Maintenance: Other Nissan Frontier D40

Precautions for 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 front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SUPPLEMENTAL RESTRAINT SYSTEM and SEAT BELTS articles.

Special Service Tools

The actual shapes of the Kent-Moore tools may differ from those of the special service tools illustrated here.

SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name Description KV10115801 (J-38956) Oil filter cap wrench Removing and installing oil filter a: 64.3 mm (2.531 in) KV991J0010 (J-23688) Engine coolant refractometer Checking concentration of ethylene glycol in engine coolant KV991J0070 (J-45695) Coolant refill tool Filling cooling system

Scheme 6

Commercial Service Tool

COMMERCIAL SERVICE TOOL (Kent-Moore No.) Tool name Description Power tool Loosening bolts and nuts Spark plug wrench Removing and installing spark plug

Scheme 7

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 owner can perform these checks and inspections or have their NISSAN dealers perform them.

OUTSIDE THE VEHICLE

The maintenance items listed here should be performed from time to time, unless otherwise specified.

MAINTENANCE CHART

INSIDE THE VEHICLE

The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc.

MAINTENANCE CHART

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).

MAINTENANCE CHART

Two different maintenance schedules are provided, and should be used, depending upon the conditions in which the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic maintenance at the same mileage or time intervals, whichever comes first.

MAINTENANCE CHART

After driving the vehicle off-road through sand, mud, or water; more frequent maintenance may be required for the following items

1. Brake pads and rotors
2. Brake lines and hoses
3. Rear final drive oil, transmission fluid, and transfer fluid
4. Steering linkage
5. Drive shafts
6. Engine air cleaner filter
7. In-cabin microfilters

EMISSION CONTROL SYSTEM MAINTENANCE CHART

EMISSION CONTROL SYSTEM MAINTENANCE CHART

CHASSIS AND BODY MAINTENANCE CHART

CHASSIS AND BODY MAINTENANCE CHART

EMISSION CONTROL SYSTEM MAINTENANCE CHART

CHASSIS AND BODY MAINTENANCE CHART

QR25DE

FLUIDS AND LUBRICANTS CAPACITY CHART

VQ40DE

FLUIDS AND LUBRICANTS CAPACITY CHART

GASOLINE ENGINE OIL

SAE 5W-30 viscosity oil is recommended for all temperatures.

Scheme 8

ANTI-FREEZE COOLANT MIXTURE RATIO

The engine cooling system is filled at the factory with a high-quality, long life, year-round, anti-freeze coolant solution. The anti-freeze solution contains rust and corrosion inhibitors. Therefore, additional cooling system additives are not necessary.

ANTI-FREEZE COOLANT MIXTURE RATIO CHART

Scheme 9

Note. On vehicles not equipped with A/C, there is an idler pulley in the A/C compressor position for the drive belt routing. Check the drive belt auto-tensioner indicator when the engine is cold. Visually check the entire drive belt for wear, damage or cracks. When the new drive belt is installed, the indicator (fixed side) should be within the range A. If the indicator (fixed side) is out of the possible use range or the drive belt is damaged, replace the drive belt. Refer to " REMOVAL AND INSTALLATION ".

Changing Engine Coolant

Scheme 10

Scheme 11

1. Remove the engine undercover using power tool.
2. Open the radiator drain plug at the bottom of the radiator, and remove the radiator filler cap. This is the only step required when partially draining the cooling system (radiator only). Do not to allow the coolant to contact the drive belts. (Scheme 8): Identifying Radiator Drain Plug
3. Follow this step for heater core removal/replacement only. Disconnect the upper heater hose at the engine side and apply moderate air pressure [103.46 kPa (15 psi, 1.055 kg/cm 2 ) maximum air pressure] into the hose for 30 seconds to blow the excess coolant out of the heater core.
4. When draining all of the coolant in the system, remove the reservoir tank and drain the coolant, then clean the reservoir tank before installation.
5. When draining all of the coolant in the system for engine removal or repair, open the drain plug on the cylinder block. (Scheme 9): Opening Drain Plug On Cylinder Block
6. Check the drained coolant for contaminants such as rust, corrosion or discoloration. If the coolant is contaminated, flush the engine cooling system. Refer to " «FLUSHING COOLING SYSTEM»(ref-272345-S24375985352007111800000) ".

Scheme 12

Scheme 13

1. Install the radiator drain plug. Install the reservoir tank and cylinder block drain plug, if removed for a total system drain or for engine removal or repair. The radiator must be completely empty of coolant and water. Apply sealant to the threads of the cylinder block drain plugs. Use Genuine High Performance Thread Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-272334-S29650495302007111800000) ". Radiator drain plug: Refer to " «RADIATOR»(ref-272341-S00430165932007111800000) ". Cylinder block drain plug: Refer to " «CYLINDER BLOCK»(ref-272340-S24105436542007111800000) ".
2. If disconnected, reattach the upper radiator hose at the engine side.
3. Set the vehicle heater controls to the full HOT and heater ON position. Turn the vehicle ignition ON with the engine OFF as necessary to activate the heater mode.
4. Install the Tool by installing the radiator cap adapter onto the radiator neck opening. Then attach the gauge body assembly with the refill tube and the venturi assembly to the radiator cap adapter. Tool number: KV991J0070 (J-45695)
5. Insert the refill hose into the coolant mixture container that is placed at floor level. Make sure the ball valve is in the closed position. Use Genuine NISSAN Long Life Anti-freeze coolant or equivalent, mixed 50/50 with distilled water or demineralized water. Refer to " «ANTI-FREEZE COOLANT MIXTURE RATIO»(ref-272345-S40481991532007111800000) ". Engine coolant capacity (with reservoir tank): Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ".
6. Install an air hose to the venturi assembly, the air pressure must be within specification. Compressed air supply pressure: 5.7-8.5 kPa (5.6-8.4 kg/cm 2, 80-120 psi) (Scheme 10): Attaching Gauge Body Assembly CAUTION: The compressed air supply must be equipped with an air dryer.
7. The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process open the ball valve on the refill hose slightly. Coolant will be visible rising in the refill hose. Once the refill hose is full of coolant, close the ball valve. This will purge any air trapped in the refill hose.
8. Continue to draw the vacuum until the gauge reaches 28 inches of vacuum. The gauge may not reach 28 inches in high altitude locations, refer to the vacuum specifications based on the altitude above sea level. Altitude above sea level Vacuum gauge reading 0-100 m (328 ft): 28 inches of vacuum 300 m (984 ft): 27 inches of vacuum 500 m (1,641 ft): 26 inches of vacuum 1,000 m (3,281 ft): 24-25 inches of vacuum (Scheme 11): Identifying Vaccum Gauge Reading
9. When the vacuum gauge has reached the specified amount, disconnect the air hose and wait 20 seconds to see if the system loses any vacuum. If the vacuum level drops, perform any necessary repairs to the system and repeat steps 6 - 8 to bring the vacuum to the specified amount. Recheck for any leaks.
10. Place the coolant container (with the refill hose inserted) at the same level as the top of the radiator. Then open the ball valve on the refill hose so the coolant will be drawn up to fill the cooling system. The cooling system is full when the vacuum gauge reads zero. CAUTION: Do not allow the coolant container to get too low when filling, to avoid air from being drawn into the cooling system.
11. Remove the Tool from the radiator neck opening.
12. Fill the cooling system reservoir tank to the specified level and install the radiator cap. Run the engine to warm up the cooling system and top up the system as necessary.

Checking Fuel Lines

Inspect the fuel lines and fuel tank for improperly attached hoses, leaks, cracks, damage, loose connections, chafing, or deterioration. If necessary, repair or replace any damaged parts.

Scheme 14

VISCOUS PAPER TYPE

Note. The viscous paper type filter does not need cleaning between specified replacement intervals. Refer to " PERIODIC MAINTENANCE ".

Scheme 15

1. Unfasten the clips and lift up the air cleaner case upper.
2. Remove the air cleaner filter.
3. Install the new the air cleaner filter.
4. Install the air cleaner case upper and fasten the clips. (Scheme 13): Identifying Air Cleaner Filter Components

Changing Engine Oil

Scheme 16

Scheme 17

1. Warm up the engine, put the vehicle horizontally and check for oil leakage from the engine components. Refer to " «ENGINE OIL LEAKAGE»(ref-272347-S17158758782007111800000) ".
2. Stop the engine and wait for 10 minutes.
3. Loosen the oil filler cap and then remove the drain plug.
4. Drain the engine oil.
5. Install the drain plug with a new washer. CAUTION: Be sure to clean the drain plug and install it with a new washer. (Scheme 14): Identifying Drain Plug, Oil Filter And Oil Filler Cap
6. Refill the engine with new engine oil. Oil specification and capacity: Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ". Oil pan drain plug: Refer to " «OIL PAN»(ref-272340-S13567720472007111800000) ". CAUTION: The refill capacity depends on the oil temperature and drain time. Use the specifications for reference only. Always use the dipstick to determine when the proper amount of oil is in the engine.
7. Warm up the engine and check the area around the drain plug and oil filter for any oil leaks.
8. Stop the engine and wait for 10 minutes.
9. Check the oil level. (Scheme 15): Identifying Engine Oil Level

Scheme 18

Scheme 19

1. Remove the oil filter using Tool as shown. Tool number: KV10115801 (J-38956) WARNING: Be careful not to get burned as the engine and engine oil are hot. CAUTION: The oil filter contains an internal relief valve. Use a Genuine NISSAN oil filter. When removing the oil filter, position a shop cloth to absorb any engine oil leakage or spillage. Do not allow the engine oil to spill on the drive belts. Completely wipe off any engine oil that spills on the engine or on the vehicle. (Scheme 16): Removing Oil Filter Using Tool
2. Remove any foreign materials adhering to the oil filter installation surface.
3. Apply new engine oil to the oil seal contact surface of new oil filter as shown. (Scheme 17): Applying Clean Engine Oil To Oil Filter Seal Circumference Of Oil Filter
4. Screw on the oil filter manually until a slight resistance is felt, then tighten the oil filter an additional 2/3 turn as shown. Or tighten to specification. Oil filter: Refer to " «CYLINDER BLOCK»(ref-272340-S24105436542007111800000) ".
5. Check the engine oil level using the dipstick as shown, adjust the engine oil level as necessary.
6. Start the engine and check for engine oil leaks, correct as necessary.
7. Stop the engine and wait for 10 minutes.
8. Check the engine oil level using the dipstick and adjust the engine oil level as necessary. (Scheme 18): Identifying Engine Oil Level

Scheme 20

Scheme 21

1. Remove the intake manifold (except for spark plug No.1). Refer to " «INTAKE MANIFOLD»(ref-272340-S36304875272007111800000) ".
2. Remove the ignition coil. Refer to " «IGNITION COIL»(ref-272340-S21902280422007111800000) ".
3. Remove the spark plug using a suitable tool. see scheme 15: Identifying Spark Plug Tool

Scheme 22

Scheme 23

1. Do not use a wire brush to clean the spark plug. (Scheme 20): Caution - Do Not Use Wire Brush To Clean Spark Plug
2. If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (5.9 bar, 6 kg/cm 2, 85 psi) Cleaning time: Less than 20 seconds
3. Checking and adjusting plug gap is not required between change intervals. (Scheme 21): Caution - Do Not Adjusting Plug Gap

Spark Plug Types

SPARK PLUG SPECIFICATION

Checking EVAP Vapor Lines

1. Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration.
2. Inspect fuel tank filler cap vacuum relief valve for clogging and sticking.

Scheme 24

1. Remove the air duct and resonator assembly (inlet) when inspecting the drive belt.
2. Visually check the entire drive belt for wear, damage or cracks.

Scheme 25

Scheme 26

1. Turn ignition switch ON and set temperature control lever all the way to HOT position or the highest temperature position. Wait 10 seconds and turn ignition switch OFF.
2. Remove the engine front undercover using power tool.
3. Open the radiator drain plug at the bottom of the radiator, and remove the reservoir cap. This is the only step required when partially draining the cooling system (radiator only). CAUTION: Do not to allow the coolant to contaminate the drive belts. (Scheme 23): Identifying Radiator Drain Plug
4. When draining all of the coolant in the system for engine removal or repair, it is necessary to drain the cylinder block. Remove the cylinder block drain plugs, and block heater if equipped, to drain the cylinder block as shown. NOTE: For Canada, the "D" cylinder block drain plug as shown, is not a cylinder block drain plug but a block heater. (Scheme 24): Identifying Cylinder Block Drain Plug And Washer
5. Remove the reservoir tank to drain the engine coolant, then clean the reservoir tank before installing it.
6. Check the drained coolant for contaminants such as rust, corrosion or discoloration. If the coolant is contaminated, flush the engine cooling system. Refer to " «FLUSHING COOLING SYSTEM»(ref-272345-S12266970762007111800000) ".

Inspect the fuel lines and fuel tank for improper mounting, leaks, cracks, damage, loose connections, chafing, or deterioration.

As necessary, repair or replace any faulty parts.

Changing Fuel Filter

The fuel filter is part of the fuel level sensor unit, fuel filter and fuel pump assembly. Refer to " FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY ".

Scheme 27

Note. The viscous paper type filter does not need cleaning between replacement intervals. Replace the air filter as necessary for required maintenance.

1. Unhook the clips and raise the air cleaner case (upper).
2. Remove the air cleaner filter from the air cleaner case (lower).
3. Install the new air cleaner filter in the air cleaner case (lower).
4. Lower the air cleaner case (upper) into position and hook the clips.

Scheme 28

1. Warm up engine, put vehicle on flat and level surface then check for engine oil leakage from engine components. Refer to " «ENGINE OIL LEAKAGE»(ref-272354-S34135790892007111800000) ".
2. Stop the engine and wait for 10 minutes.
3. Loosen the oil filler cap, then remove the drain plug.
4. Drain the engine oil.
5. Install the drain plug with a new washer. Oil pan drain plug: Refer to " «CYLINDER BLOCK»(ref-272352-S32851131842007111800000) ". CAUTION: Clean the drain plug and install with a new washer.
6. Refill with new engine oil. Oil viscosity and capacity: Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ". CAUTION: The refill capacity depends on the oil temperature and drain time. Use the specifications for reference only. Always use the dipstick to determine when the proper amount of oil is in the engine.
7. Warm up the engine and check the area around the drain plug and oil filter for any oil leaks.
8. Stop the engine and wait for 10 minutes.
9. Check the oil level using the dipstick as shown. see scheme 26: Identifying Engine Oil Level On Dipstick

Scheme 29

Scheme 30

1. Remove the undercover using power tool.
2. Remove the oil filter using Tool. Tool number: KV10115801 (J-38956) WARNING: Be careful not to burn yourself, as the engine and engine oil are hot. CAUTION: Oil filter is provided with relief valve. Use Genuine NISSAN Oil Filter or equivalent. When removing, prepare a shop cloth to absorb any engine oil leakage or spillage. Do not allow engine oil to adhere to drive belts. Completely wipe off any engine oil that adheres to engine and vehicle. (Scheme 27): Identifying Oil Filter Tool
3. Remove any foreign materials adhering to the oil filter installation surface.
4. Apply new engine oil to the oil seal contact surface of new oil filter as shown. (Scheme 28): Applying Clean Engine Oil To Oil Filter Seal
5. Screw on the oil filter manually until a slight resistance is felt, then tighten the oil filter an additional 2/3 turn as shown. Or tighten to specification. Oil filter: Refer to " «CYLINDER BLOCK»(ref-272352-S32851131842007111800000) ". (Scheme 29): Identifying Oil Filter Turning Direction
6. Install the undercover.
7. Check the engine oil level using the dipstick as shown, adjust the engine oil level as necessary.
8. Start the engine and check for engine oil leaks, correct as necessary.
9. Stop the engine and wait for 10 minutes.
10. Check the engine oil level using the dipstick and adjust the engine oil level as necessary. see scheme 30: Identifying Engine Oil Level On Dipstick

Scheme 31

Scheme 32

1. Remove the ignition coil. Refer to " «IGNITION COIL»(ref-272352-S34501436232007111800000) ".
2. Remove the spark plug using a suitable tool. CAUTION: Do not drop or shock it. see scheme 32: Identifying Park Plug Tool

1. Visually inspect EVAP vapor lines for improper attachment, cracks, damage, loose connections, chafing or deterioration.
2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to " «HOW TO DETECT FUEL VAPOR LEAKAGE»(ref-272339-S14393568022007111800000) ".

Scheme 33

Scheme 34

Scheme 35

1. Open the lower glove box and press in on the sides so that it will open completely allowing it to hang by the cord. see scheme 35: Locating Lower Glove Box Hinge Pins
2. Remove the screw and remove the in-cabin microfilter cover.
3. Remove the in-cabin microfilters from the front heater and cooling unit housing. see scheme 36: Identifying In-Cabin Microfilter Cover
4. Insert the first new in-cabin microfilter into the front heater and cooling unit housing and slide it over to the right. Insert the second new in-cabin microfilter into the front heater and cooling unit housing. NOTE: The in-cabin microfilters are marked with air flow arrows. The end of the microfilter with the arrow should face the rear of the vehicle. The arrows should point downward. (Scheme 33): Inserting First In-Cabin Microfilter Into Front Heater
5. Install the in-cabin microfilter cover. (Scheme 34): Identifying In-Cabin Microfilter Cover
6. Close the lower glove box completely.

Checking the Exhaust System

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

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Before driving, the ATF level can be checked at ATF temperatures of 30° to 50° C (86° to 122° F) using the "COLD" range on the ATF level gauge as follows: Park the vehicle on a level surface and set the parking brake. Start the engine and move the selector lever through each gear position. Shift the selector lever into the "P" position. Check the ATF level with the engine idling. Remove the ATF level gauge and wipe it clean with a lint-free paper. see scheme 40: Identifying ATF Level Marks On Dipstick CAUTION: When wiping the ATF from the ATF level gauge, always use a lint-free paper, not a cloth. Re-insert the ATF level gauge into the charging pipe until the cap contacts the top of the charging pipe as shown. CAUTION: To check ATF level, insert the ATF level gauge until the cap contacts the top of the charging pipe, with the gauge reversed from the normal inserted position. Remove the ATF level gauge and note the ATF level. If the ATF level is at low side of range, add ATF to the transmission through the charging pipe. CAUTION: Do not overfill the transmission with ATF. (Scheme 36): Identifying A/T Fluid Level Gauge And Charging Pipe Install the ATF level gauge and the ATF level gauge bolt. ATF level gauge bolt: Refer to " «COMPONENTS»(ref-272346-S05552466662007111800000) ".
2. Warm up the engine and transmission.
3. Check for any ATF leaks.
4. Drive the vehicle to increase the ATF temperature to 80°C (176°F).
5. Allow the ATF temperature to fall to approximately 65°C (149°F). Use the CONSULT-II to monitor the ATF temperature as follows: (Scheme 37): ATF Fluid Temperature Graph NOTE: The ATF level will be significantly affected by the ATF temperature as shown. Therefore monitor the ATF temperature data using the CONSULT-II. Connect CONSULT-II to data link connector. Select "MAIN SIGNALS" in "DATA MONITOR" mode for "A/T" with CONSULT-II. Read out the value of "ATF TEMP 1".
6. Re-check the ATF level at ATF temperatures of approximately 65°C (149°F) using the "HOT" range on the ATF level gauge as shown. The HOT range is between 50° - 80°C (122° - 176°F). CAUTION: When wiping the ATF from the ATF level gauge, always use lint-free paper, not a cloth. (Scheme 38): Identifying ATF Level Marks On Dipstick To check the ATF level, insert the ATF level gauge until the cap contacts the top of the charging pipe, with the gauge reversed from the normal inserted position as shown.
7. Check the ATF condition. If the ATF is very dark or has some burned smell, there may be an internal problem with the transmission. Refer to " «TROUBLE DIAGNOSIS FOR SYMPTOMS»(ref-272346-S10563212862007111800000) ". Flush the transmission cooling system after repairing the transmission. If the ATF contains frictional material (clutches, bands, etc.), replace the radiator and flush the transmission cooler lines using cleaning solvent and compressed air after repairing the transmission. (Scheme 39): Identifying A/T Fluid Level Gauge And Charging Pipe
8. Install the ATF level gauge in the charging pipe.
9. Tighten the ATF level gauge bolt to specification. ATF level gauge bolt: Refer to " «COMPONENTS»(ref-272346-S05552466662007111800000) ".

FILLING

1. Remove the filler plug. Fill with new oil until oil level reaches the specified limit near the filler plug hole. Oil grade and viscosity: Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ". Oil capacity: Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ".
2. After refilling the oil, check oil level. Set a gasket to the filler plug, then install it to the transmission. Tighten the filler plug to the specified torque. Refer to " «CASE COMPONENTS»(ref-272349-S31397233932007111800000) " (5 M/T), " «COMPONENTS»(ref-272349-S23660554562007111800000) " (6 M/T). CAUTION: Do not reuse gasket. see scheme 48: Checking Oil Level From Filler Plug Hole

Scheme 40

1. Make sure that fluid is not leaking from the transfer assembly or around it.
2. Check fluid level from the filler plug hole as shown. CAUTION: Do not start engine while checking fluid level.
3. Install the filler plug with a new gasket to the transfer. Tighten to the specified torque. Refer to " «COMPONENTS»(ref-272365-S03611311312007111800000) ". CAUTION: Do not reuse gasket. see scheme 49: Checking Fluid Level

Scheme 41

1. Stop engine.
2. Remove the drain plug and gasket. Drain the fluid.
3. Install the drain plug with a new gasket to the transfer. Tighten to the specified torque. Refer to " «COMPONENTS»(ref-272365-S03611311312007111800000) ". CAUTION: Do not reuse gasket. see scheme 50: Identifying Drain Plug

1. Remove the filler plug and gasket.
2. Fill the transfer with new fluid until the fluid level reaches the specified limit near the filler plug hole. Fluid grade and capacity: Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ". CAUTION: Carefully fill fluid. (Fill up for approximately 3 minutes.)
3. Leave the vehicle for 3 minutes, and check fluid level again.
4. Install the filler plug with a new gasket to the transfer. Tighten to the specified torque. Refer to " «COMPONENTS»(ref-272365-S03611311312007111800000) ". CAUTION: Do not reuse gasket. (Scheme 40): Checking Fluid Level

Checking Propeller Shaft

Check the front and rear propeller shafts for damage, dents, and cracks. Check the joints for looseness and any damage. Repair or replace as necessary. Refer to " NVH TROUBLESHOOTING CHART ".

Scheme 42

1. Make sure that oil is not leaking from the final drive assembly or around it.
2. Check oil level from the filler plug hole as shown. CAUTION: Do not start engine while checking oil level.
3. Install the filler plug with a new gasket on it to the final drive assembly. Tighten to the specified torque. Refer to " «COMPONENTS»(ref-272355-S14108353332007111800000) ". CAUTION: Do not reuse gasket. (Scheme 41): Checking Fluid Level From Filler Plug Hole

Scheme 43

1. Stop the engine.
2. Remove the drain plug and gasket. Drain the gear oil.
3. Install the drain plug with a new gasket to the final drive asssembly. Tighten to the specified torque. Refer to " «COMPONENTS»(ref-272355-S14108353332007111800000) ". CAUTION: Do not reuse gasket. see scheme 53: Locating Drain Plug

1. Remove the filler plug and gasket. Fill with new gear oil until the oil level reaches the specified level near the filler plug hole. Oil grade and capacity: Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ".
2. After refilling oil, check the oil level. Install the filler plug with a new gasket on it to the final drive assembly. Tighten to the specified torque. Refer to " «COMPONENTS»(ref-272355-S14108353332007111800000) ". CAUTION: Do not reuse gasket. (Scheme 42): Checking Fluid Level From Filler Plug Hole

Checking Rear Final Drive Oil

Note. The C220 is shown, the M226 with electronic locking differential, and the M226 without electronic locking differential are similar.

Scheme 44

1. Make sure that gear oil is not leaking from final drive assembly or around it.
2. Check oil level from filler plug hole as shown. CAUTION: Do not start engine while checking oil level.
3. Apply sealant to filler plug. Install filler plug to final drive assembly and tighten to the specified torque. Refer to " «COMPONENTS»(ref-272368-S09140947482007111800000) " (C200), " «COMPONENTS»(ref-272368-S09140947482007111800000) " (M226 without electronic locking differential), " «COMPONENTS»(ref-272368-S41561754442007111800000) " (M226 with electronic locking differential). Use Genuine Silicone RTV or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-272334-S29650495302007111800000) ". (Scheme 43): Checking Differential Gear Oil

Changing Rear Final Drive Oil

Note. The C220 is shown, the M226 with electronic locking differential, and the M226 without electronic locking differential are similar.

Scheme 45

1. Stop engine.
2. Remove drain plug and drain gear oil.
3. Set a gasket on drain plug and install it to final drive assembly and tighten to the specified torque. Refer to " «COMPONENTS»(ref-272368-S36163325402007111800000) " (C200), " «COMPONENTS»(ref-272368-S09140947482007111800000) " (M226 without electronic locking differential), " «COMPONENTS»(ref-272368-S41561754442007111800000) " (M226 with electronic locking differential). CAUTION: Do not reuse gasket. see scheme 56: Identifying Drain Plug

1. Remove filler plug. Fill with new gear oil until oil level reaches the specified level near filler plug hole. Oil grade and viscosity: Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ". Oil capacity: Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ".
2. After refilling oil, check oil level. Apply sealant to filler plug. Install filler plug to final drive assembly and tighten to the specified torque. Refer to " «COMPONENTS»(ref-272368-S36163325402007111800000) " (C200), " «COMPONENTS»(ref-272368-S09140947482007111800000) " (M226 without electronic locking differential), " «COMPONENTS»(ref-272368-S41561754442007111800000) " (M226 with electronic locking differential). Use Genuine Silicone RTV or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-272334-S29650495302007111800000) ". (Scheme 44): Checking Differential Gear Oil

Wheel Balance (Maximum Allowable Imbalance)

WHEEL BALANCE SPECIFICATION

Scheme 46

1. Rotate the tires on each side from front to back as shown, using power tool. Wheel nuts: Refer to " «WHEEL AND TIRE ASSEMBLY»(ref-272362-S30401920942007111800000) ". Follow the maintenance schedule for tire rotation maintenance intervals. Refer to " «PERIODIC MAINTENANCE»(ref-272345-S20926376742007111800000) ". Do not include the spare tire when rotating the tires. CAUTION: When installing the wheels, tighten the wheel nuts diagonally by repeating the tightening pattern two or three times in order to prevent the wheels from developing any distortion. see scheme 61: Identifying Tire Rotation Procedure
2. Adjust the tire pressure to specification. Refer to " «TIRE»(ref-272362-S29539772692007111800000) ".
3. After the tire rotation, retighten the wheel nuts after the vehicle has been driven for 1,000 km (600 miles), and also after a wheel and tire have been installed such as after repairing a flat tire.

Scheme 47

1. Check the brake fluid level in the reservoir tank. It should be between the "MAX" and "MIN" lines on the reservoir tank.
2. If the fluid level is extremely low, check the brake system.
3. If the brake warning lamp comes on when the fluid is at the correct level, check the brake fluid level switch and the parking brake switch. see scheme 62: Identifying Brake Fluid Level

Scheme 48

1. Check the brake lines and hoses for cracks, deterioration, and other damage. Replace any damaged parts. CAUTION: If brake fluid leaks are visible around the brake line joints, retighten the joint, or replace damaged parts as necessary.
2. Check for brake fluid leaks by fully depressing brake pedal while engine is running. (Scheme 46): Checking Brake Fluid Lines And Parking Brake Cables For Improper Attachment And Leaks

ROTOR

Check the condition of the rotor, and for any wear or damage. Repair or replace as necessary.

Standard thickness: Refer to " FRONT DISC BRAKE ", " REAR DISC BRAKE ".

Repair limit thickness: Refer to " FRONT DISC BRAKE ", " REAR DISC BRAKE ".

Checking Pad. Scheme 49

CALIPER

Check for any fluid leakage. Repair as necessary.

Scheme 50

PAD

Check for any wear or damage. Repair or replace as necessary.

Standard thickness: Refer to " FRONT DISC BRAKE ", " REAR DISC BRAKE ".

Repair limit thickness: Refer to " FRONT DISC BRAKE ", " REAR DISC BRAKE ".

Scheme 51

1. Check the steering gear housing for looseness, damage and oil leakage as shown.
2. Check the steering column connections for looseness. (Scheme 50): Checking Fluid Leakage

STEERING LINKAGE

1. Check the ball joint, dust cover and other component parts for looseness, wear, damage and grease leakage.

CHECKING LINES

1. Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. (Scheme 51): Checking Fluid Leakage

FRONT AND REAR AXLE AND SUSPENSION PARTS

Check front and rear axle and suspension parts for excessive play, cracks, wear or other damage.

Scheme 52

1. Shake each wheel to check for excessive play.
2. Rotate each wheel to check for abnormal noise.
3. Check axle and suspension nuts and bolts for looseness. see scheme 70: Checking Axle And Suspension Parts For Excessive Play
4. Check the strut and shock absorber for oil leakage or other damage.
5. Check suspension ball joints for grease leakage and ball joint dust cover for cracks or other damage.

FRONT DRIVE SHAFT

Check the boots and drive shaft for cracks, wear, damage, and grease leakage.

Scheme 53

Scheme 54

1. Lubricate the locations shown. Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S25092981132007111800000) ".

Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters

Check the seat belt buckles, webbing, retractors, anchors and adjusters. Replace any seat belt assembly as necessary. Refer to " SEAT BELT INSPECTION ".

1. Check the seat belt anchors for loose mounting bolts, damage, or excessive wear.
2. Check the seat belt webbing for any damage, cuts, fraying, or excessive wear.
3. Check the retractor for smooth operation.
4. Check the function of the buckles by inserting the seat belt tongue and checking for proper engagement of the buckle and press the button on the buckle to check for proper release of the seat belt tongue.