBUSTION

backfire

after

fire

runn etc

Ignition

system

in trouble

Fuel

system

malfunction

MA

2

Probable cause

This

is

a

little

higherpitched

noise

than the

crankshaft

knocking

and

also

increases

when

engine

is

accelerated

Cause a misfue

on

each

cylinder

and ifthe

noise

diminishes

almost

completely

this crankshaft

bearing

generates

the

noise

When

you

hear

an

overlapping

metallic

noise

which

increases its

magnitude with the

revolutiono

engine

and

which

decreases

engine

is

wanned

up

this

noise is

caused

by

piston

lUId

cylinger

To locate

the

place

cause

a

misfueon

each

cylinder

This

noise is

heard at each

highest

and

lowest

dead

end of

piston

To

locate the

place

cause

amisfire

oneach

cylinder

This

noise

may

be caused

by

worn

or

damaged bearings

or

by

theuneven

surface

of

sliding

parts

An

improper

adjustment

of

valve clearance

Noiseoftinringchmn

Anexcessive

end

play

oncrankshaft

Wear

on

clutch

pilot

bushing

This

noise

wll be heard

when

clutch

is

disengaged

Improper

ignition tinring

Improper

heat

range

o

spark

plugs

Intake

air

leakage

at

following

points

Dipstick

Ol

f l er

cap

B l o w

y hoses

Intake

air

duct

air

flow

meter

to

throttle

chamber

etc

Damaged

electronic

fuel

injection

harness

Damaged

control

unt

Malfunctioning

air

flow

meter

Damaged

water

temp

sensor

Corrective

action

Same

as

the case

of

crankshaft

bearings

This

may

cause an

abnonnal

wearing

o

cylinder

and

lower

compression

which

in

turn will

cause

a

lower

out

put power

and

excessive

consumption

ooil

Overhaul

engine

This

may

cause

a

wea

on

piston

pin

or

piston pin

hole

Renew

piston

and

piston

pin

assembly

Replace

water

pump

with

a new one

Adjust

Adjust

thetensionof

chmn

Disassemble

engine

and renew

main

bearing

Renew

bushing

and

adjust

drive shaft

Adjust

ignition

timing

Use

specified

spar k p lugs

Repair

or

replace

Replace

Replace

Replace

Replace

J

For

inspection

procedures

for

electronic

fuel

injection

sys

tern

components

refer

to

Engine

Fuel

Section


30/571

Condition

Defective

cylinder

head

ec

Others

EXCESSIVE

OIL

CONSUMPTION

Ol

leakage

Others

POOR FUEL

ECONOMY

Engine

power

belownormal

Fuel

system

malfunction

MAINTENANCE Minor Trouble

Diagnoses

and

Corrections

Probable cause

Improperly

adjusted

valve clearance

Excess carbon in combustion

chamber

Damaged

v

alve

spring

backfire

after fire

Malfunctioning

E

G

R

control

system

Loose

oil drain

plug

Loose

or

damaged

oil

pan gasket

Loose

or

damaged

chain

cover gasket

Damaged

oil seal in front and rear of

crankshaft

Lo

e

or

damaged

rockercove

gasket

Improper tightening

of

oil

fIlter

Loose

or

damaged

oil

pressure

switch

I

Cylinder

and

piston

wea

Improper

location of

pistonring

or

reversely

assembled

piston

ring

Damaged

piston

rings

Worn

piston ring groove

and

ring

Fatigue

ovalve oil

seal

lip

Worn

valve stem

Inadequate

quality

o

engine

oil

Engine

overheat

Exceeding idling

revolution

Fuel

leakage

from

fuel

line

Damaged

electronic

fuel

injection

harness

Damaged

control

unit

Malfunctioning

air flow

meter

Damaged

air

temperature

sensor

Malfunctioning

throttle

valve

switch

Irregular

fuel

pressure

Corrective

action

Adjust

Remove

head

and

get

ridofcarbon

Replace

it

with

a

new

one

Correct

or

replace

Tighten

it

Renew

gasket

or

tighten

it

Renew

gaskei

or

tighten

it

Renewoil

seal

Renew

gasket

or

tighten

it

but

not too

much

Renew

gasket

and

tighten

it

with the

proper

torque

Renewoil

pressure

switch

or

tighten

it

Overhaul

cylinder

and

renew

piston

Remount

piston

rings

Renew

rings

Repair

r

renew

iston

and

cylinder

Renew

piston

and

piston

ring

Replace

seal

lip

with

a

new

one

Renew

valve

or

guide

Use the

designated

oil

Previously

mentioned

Previously

mentioned

Adjust

it

to

the

designated

rpm

Repair

replace

or

tighten

the

connection

o

fuel

pipes

Replace

Replace

Replace

Replace

Replace

Replace

pressure

regulator

if

necessary

For

inspection procedures

for

electronic

fuel

injection

sys

tern

components

refer

to

Engine

Fuel Section

MA

2


31/571

Minor

Trouble

Diagnoses

and

Correctiom

MAINTENANCE

Condition

TROUBLE

IN

OTHER

FUNCTIONS

Decreased oil

pressure

Excessive

wearon

the

sliding parts

Scuffing

of

sliding

parts

MA22

Probable cause

Inadequate

oil

quality

Overheat

Malfunctioning

oil

pump regulator

valve

Functional deteriorationo

oil

pump

Blockedoil f lter

Increased clearance

invarious

sliding

parts

Blocked

oil

strainer

Malfunctioning

o

gauge

pressure

switch

Ol

pressure

decreases

Damaged quality

or

contamination

ooil

Air

leakage

from

air intake

duct

Damaged

air

cleaner

Overheat

or

overcoat

Improper

fuel

mixture

Decrease

ooil

pressure

Insufficient

clearances

Overheat

Improper

fuelmixture

Corrective

action

Use the

designated

oil

Previously

mentioned

Disassemble

oil

pump

and

repair

or

renew

t

Repair

or

replace

it

with

anew

ne

Renew

it

Disassemble

and

replace

the

worn

parts

wth

new ones

Clean

it

Replace

it

with

a

new one

Previously

mentioned

Exchange

the oil with

proper

one and

change

element

Repair

or

replace

Change

element

Prev iously

mentioned

Check the

fuel

system

Previously

mentioned

Readjust

to lIie

designated

clearances

Prev iously

mentioned

Check

the fuel

system


32/571

MAINTENANCE

Chassis and

Body

Mainwnance

service_manual_datsun_200sx_1980 z20e.pdf

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