1998 NISSAN PICK-UP Repair Manual

Clutch Disc and Flywheel
INSPECTION
lCheck clutch disc for burns, discoloration or oil or grease
leakage. Replace if necessary.
lCheck clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)
lCheck clutch disc for backlash of spline and runout of facing.
Maximum backlash of spline (at outer edge of disc):
240 1.0 mm (0.039 in)
250 1.0 mm (0.039 in)
Runout limit:
0.7 mm (0.028 in) TD25 engine
1.0 mm (0.039 in) Except TD25 engine
Distance of runout check point (from hub center):
240 115 mm (4.53 in)
250 120 mm (4.72 in)
lCheck flywheel and clutch disc contact surface for slight
burns or discoloration. Repair flywheel with emery paper.
lCheck flywheel runout.
Maximum allowable runout:
Refer to EM section (``Inspection'', ``CYLINDER
BLOCK'').
SCL206
SCL229-A
SCL221-A
SEM929A
CLUTCH DISC AND CLUTCH COVER
CL-12

INSTALLATION
lApply recommended grease to contact surface of spline por-
tion.
Too much lubricant might cause clutch disc facing damage.
Clutch Cover
INSPECTION
lAdjust unevenness of diaphragm spring with Tool.
Uneven limit:
250 0.5 mm (0.020 in)
240 0.5 mm (0.020 in) Except TD25 engine
0.7 mm (0.028 in) TD25 engine
lSet Tool and check height and unevenness of diaphragm
spring.
Set 0.2 mm (0.008 in) feeler gauges on distance pieces
(ST20050100) when checking 240 or 250.
Diaphragm spring height ``A'':
240 37.5 - 39.5 mm (1.476 - 1.555 in)
250 37.0 - 39.0 mm (1.457 - 1.535 in)
lCheck thrust rings for wear or damage by shaking cover
assembly up and down to listen for chattering noise, or lightly
hammering on rivets for a slightly cracked noise. Replace
clutch cover assembly if necessary.
lCheck pressure plate and clutch disc contact surface for
slight burns or discoloration. Repair pressure plate with
emery paper.
lCheck pressure plate and clutch disc contact surface for
deformation or damage. Replace if necessary.
INSTALLATION
lInsert Tool into clutch disc hub while installing clutch cover
and disc.
lBe careful not to allow grease to contaminate clutch facing.
lTighten bolts in numerical order, in two steps.
First step:
:10-20Nzm (1.0 - 2.0 kg-m,7-14ft-lb)
Final step:
:22-29Nzm (2.2 - 3.0 kg-m, 16 - 22 ft-lb)
SCL466-A
SCL219-A
SCL749
CLUTCH DISC AND CLUTCH COVER
Clutch Disc and Flywheel (Cont'd)
CL-13

General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch control Hydraulic
CLUTCH MASTER CYLINDER (All models)
Inner diameter mm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Unit: mm (in)
Inner
diameterLHD model 17.46 (11/16)
RHD model 19.05 (3/4)
CLUTCH DISC
Destination Europe
Model 240
Engine KA24E TD25
Facing size
mm (in)
(Outer dia. x inner
dia. x thickness)240 x 150 x 3.5
(9.45 x 5.91 x 0.138)240 x 160 x 3.5
(9.45 x 6.30 x 0.138)
Thickness of disc
assembly
With load
mm (in)7.8 - 8.2
(0.307 - 0.323)
With 4,904 N
(500 kg, 1,103 lb)7.5 - 7.9
(0.295 - 0.311)
With 3,923 N
(400 kg, 882 lb)
CLUTCH COVER
Model 240
Engine TD25 KA24E
Full load
N (kg, lb)3,923
(400, 882)4,413
(450, 992)
Inspection and Adjustment
CLUTCH PEDALUnit: mm (in)
Pedal height ``H*''
LHD model
TD25 and KA24E engine models 221 - 231 (8.70 - 9.09)
RHD model
TD25 andKA24E engine models 195 - 205 (7.68 - 8.07)
Pedal free play (at clevis pin) 1 - 1.5 (0.039 - 0.059)
*: Measured from surface of melt sheet to pedal pad
CLUTCH DISCUnit: mm (in)
Model 240
Engine model KA24E TD25
Wear limit of facing surface to rivet
head0.3 (0.012) or more
Runout limit of facing 1.0 (0.039) 0.7 (0.028)
Unit: mm (in)
Model 240
Distance of runout check point
(from the hub center)115 (4.53)
Maximum backlash of spline
(at outer edge of disc)1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Model 240
Engine model KA24E TD25
Diaphragm spring
height37.5 - 39.5
(1.476 - 1.555)
Uneven limit of dia-
phragm spring toe
height0.5 (0.020) 0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14

BODY & TRIM
SECTIONBT
CONTENTS
PRECAUTIONS......................................................... 1
Service Notice ........................................................ 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models).............................................. 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models).............................................. 1
GENERAL SERVICING............................................. 2
Clip and Fastener .................................................. 2
BODY END................................................................ 5
Body Front End ...................................................... 5
Body Rear End ...................................................... 8
DOOR....................................................................... 10
Front Door ............................................................ 10
Rear Door ............................................................ 11
INSTRUMENT PANEL............................................. 12
INTERIOR TRIM...................................................... 15
Side and Floor Trim ............................................. 15
Door Trim ............................................................. 18
Roof Trim ............................................................. 21EXTERIOR............................................................... 24
SEAT........................................................................ 30
Front Seat ............................................................ 30
Heated Seat ......................................................... 32
Rear Seat ............................................................. 33
Jump Seat ............................................................ 34
SUNROOF................................................................ 35
WINDSHIELD AND WINDOWS.............................. 36
Windshield............................................................ 37
Side Window ........................................................ 38
MIRROR................................................................... 39
Door Mirror ........................................................... 39
CAB AND REAR BODY.......................................... 40
Removal ............................................................... 40
Body Mounting ..................................................... 41
BODY ALIGNMENT................................................. 43
Engine Compartment ........................................... 44
Underbody............................................................ 46
.For seat belt, refer to MA and RS section.
.For wiring diagrams of body electrical systems, refer to EL section.BT

Service Notice
lWhen removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
lHandle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil
or damage them.
lApply sealing compound where necessary when installing parts.
lWhen applying sealing compound, be careful that the sealing compound does not protrude from parts.
lWhen replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust
prevention measures.
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag
module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness
and spiral cable. Information necessary to service the system safely is included in theRS sectionof this
Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag
module (located in the center of the steering wheel), diagnosis sensor unit, warning lamp, wiring harness
and spiral cable. Information necessary to service the system safely is included in theRS sectionof this
Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual.
PRECAUTIONS
BT-1

Clip and Fastener
lClips and fasteners in BT section correspond to the following numbers and symbols.
lReplace any clips and/or fasteners which are damaged during removal or installation.
Symbol
No.Shapes Removal & Installation
C101
SBF302H
SBF367BA
C103
SBT095SBF423H
C203
SBF258GSBF708E
C205
MBF518BSBF638C
GENERAL SERVICING
BT-2

Symbol
No.Shapes Removal & Installation
CE103
SBF104BSBF147B
CG104
SBF351CSBF352C
CE114
SBF353C
Ð
CG101
SBF145BSBF085B
CR103
SBF768BSBF770B
GENERAL SERVICING
Clip and Fastener (Cont'd)
BT-3

Symbol
No.Shapes Removal & Installation
CS101
SBF078BSBF992G
GENERAL SERVICING
Clip and Fastener (Cont'd)
BT-4