SECTION

MAINTENANCE
MA MA

CONTENTS
SPECIAL SERVICING TOOLS ................................... 2 STEERING SYSTEM ................................................ 45
PRE-DELIVERY INSPECTION OPERATIONS .......... 3 Checking the level in the power steering fluid res-
GENERAL MAINTENANCE ....................................... 4 ervoir ....................................................................... 45
SCHEDULED MAINTENANCE .................................. 5 FRONT AXLE AND SUSPENSION .......................... 47
Maintenance intervals for vehicles covering less Checking front axle and suspension parts ............. 47
than 30,000 km/year ................................................ 5 REAR AXLE AND SUSPENSION ............................ 49
Maintenance under adverse driving conditions Checking rear axle and suspension parts .............. 49
(annual distance covered less than 30,000 km/year)..... 7 BRAKE AND CLUTCH SYSTEMS ........................... 50
Maintenance intervals for vehicles covering more Brake and clutch fluid level ..................................... 50
than 30,000 km/year ................................................ 8 Changing the brake and clutch liquid ..................... 50
Maintenance under adverse driving conditions Checking the brake system .................................... 50
(annual distance covered more than 30,000 km/ Checking the brake servo vacuum system ............. 50
year) ....................................................................... 10 Checking the disc brakes ........................................ 51
RECOMMENDED FUEL, LUBRICANTS AND FLU- Checking the drum brakes ...................................... 52
IDS ............................................................................ 11 WHEELS AND TYRES ............................................. 53
Table of recommended viscosities (SAE) ............... 11 Checking the state of the tyres ............................... 53
ENGINE MAINTENANCE - BD-30 T ........................ 12 Swapping of tyres ................................................... 54
Inspecting the drive belts ....................................... 12 Fitting the wheels .................................................... 54
Adjust valve clearances .......................................... 13 Tyres ....................................................................... 55
Checking the injectors ............................................ 14 ELECTRICAL SYSTEM ............................................ 56
Checking the lubrication system ............................ 16 Battery .................................................................... 56
Checking the cooling system ................................. 19 Pre-heating glow plugs ........................................... 58
Checking the fuel and exhaust systems ................. 22 Air heater ................................................................ 58
Checking the air intake system .............................. 26 BODYWORK ............................................................. 59
ENGINE MAINTENANCE - BD-30 TI ....................... 27 Checking the safety belts, buckles, retractors,
Inspecting the drive belts ....................................... 27 anchorings and adjuster ......................................... 59
Adjust valve clearances .......................................... 28 TECHNICAL DATA AND CHARACTERISTICS / BD-
Checking the injectors ............................................ 29 30 T ........................................................................... 61
Checking the lubrication system ............................ 30 Technical data ......................................................... 61
Checking the cooling system ................................. 33 TECHNICAL DATA AND CHARACTERISTICS / BD-
Checking the fuel and exhaust systems ................. 39 30 TI .......................................................................... 62
Checking the air intake system .............................. 43 Technical data ......................................................... 62
GEARBOX ................................................................ 44
Checking oil level and changing oil ........................ 44

MA-1
 SPECIAL SERVICING TOOLS

SPECIAL SERVICING TOOLS PFP:_

REFERENCE
NAME
NUMBER
40900605-A-1 Pressure pump (check losses in the cooling)

40900605-A-2 Adapter connector

40900605-A-3 Adapter for the expansion tank

40900605-A-6 Checker for the stopper of the expansion tank

MA-2
 PRE-DELIVERY INSPECTION OPERATIONS

PRE-DELIVERY INSPECTION OPERATIONS

Predelivery inspection operations are required in the points detailed below. It is advisable to also
include those points not listed here but necessary according to the specific conditions of each country

MA-3
 GENERAL MAINTENANCE

GENERAL MAINTENANCE PFP:_

General maintenance includes those points which must be checked during the normal daily use of the vehicle.
They are essential for the vehicle's correct operation. Owners may carry out the checks and inspections
themselves or have them done by a Nissan dealer.
Component Reference pages
VEHICLE EXTERIOR
The maintenance points described below must be checked regularly, unless otherwise specified.
Tyres. Check the pressure weekly with a pressure gauge when visiting a service station, including that of the
spare wheel, and adjust to the specified pressures if necessary. Carefully check for damage, cuts and excessive _
wear.
Windscreen wiper blades. Check for cracks, wear and correct operation. _

Battery. Check the electrolyte level in each cell; it must be between the "MAX" and "MIN" marks. _
Doors. Check that the doors operate correctly and that the locks close firmly. Lubricate if necessary.

When driving in areas with salt or other corrosive materials, check the lubrication more frequently.
Tyre swapping. The tyres must be swapped around half way through their useful life MA-54
Engine coolant level (chassis cab models)*. Check the engine coolant level when the engine is cold. MA-19 and MA-34
Lights. Ensure that the headlamps, brake lights, rear lights, sidelights and other lights operate correctly and are
firmly installed. Also check the headlamp alignment.
INTERIOR OF VEHICLE
The following maintenance points must be checked regularly, as well as during scheduled maintenance, when
cleaning the vehicle, etc.
Engine inspection hatch. Check that it operates correctly. Lubricate if necessary. When driving in areas with
_
salt or other corrosive materials, check the lubrication more frequently.
Warning lights and signals / warning buzzer. Ensure that all the warning lights and audio signals/warning
_
buzzer operate correctly.
Steering wheel. Check for changes in the steering, such as excessive free play, unusual noises, hard steering,
_
etc.
Windscreen washer liquid*. Check that there is a suitable amount of liquid in the reservoir. _
Engine coolant level (double cab models)*. Check the coolant level when the engine is cold. MA-36
Brake and clutch fluid level*. Check that the level is between the "MAX" and "MIN" marks on the reservoir. MA-50
UNDER THE BONNET
The following maintenance points must be checked regularly, or at least whenever checking the engine oil level
or filling up with fuel.
Engine oil level. Check the level with the engine warm, after parking the vehicle (on a level surface) and with the
MA-16 and MA-30
engine stopped.
Power steering oil level. Ensure that the oil level is between the "MAX" and :MIN: marks with the engine cold. MA-45
*These points must be checked more frequently, or at least whenever checking the engine oil level or filling up with fuel.

MA-4
 SCHEDULED MAINTENANCE

SCHEDULED MAINTENANCE PFP:_

Maintenance intervals for vehicles covering less than 30,000 km/year CIADIEJA

Abbreviations I = Inspect and correct or replace if necessary; R = Replace; A = Adjust; L = Lubricate; T = Tighten; C = Clean; D = Drain the water

MAINTENANCE OPERATIONS MAINTENANCE INTERVALS

Every six months, once a year or at the distance shown in the table, miles x 1,000 6.2 12.4 18.6 24.8 31 37.2 43.5 50

km x 1,000 10 20 30 40 50 60 70 80

whichever occurs first Months 6 12 18 24 30 36 42 48

Engine Engine compartment and vehicle underside

Engine oil level Check WEEKLY

BD-30 T Engine R R R R
Engine oil (use only recommended oil)*
BD-30Ti Engine R R R R

BD-30T Engine R R R R
Engine oil filter (use original parts)*
BD-30Ti Engine R R R R

Belts I I I I I

Engine coolant (monoethylene glycol based) (1)

Cooling system I I I I

Leaks in the fuel system I I

Air filter (dry type)* C R C R

BD-30T Engine
Fuel filter* (Replace) Every 24 months or 50,000 km (31,000 miles)
BD-30Ti Engine

Injectors (2)

Water in the fuel filter D D D D

Valve clearances** A A A A

MA-5
 SCHEDULED MAINTENANCE

Bodywork and frame Engine compartment and vehicle underside

Brake and clutch fluid* R R

Brake servo hoses and connections, and retention valve I I

Power steering oil and pipes (check level and for leaks) I I I I

Brake and clutch systems (check levels and for leaks) I I I I

Gearbox oil* (check levels and for leaks) I I R I

Mechanism and steering linkage, propeller shaft and suspension I I

Differential oil level* (check levels and for leaks) I I R I

Air bag system (4)

Wheel alignment I I I I

Brake pads, discs and other components* I I I I

Brake shoes, drums and other components* I I I I

Bearings of front wheels* I L I L

Propeller shafts, stub axles, locks, hinges, etc. * L L L L

Leaf spring flanges L L L L

Grease of the wheel hub and hub cap* (both axles) I R I R

Seat belts, along with their buckles, retractors and anchorings I

Adjustment of headlamps I I I I

Service and parking brakes, clutch pedal clearance, travel, free play and
I I I I
clutch operation

Throttle stops of engine brake (BD-30Ti Engine) A

Cab tilt system I

State of the bodywork (rust) Check ANNUALLY

Confirm compliance with bodywork standards (3) After the first 1,000 km (621 miles)

(1) Change at 48 months or 80,000 km and then every 36 months or 60,000 km.
(2) If the engine looses power, emits smoke or makes excessive noise, check the injection opening pressure and the fuel spray pattern
and adjust if necessary.
(3) In Chassis Cab models, adjust the braking regulator valve once the vehicle has had bodywork fitted.
(4) Inspect after 10 years, then every 2 years.
(*) These operations must be carried out more frequently, as described in "MAINTENANCE UNDER ADVERSE DRIVING CONDI-
TIONS".
(**) Regardless of the specified interval, inspect and adjust if engine noise increases.

MA-6
 SCHEDULED MAINTENANCE

Maintenance under adverse driving conditions (annual distance covered less

than 30,000 km/year) CIAJDIJD

The maintenance intervals shown in the previous page apply under normal driving conditions. If the vehicle is
used mostly under adverse conditions, as described below, the maintenance of the points shown in the table
below must be carried out more frequently.
Adverse driving conditions
A - Driving in very dusty areas. F - Driving in very humid or mountainous regions.
B - Repeated driving over short distances. G - Driving in areas with salt on the roads or in corrosive environments
C - Driving with a trailer. (industrial areas).
D - Prolonged operation at idling speed. H - Driving on unsurfaced or muddy roads or in the desert.
E - Driving in extreme weather conditions or in areas I - Driving with intense use of brakes or in mountainous regions.
where the temperature is extremely high or low. J - Driving frequently in the rain.

Maintenance operation: Checking = Verify and correct or replace if necessary.

DRIVING CONDITIONS COMPONENT MAINTENANCE OPERATION MAINTENANCE INTERVAL

Engine lubrication service

Engine oil (use only the

ABCD......
recommended oil) Replacement Half of that shown in the table
ABCD...... Oil filter (use original parts)

General maintenance

BD-30T Every 12 months or 25,000 km

A...E..... Fuel filter Replacement
BD-30 Ti (15,500 miles)

Every 6 months or 10,000 km

Clean
(6,200 miles)
A......... Air filter (dry type)
Every 12 months or 20,000 km
Replacement
(12,400 miles)

Every 12 months or 20,000 km

.....F.... Brake and clutch fluid
(12,400 miles)

..C....H.. Gear oil for the gearbox Every 18 months or 30,000 km

Replacement (18,600 miles)
..C....H.. Gear oil for the differential

Grease of the wheel hub and Every 12 months or 20,000 km

......G...
hub cap (both axles) (12,400 miles)

Pads, discs and other brake Every 6 months or 10,000 km

A.C...GHI.
components (6,200 miles)

Steering mechanism and link- Check

Every 12 months or 20,000 km
......GH.. age, propeller shaft and sus-
(12,400 miles)
pension.

Grease stub axles propeller Every 6 months or 10,000 km

......GH.J Lubrication
shafts, locks, hinges, etc. (6,200 miles)

MA-7
 SCHEDULED MAINTENANCE

Maintenance intervals for vehicles covering more than 30,000 km/year CIADFJBA

Abbreviations I = Inspect and correct or replace if necessary; R = Replace; A = Adjust; L = Lubricate; T = Tighten; C = Clean; D = Drain the water

MAINTENANCE OPERATIONS MAINTENANCE INTERVALS

Carry out at the distance shown miles x 1,000 6.2 12.4 18.6 24.8 31 37.2 43.5 50

in the table km x 1,000 10 20 30 40 50 60 70 80

Engine Engine compartment and vehicle underside

Engine oil level Check WEEKLY

BD-30T Engine R R R R
Engine oil (use only recommended oil)*
BD-30Ti Engine R R R R

BD-30T Engine R R R R
Engine oil filter (use original parts)*
BD-30Ti Engine R R R R

Belts I I I I I

Engine coolant (monoethylene glycol based) (1)

Cooling system I I
Leaks in the fuel system I
Air filter (dry type)* C R C R

BD-30T Engine
Fuel filter* (Replace) R
BD-30Ti Engine

Injectors (2)

Water in the fuel filter D D D D

Valve clearances** A A A A

MA-8
 SCHEDULED MAINTENANCE

Bodywork and frame Engine compartment and vehicle underside

Brake and clutch fluid* R

Brake servo hoses and connections, and retention valve I

Power steering oil and pipes (check level and for leaks) I

Brake and clutch systems (check levels and for leaks) I

Gearbox oil* (check levels and for leaks) R

Mechanism and steering linkage, propeller shaft and suspension I

Differential oil level* (check levels and for leaks) I R

Air bag system (4)

Wheel alignment I I

Brake pads, discs and other components* I I

Brake shoes, drums and other components* L L

Bearings of front wheels* L L

Propeller shafts, stub axles, locks, hinges, etc. * L L

Leaf spring flanges L L

Grease of the wheel hub and hub cap* (both axles) R R

Seat belts, along with their buckles, retractors and anchorings I

Adjustment of headlamps I I

Service and parking brakes, clutch pedal clearance, travel, free

I I
play and clutch operation

Throttle stops of engine brake (BD-30Ti Engine) A

Cab tilt system I

State of the bodywork (rust) Check ANNUALLY

Confirm compliance with bodywork standards (3) After the first 1,000 km (621 miles)

(1) Change at 90,000 km and then every 60,000 km.

(2) If the engine looses power, emits smoke or makes excessive noise, check the injection opening pressure and the fuel spray pattern
and adjust if necessary.
(3) In Chassis Cab models, adjust the braking regulator valve once the vehicle has had bodywork fitted.
(4) Inspect after 10 years, then every 2 years.
(*) These operations must be carried out more frequently, as described in "MAINTENANCE UNDER ADVERSE DRIVING CONDI-
TIONS".
(**) Regardless of the specified interval, inspect and adjust if engine noise increases

MA-9
 SCHEDULED MAINTENANCE

Maintenance under adverse driving conditions (annual distance covered more

than 30,000 km/year) CIAJDGEH

The maintenance intervals shown in the previous page apply under normal driving conditions. If the vehicle is
used mostly under adverse conditions, as described below, the maintenance of the points shown in the table
below must be carried out more frequently.
Adverse driving conditions
A - Driving in very dusty areas. F - Driving in very humid or mountainous regions.
B - Repeated driving over short distances. G - Driving in areas with salt on the roads or in corrosive environments
C - Driving with a trailer. (industrial areas).
D - Prolonged operation at idling speed. H - Driving on unsurfaced or muddy roads or in the desert.
E - Driving in extreme weather conditions or in areas I - Driving with intense use of brakes or in mountainous regions.
where the temperature is extremely high or low. J - Driving frequently in the rain.

Maintenance operation: Checking = Verify and correct or replace if necessary.

DRIVING CONDITIONS COMPONENT MAINTENANCE OPERATION MAINTENANCE INTERVAL

Engine lubrication service

Engine oil (use only the

ABCD......
recommended oil) Replacement Half of that shown in the table
ABCD...... Oil filter (use original parts)

General maintenance

BD-30 T
A...E..... Fuel filter Replacement Every 25,000 km (15,500 miles)
BD-30 Ti

Replacement Every 10,000 km (6,200 miles)

A......... Air filter (dry type)
Replacement Every 20,000 km (12,400 miles)

.....F.... Brake and clutch fluid

..C....H.. Gear oil for the gearbox

..C....H.. Gear oil for the differential Replacement Every 30,000 km (18,600 miles)

Grease of the wheel hub and

......G... Every 20,000 km (12,400 miles)
hub cap (both axles)

Pads, discs and other brake

A.C...GHI. Every 15,000 km (9,300 miles)
components

Steering mechanism and link- Check

......GH.. age, propeller shaft and sus- Every 30,000 km (18,600 miles)
pension.

Grease stub axles propeller

......GH.J Lubrication Every 15,000 km (9,300 millas)
shafts, locks, hinges, etc.

MA-10
 RECOMMENDED FUEL, LUBRICANTS AND FLUIDS

RECOMMENDED FUEL, LUBRICANTS AND FLUIDS PFP:_

Capacity (approximate) Specification

APPLICATION/MODEL Comments
Litres Imp. qt Warm countries Cold countries

Engine oil
API CF-4 API CF-4
MOTIBER
BD-30 T 7.2 (**) 12 5/8 pt CCMC-PD2 CCMC-PD2
15 W 40 ***
and D4* and D4*
BD-30 Ti 7.2 (**) 12 5/8 pt

Cooling liquid

BD-30 T
15 26 3/8 pt LLCL-1 LLCL-1 Monoethylene-glycol based anti-
BD-30 Ti 35% (-20°C -4°F) 50% (-30°C -22°F) freeze

Gearbox oil
API GL-4
M5 - 35 A 2.7 2.37 [Link]
*
Differential oil
API GL-5 80 W / 90 MPS
H233BII Standard
2 3 1/2 pt
LSD (opc.) 80 W / 90 LS (1)

Power-steering fluid
_
TAS 15M 1.2 2 1/8 pt DEXRON II

Fuel 90 20 gal. – Diesel type cetane N° 50

Brake and clutch fluid 1.25 2 1/4 pt DOT-4 –

Unsalted water with 15% wind-

Windscreen washer reservoir 2.2 3 7/8 pt –
screen washer liquid

Greases – NLGI N.° 2 Lithium base

Contact an official Nissan Dealer

Air conditioning lubricant – Nissan A/C System Oil Type R or equivalent
or Service Centre

* For more details see the "Table of recommended viscosities (SAE)".

** Including filter and cooler.
1) Use only oil approved for Nissan self-locking differentials.

Table of recommended viscosities (SAE) CIAJCFAG

0040MA

Use an oil of a suitable viscosity for the temperatures in the area in which the vehicle is used.
* Not recommended for sustained driving at high speeds.

MA-11
 ENGINE MAINTENANCE - BD-30 T

ENGINE MAINTENANCE - BD-30 T PFP:_

Inspecting the drive belts EXS00A01

1. Check for cracks, damage, wear or oil stains on the belt and
replace with a new one if necessary.
2. Check the belt tension by pressing it half way between the two
pulleys as shown in the adjacent figure.
Adjust the deflection of the belts with the bolt from power
steering pump, to allow the deflection of the belts indicated
in the table.

NMA110

BELT MOVEMENT:
Unit: mm (inches)
Used belt movement:
New belt movement:
Limit Movement after adjustment
6 (0.23) 13 (0.51) 7.5 (0.29)
Applied force 98 N (10 kg; 72,3 lb)

BELT CIRCUIT

NMA109

COMPONENTS
1. Crankshaft pulley 4. Water pump pulley Belt tension check points
2. Air conditioner compressor pulley 5. Alternator pulley
3. Power steering pump pulley 6. Idler pulley

NOTE:
Measure the deflection of the belts with the engine cold and after the crankshaft has turned several times, to allow the belts to
seat correctly on their pulleys.

MA-12
 ENGINE MAINTENANCE - BD-30 T

Adjust valve clearances

This adjustment must be made with the engine warm but stopped
1. Remove the rocker cover
2. Set cylinder 1 to TDC and adjust the clearances of valves (1),
(2), (3), and (6).
3. Set cylinder 4 to the TDC of its compression stroke and adjust
the clearances of valves (4), (5), (7) and (8).
Adjustment screw lock nut:
15÷20 N-m (1.5÷2.0 kgm, 11.1÷14.8 ft-lb)
Valve clearances Unit: mm (inches)
Hot
Intake 0.25 ± 0,1 (0,009 ± 0,003)
Exhaust

(a) Front part

0228MA

MA-13
 ENGINE MAINTENANCE - BD-30 T

Checking the injectors CIAEICEF

REMOVAL
1. Remove the fuel injection(1) and return pipes (2).
2. Remove the injector using a suitable tool.

NEM408

CHECK
1. Fit the injector in the pressure tester.
2. Operate the tester lever slowly (once per second).
WARNING:
When using the injector tester, do not allow the fuel spray
from the nozzle to come into contact with your hands or
other parts of your body. Protect your eyes with suitable
safety goggles.
Injector pressure rating:
bar kPa kg/cm2 Ib/psi
Used injector 252 25.242 257 3.655 0254MA

New injector 270 26.997 275 3.910

● Always check the initial pressure before fitting a new injector.

3. Check the spray shape by pumping with the tester lever rapidly
(4 to 6 times per second).
4. If the spray cone shape is not correct, clean or replace the
nozzle.
See EC-24, "INJECTION PRESSURE TEST" in section EC in
this manual.

0255MA

MA-14
 ENGINE MAINTENANCE - BD-30 T

FITTING
1. Fit the injectors into the housings in the cylinder head.
Connect the fuel injection and return pipes.
Whenever an injector is removed, replace the gasket (1) and
the washer (2) with new ones.
Fixing of injector to cylinder head:
39÷44 N-m (4.0÷4.5 kgm, 28.8÷32.5 ft-lb)
2. Bleed the fuel system (see MA-23, "BLEEDING THE FUEL
SYSTEM" in this section) and check for leaks with the engine
running.

1. Gasket
2. Washer
0412MA

NOTE:
The gasket (1) is symmetrical, so it may be fitted to the cylinder head in any position.

MA-15
 ENGINE MAINTENANCE - BD-30 T

Checking the lubrication system CIAHFGIE

REPLACEMENT OF ENGINE OIL AND FILTER

WARNING:
● To avoid scalding, never change the filter or the oil when the engine is hot.
● Clean the drain plug, fit it with a new washer and re-install it.
● The replacement oil capacity will depend on the temperature of the oils and the draining time; use
these values as reference and take care to check the level with the dipstick when changing the oil.
● Both used oil and filters must be discarded in a specialized waste tip.
● Environmental pollution is punishable by law. Use suitable containers for collecting and transporting
the used oil and filters to the tip.
● Prolonged and repeated contact with oil may cause serious skin afflictions such as dermatitis,
cancer, etc.
● Avoid any contact with oil as far as possible and always wash your hands thoroughly.

1. Park the vehicle on a horizontal surface and apply the parking

brake.
2. Start the engine and run it until it reaches its normal working
temperature and check for oil leaks. Stop the engine.
3. Open the engine inspection hatch.
● Remove the clips (1) fixing the carpet.

● Remove the fixing clips (2) on the front of the passenger seat.

● Raise the engine inspection hatch (3).

● Fix the engine inspection hatch with the belt located behind
the passenger seat.

0457MA

MA-16
 ENGINE MAINTENANCE - BD-30 T

4. Remove the filler cap and the oil dipstick. Left hand drive
5. Collect the used oil in a suitable container. Interior of vehicle
a. Loosen and remove the drain plug. Allow the oil to drain out fully
and remove the filter as shown in the figures.
b. Clean the drain plug, fit a new washer and re-fit the plug.
Drain plug:
20 - 29 N-m (2 - 3 kgm; 14.8 - 21.4 ft-lb)

Below the vehicle

Front part MNA112

Right hand drive

Interior of vehicle

Below the vehicle

Front part MNA113

MA-17
 ENGINE MAINTENANCE - BD-30 T

6. Oil the gasket of the new filter and thread it in until a slight
resistance is felt, then tighten it manually by 2/3 turn.

0002LC

7. Fill the engine with recommended oil. Check the oil level.
Re-fit the filler cap. Left hand drive
Oil type and capacity (approximate)
See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND
FLUIDS".
MAX Maximum oil level mark. Do not exceed.
MIN. Minimum level. The level must always be below this
mark.
8. Start the engine and check for leaks around the drain plug and
filter.
9. Stop the engine and wait for several minutes. Re-check the oil
level and top up if necessary.
10. Close the engine inspection hatch, fixing it properly with its clips.
WARNING:
● After closing the inspection hatch, fix the respective clips.
● Take care not to trap your fingers in the inspection hatch.

NEM408

Right hand drive

NEM412

MA-18
 ENGINE MAINTENANCE - BD-30 T

Checking the cooling system CIAGFCAC

USE OF ANTI-FREEZE
When using pure anti-freeze, it must be mixed with lime- and chlorine-free water or demineralised water
following the instructions on the packaging. If there are no instructions, and it is expected that the ambient
temperature will drop to at least 0 °C (32°F), use the anti-freeze (monoethylene glycol) mixing ratio for the
lowest expected temperature on the table below.
Exterior temperature
Antifreeze Demineralised water
°C °F
-15 5 35% 65%
-30 -22 50% 50%

Use an anti-rust solution when anti-freeze is not used.

● Check for leaks in the cooling system.
CHECKING HOSES AND CONNECTIONS
Check that the hoses and connections are not loose or damaged.
CHECKING THE EXPANSION TANK CAP
1. Use a suitable tester to check the expansion tank cap safety
pressure.
If the pressure drops rapidly or excessively, change the expansion
tank cap.
Expansion tank safety cap release pressure
59÷98 kPa (0,59÷0,98 bar, 0,6÷1,0 kg/cm2, 8÷14 psi)

0271MA

CHECKING FOR LEAKS IN THE COOLING SYSTEM

1. Connect the tester to the filler hole of the expansion tank and
apply the specified pressure. If it drops, check the hoses,
radiator or water pump. If no leaks are found, check the heater
radiator, the cylinder block and the cylinder head.
Cooling system leak test pressure
157 kPa (1,57 bar, 1,6 kg/cm2, 22 psi)
● A pressure that is higher than specified may damage the
radiator.

0210MA

MA-19
 ENGINE MAINTENANCE - BD-30 T

REPLACEMENT OF ENGINE COOLANT

WARNING:
● To avoid scalding, never change the coolant when the engine is hot.
1. Park the vehicle on a horizontal surface and apply the parking brake.
2. Move the heater temperature control to the maximum temperature
position (all the way to the right) to fully open the heating system
stop cock.

0074HA

3. Remove the radiator drain plug and the expansion tank filler cap.

0307MA

0305MA

MA-20
 ENGINE MAINTENANCE - BD-30 T

4. Loosen and remove the cylinder block drain plug.

5. Drain the cooling system and clean it by flushing it with water.
● Take care not to spill coolant onto the drive belts.

6. Remove the expansion tank and clean it.

Refit it.
Bolts fixing expansion tank to bracket:
15 N-m (1.5 kgm; 11,1 ft-lb)
7. Fit the radiator and cylinder block drain plugs.
Cylinder block drain plug:
0359MA
29÷39 N-m (3.0÷4.0 kgm; 21.4÷ 28.8 ft-lb)
● Apply sealant to the cylinder block drain plug.
8. Fill the cooling system by pouring coolant into the expansion tank.
Fill slowly to allow air pockets in the interior to exit, until the level in the expansion tank is correct.
9. Start the engine and allow it to run for several minutes.
10. Stop the engine and when it has cooled, top up the expansion tank to the correct level. The correct level is
about 15 mm (0.59 inches) below the filler pipe.
11. Check for leaks.
CAUTION:
● The complete filling of the cooling system must be carried out with the engine cold.
● Do not add cold fluid when the engine is hot. If this is essential, do so with the engine running.
● Fill slowly to allow air pockets in the interior to exit, until the level in the expansion tank is correct.
● Check the coolant level frequently. If a significant amount of coolant must be added before servicing,
the leak must be located and repaired.
● A suitable mixture of water and anti-freeze must be used in both winter and summer, using, if pos-
sible, water that is free of lime, chlorine and minerals.
● The cooling liquid must be replaced at the intervals indicated in MA-5, "SCHEDULED MAINTE-
NANCE"
in this same Section MA. Clean the circuit well before refilling.
● See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND FLUIDS" for the type of fluid and capacity
(approximate) of the cooling system.

MA-21
 ENGINE MAINTENANCE - BD-30 T

Checking the fuel and exhaust systems CIAIAGBG

FUEL FILTER
Draining water
Periodically empty the water in the fuel filter. To do this, proceed as follows:
Proceed as follows:
1. Place a receptacle under the filter.
2. Loosen the water detector (1) a couple of turns.
3. After draining the water completely, screw the detector back in
(1).

0467MA

REPLACE FUEL FILTER

The fuel filter is of the cartridge type.
1. Put an appropriate receptacle under the filter.
2. Remove the filter and throw it away.
3. Unscrew the water purging valve unit and check the state of the
o-ring (1).
4. Replace if this is necessary.

0467MA

5. Fit the water purging valve unit in the new filter cartridge.
6. Lubricate the seal of the new filter.
7. Fit the new filter by threading it in until a slight resistance is felt
between the rubber gasket and the bracket, and then tighten it
manually 2/3 of a turn.

0468MA

8. Bleed the fuel system as described in the section MA-23,

"BLEEDING THE FUEL SYSTEM".

0002LC

MA-22
 ENGINE MAINTENANCE - BD-30 T

BLEEDING THE FUEL SYSTEM

If air enters the fuel system, either because of repair work or because the vehicle has run out of fuel, the
following must be taken into account before bleeding is carried out:
1. Ensure that there is sufficient fuel in the tank.
2. Access to bleed the system is through the right wheel arch.
3. Loosen the connector (1) of the fuel inlet in the injection pump a
couple of turns.

0500MA

MA-23
 ENGINE MAINTENANCE - BD-30 T

MNA111

4. Work on the priming piston (2) on the fuel filter until bubble-free petrol comes out of the connection (1).
5. Tighten the connector and continue to work on the priming piston (2) until you notice an increase in the
pressure of the piston and it becomes very difficult to work.
6. Start the engine. If the engine should still fail to start, release the injection pipes (3) and use the starter
motor until bubble-free fuel comes out of the pipes (3).
CAUTION:
Do not use the starter motor continuously for more than 10 seconds.
Before using it again, wait 10 seconds to avoid the battery discharging or the motor from being dam-
aged.
7. Tighten the injection pipes (3).
8. Start the engine and make sure there are no leaks in the connector or any other element that has been
handled.

MA-24
 ENGINE MAINTENANCE - BD-30 T

CHECKING THE FUEL SYSTEM

Check that the fuel system and tank are installed correctly and that
there are no leaks, cracks, damage, loose connections, worn points
or deterioration.
Repair or replace affected parts where necessary.

0270MA

CHECKING THE EXHAUST SYSTEM

0054FE

1. Check the silencer and all other parts of the exhaust system for cracks, corrossion or any other damage.
Replace any worn parts.
2. Replace the SilentBlocs if they are cracked or worn.

MA-25
 ENGINE MAINTENANCE - BD-30 T

Checking the air intake system CIABGFBG

REPLACEMENT OF AIR FILTER

● Check that the lips of the discharge valve (1) close correctly
without sticking. It is important that they maintain the
necessary flexibility to open under the weight of the dust
that accumulates inside, allowing periodic discharge.
1. Release the clips (2) and remove the housing (3).
2. Remove the filter (4).
3. Clean the inside of the housing (3).
4. Clean and re-fit the filter element (4) or fit a new one.
5. Fit the housing (3).
● Align the lug (5) on the lid with the notch on the cover (6).
WARNING:
Do not run the engine without the air filter fitted since it also
performs as a fire extinguisher when the engine backfires.

0444MA

CLEANING OF FILTER CARTRIDGE

1. Clean the cartridge with low pressure air from the inside.

0039MA

MA-26
 ENGINE MAINTENANCE - BD-30 TI

ENGINE MAINTENANCE - BD-30 TI PFP:_

Inspecting the drive belts

1. Check for cracks, damage, wear or oil stains on the belt and
replace with a new one if necessary.
2. Check the belt tension by pressing it half way between the two
pulleys as shown in the adjacent figure.
Adjust the deflection of the belts with 30the bolt from power
steering pump, to allow the deflection of the belts indicated
in the table.

NMA110

BELT MOVEMENT:
Unit: mm (inches)
Used belt movement:
New belt movement:
Limit Movement after adjustment
6 (0.23) 13 (0.51) 7.5 (0.29)
Applied force 98 N (10 kg; 72.3 lb)

BELT CIRCUIT

NMA109

COMPONENTS
1. Crankshaft pulley 4. Water pump pulley Belt tension check points
2. Air conditioner compressor pulley 5. Alternator pulley
3. Power steering pump pulley 6. Idler pulley

NOTE:
Measure the deflection of the belts with the engine cold and after the crankshaft has turned several times, to allow the belts to
seat correctly on their pulleys.

MA-27
 ENGINE MAINTENANCE - BD-30 TI

Adjust valve clearances CIAIGACC

This adjustment must be made with the engine warm but stopped.
1. Remove the rocker cover
2. Set cylinder 1 to TDC and adjust the clearances of valves (1),
(2), (3), and (6).
3. Set cylinder 4 to the TDC of its compression stroke and adjust
the clearances of valves (4), (5), (7) and (8).
Adjustment screw lock nut:
15÷20 N-m (1.5÷2.0 kgm, 11.1÷14.8 ft-lb)
Valve clearances Unit: mm (inches)

Hot

Intake 0.25 ± 0,1 (0,009 ± 0,003)

Exhaust

(a) Front part

0228MA

MA-28
 ENGINE MAINTENANCE - BD-30 TI

Checking the injectors CIABDIIB

REMOVAL
1. Remove the fuel injection and return pipes.
2. Remove the injector (1) using a suitable tool.
● Also remove the washer from the end of the injector and
the o-ring.

0524MA

CHECK
1. Fit the injector in the pressure tester.
2. Operate the tester lever slowly (once per second).

0003EF

WARNING:
When using the injector tester, do not allow the fuel spray from the nozzle to come into contact with
your hands or other parts of your body. Protect your eyes with suitable safety goggles.

Injector pressure rating:

bar kPa kg/cm2 psi

Used injector 252 25,242 257 3,655
New injector 270 26,997 275 3,910

● Always check the initial pressure before fitting a new injector.

3. Check the spray shape by pumping with the tester lever rapidly
(4 to 6 times per second).
4. If the spray cone shape is not correct, clean or replace the
nozzle.
See EC-24, "INJECTION PRESSURE TEST" in section EC in
this manual.

0008EC

MA-29
 ENGINE MAINTENANCE - BD-30 TI

FITTING
1. Fit the injector by reversing the removal procedure.
Bolt fixing clamp
39÷44 N-m (4÷4.5 kgm; 28.8÷32.5 ft-lb)

Injector to injection pipe

24÷29 N-m (2.5÷3 kgm; 17.7÷21.4 ft-lb
● Always clean the injector housing hole.
● Always replace the washers and O-rings with new ones.
● Purge the air from the fuel system. (see MA-27, "ENGINE
MAINTENANCE - BD-30 Ti").

1. Washer
2. O-ring
0292EC

Checking the lubrication system CIACCBBE

REPLACEMENT OF ENGINE OIL AND FILTER

WARNING:
● To avoid scalding, never change the filter or the oil when the engine is hot.
● Clean the drain plug, fit it with a new washer and re-install it.
● The replacement oil capacity will depend on the temperature of the oils and the draining time; use
these values as reference and take care to check the level with the dipstick when changing the oil.
● Both used oil and filters must be discarded in a specialized waste tip.
● Environmental pollution is punishable by law. Use suitable containers for collecting and transport-
ing the used oil and filters to the tip.
● Prolonged and repeated contact with oil may cause serious skin afflictions such as dermatitis,
cancer, etc.
● Avoid any contact with oil as far as possible and always wash your hands thoroughly.
1. Park the vehicle on a horizontal surface and apply the parking
brake.
2. Start the engine and run it until it reaches its normal working
temperature and check for oil leaks. Stop the engine.
3. Open the engine inspection hatch.
● Remove the clips (1) fixing the carpet.

● Remove the fixing clips (2) on the front of the passenger seat.

● Raise the engine inspection hatch (3).

● Fix the engine inspection hatch with the belt located behind
the passenger seat.

0457MA

MA-30
 ENGINE MAINTENANCE - BD-30 TI

4. Remove the filler cap and the oil dipstick. Left hand drive
5. Collect the used oil in a suitable container. Interior of vehicle
a. Loosen and remove the drain plug. Allow the oil to drain out fully
and remove the filter as shown in the figures.
b. Clean the drain plug, fit a new washer and re-fit the plug.
Drain plug:
20 ÷29 N-m (2 ÷ 3 kgm; 14.8 ÷ 21.4 ft-lb)

Below the vehicle

Front part
0522MA

Right hand drive

Interior of vehicle

Below the vehicle

Front part 0453MA

MA-31
 ENGINE MAINTENANCE - BD-30 TI

6. Oil the gasket of the new filter and thread it in until a slight
resistance is felt, then tighten it manually by 2/3 turn.

0002LC

7. Fill de engine with recommended oil. Check the oil level. Left hand drive
Refit de filler cap
Oil type and capacity (approximate)
See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND
FLUIDS".
MAX Maximum oil level mark. Do not exceed
MIN. Minimum level. The level must always be
below this mark
8. Start the engine and check for leaks around the drain plug and
0491MA
filter.

9. Stop the engine and wait for several minutes. Re-check the oil Right hand drive
level and top up if necessary.
10. Close the engine inspection hatch, fixing it properly with its clips.
WARNING:
● After closing the inspection hatch, fix the respective clips.
● Take care not to trap your fingers in the inspection hatch.

0451MA

MA-32
 ENGINE MAINTENANCE - BD-30 TI

Checking the cooling system CIACCDIC

USE OF ANTI-FREEZE
When using pure anti-freeze, it must be mixed with lime- and chlorine-free water or demineralised water
following the instructions on the packaging. If there are no instructions, and it is expected that the ambient
temperature will drop to at least 0 °C (32°F), use the anti-freeze (monoethylene glycol) mixing ratio for the
lowest expected temperature on the table below.
Exterior temperature
Antifreeze Demineralised water
°C °F
-15 5 35% 65%
-30 -22 50% 50%

Use an anti-rust solution when anti-freeze is not used.

● Check for leaks in the cooling system.
CHECKING HOSES AND CONNECTIONS
Check that the hoses and connections are not loose or damaged.
CHECKING THE STOPPER OF THE EXPANSION TANK
1. With a suitable checker, make sure the top of the expansion tank
has the right security pressure.
If the pressure falls fast and excessively, change the top of the
expansion tank.
Safety pressure of the stopper of the expansion tank:
59÷98 kPa (0,59÷0,98 bar, 0,6÷1,0 kg/cm2, 8÷14 psi)

0271MA

CHECKING FOR LEAKS IN THE COOLING SYSTEM

1. Connect the tester to the filler hole of the expansion tank and
Chassis cab
apply the specified pressure. If it drops, check the hoses,
radiator or water pump. If no leaks are found, check the heater
radiator, the cylinder block and the cylinder head.
Cooling system leak test pressure
157 kPa (1,57 bar, 1,6 kg/cm2, 22 psi)
● A pressure that is higher than specified may damage the
radiator.

0210MA

Double cab

0233MA

MA-33
 ENGINE MAINTENANCE - BD-30 TI

REPLACEMENT OF ENGINE COOLANT

Draining the system
CHASSIS CAB
WARNING:
● To avoid scalding, never change the coolant when the engine is hot.
1. Park the vehicle on a horizontal surface and apply the parking
brake.
2. Move the heater temperature control to the maximum temperature
position (all the way to the right) to fully open the heating system
stop cock.

0074HA

3. Remove the left side soundproof panel.

0304MA

4. Remove the expansion tank filler cap.

0305MA

● When the engine is hot, loosen the radiator or expansion tank cap SLOWLY to the first notch to
allow steam to escape before removing it completely.

MA-34
 ENGINE MAINTENANCE - BD-30 TI

5. Loosen and remove the cylinder block drain plug.

6. Drain the cooling system and clean it by flushing it with water.
● Take care not to spill coolant onto the drive belts.

7. Remove the expansion tank and clean it.

Refit it.
Bolts fixing expansion tank to bracket:
15 N-m (1.5 kgm; 11,1 ft-lb)
8. Fit the cylinder block drain plug.
0309MA
Cylinder block drain plug:
29÷39 N-m (3.0÷4.0 kgm; 21.4÷ 28.8 ft-lb)
● Apply sealant to the cylinder block drain plug.
9. Fill the cooling system by pouring coolant into the expansion tank.
Fill slowly to allow air pockets in the interior to exit, until the level in the expansion tank is correct.
10. Start the engine and allow it to run for several minutes.
11. Stop the engine and when it has cooled, top up the expansion tank to the correct level.
The correct level is about 15 mm (0.59 inches) below the filler pipe.
12. Check for leaks.
13. Fit the soundproofing screen on the left side.
CAUTION:
● The complete filling of the cooling system must be carried out with the engine cold.
● Do not add cold fluid when the engine is hot. If this is essential, do so with the engine running.
● Fill slowly to allow air pockets in the interior to exit, until the level in the expansion tank is correct.
● Check the coolant level frequently. If a significant amount of coolant must be added before
servicing, the leak must be located and repaired.
● A suitable mixture of water and anti-freeze must be used in both winter and summer, using, if
possible, water that is free of lime, chlorine and minerals.
● The cooling liquid must be replaced at the intervals indicated in MA-5, "SCHEDULED MAINTE-
NANCE"
● See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND FLUIDS" for the type of fluid and capacity
(approximate) of the cooling system.

MA-35
 ENGINE MAINTENANCE - BD-30 TI

DOUBLE CAB
1. Park the vehicle on a horizontal surface and apply the parking
brake.
2. Move the heater temperature control to the maximum temperature
position (all the way to the right) to fully open the heating system
stop cock.

0074HA

3. Remove the left side soundproof panel.

0304MA

4. Open the engine inspection hatch.

– Remove the clips (1) fixing the carpet.
– Remove the fixing clips (2) on the front of the passenger seat.
– Raise the engine inspection hatch (3).
– Fix the engine inspection hatch with the belt located behind the
passenger seat.
WARNING:
● After closing the inspection hatch, fix the respective
clips.
● Take care not to trap your fingers in the inspection hatch.

0457MA

MA-36
 ENGINE MAINTENANCE - BD-30 TI

5. Loosen and remove the emptying stopper af the expansion tank

and the cylindre block.
6. Drain the cooling system and clean it by flushing it with water.
– Take care not to spill coolant onto the drive belts.
7. Remove the expansion tank and clean it.
Refit it.
Bolts fixing expansion tank to bracket:
15 N-m (1.5 kgm; 11,1 ft-lb)
8. Fit the cylinder block drain plug. 0306MA

Cylinder block drain plug:

29÷39 N-m (3.0÷4.0 kgm; 21.4÷ 28.8 ft-lb)
– Apply sealant to the cylinder block drain plug.
9. Fill the cooling system by pouring coolant into the expansion
tank.
Fill slowly to allow air pockets in the interior to exit, until the level
in the expansion tank is correct.
10. Start the engine and allow it to run for several minutes.
11. Stop the engine and when it has cooled, top up the expansion
tank to the correct level.
If the level is below the "MIN" mark, add cooling liquid until it is
some 15 mm (0.59 inches) above the mark. 0309MA
12. Check for leaks.
13. Fit the soundproofing screen on the left side.

MA-37
 ENGINE MAINTENANCE - BD-30 TI

CAUTION:
● The complete filling of the cooling system must be carried out with the engine cold.
● Do not add cold fluid when the engine is hot. If this is essential, do so with the engine running.
● Fill slowly to allow air pockets in the interior to exit, until the level in the expansion tank is correct.
● Check the coolant level frequently. If a significant amount of coolant must be added before servicing,
the leak must be located and repaired.
● A suitable mixture of water and anti-freeze must be used in both winter and summer, using, if
possible, water that is free of lime, chlorine and minerals.
● The cooling liquid must be replaced at the intervals indicated in MA-5, "SCHEDULED MAINTE-
NANCE". Clean the circuit well before refilling.
● See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND FLUIDS" for the type of fluid and capacity
(approximate) of the cooling system.

MA-38
 ENGINE MAINTENANCE - BD-30 TI

Checking the fuel and exhaust systems CIADHGJG

FUEL FILTER
Draining water
Periodically empty the water in the fuel filter. To do this, proceed as follows: Proceed as follows:
1. Place a receptacle under the filter.
2. Loosen the water detector (1) a couple of turns.
3. After draining the water completely, screw the detector back in
(1).

0467MA

REPLACE FUEL FILTER

The fuel filter is of the cartridge type.
1. Put an appropriate receptacle under the filter.
2. Remove the filter and throw it away.
3. Unscrew the water purging valve unit and check the state of the
o-ring (1).
4. Replace if this is necessary.

0467MA

5. Fit the water purging valve unit in the new filter cartridge.
6. Lubricate the seal of the new filter.
7. Fit the new filter by threading it in until a slight resistance is felt
between the rubber gasket and the bracket, and then tighten it
manually 2/3 of a turn.

0468MA

8. Bleed the fuel system as described in the section MA-40,

"BLEEDING THE FUEL SYSTEM".

0002LC

MA-39
 ENGINE MAINTENANCE - BD-30 TI

BLEEDING THE FUEL SYSTEM

If air enters the fuel system, either because of repair work or
because the vehicle has run out of fuel, the following must be taken
into account before bleeding is carried out:
1. Ensure that there is sufficient fuel in the tank.
2. Remove the soundproofing screen on the right side.
● In vehicles with tilting cabs, tilt the cab to aid access to
the sound proofing panel.

0304MA

3. Loosen the connection (1) of the fuel inlet in the injection pump a
couple of turns.

0483MA

MA-40
 ENGINE MAINTENANCE - BD-30 TI

0523MA

4. Work on the priming piston (2) on the fuel filter until bubble-free petrol comes out of the connection (1).
5. Tighten the connector and continue to work on the priming piston (2) until you notice an increase in the
pressure of the piston and it becomes very difficult to work.
6. Start the engine. If the engine should still fail to start, release the injection pipes (3) and use the starter
motor until bubble-free fuel comes out of the pipes (3).
CAUTION:
Do not use the starter motor continuously for more than 10 seconds.
Before using it again, wait 10 seconds to avoid the battery discharging or the motor from being
damaged.
7. Tighten the injection pipes (3).
8. Start the engine and make sure there are no leaks in the connector or any other element that has been
handled.
9. Fit the right side soundproof panel.

MA-41
 ENGINE MAINTENANCE - BD-30 TI

CHECKING THE FUEL SYSTEM

Check that the fuel system and tank are installed correctly and that
there are no leaks, cracks, damage, loose connections, worn points
or deterioration. Recycle or replace affected parts where necessary.

0270MA

CHECKING THE EXHAUST SYSTEM

0054FE

1. Check the silencer and all other parts of the exhaust system for cracks, corrossion or any other damage.
Replace any worn parts.
2. Replace the SilentBlocs if they are cracked or worn.

MA-42
 ENGINE MAINTENANCE - BD-30 TI

Checking the air intake system CIAGBGFC

REPLACEMENT OF AIR FILTER

● Check that the lips of the discharge valve (1) close correctly Chassis cab
without sticking. It is important that they maintain the
necessary flexibility to open under the weight of the dust
that accumulates inside, allowing periodic discharge.
1. Release the clips (2) and remove the housing (3).
2. Remove the filter (4).
3. Clean the inside of the housing (3).
4. Clean and re-fit the filter element (4) or fit a new one. Double cab
5. Fit the housing (3).
● Align the lug (5) on the lid with the notch on the cover (6).
WARNING:
Do not run the engine without the air filter fitted since it also
performs as a fire extinguisher when the engine backfires.

0208MA

CLEANING OF FILTER CARTRIDGE

1. Clean the cartridge with low pressure air from the inside.

0039MA

MA-43
 GEARBOX

GEARBOX PFP:_

Checking oil level and changing oil CIAFBGHH

CABSTAR.E-100/ 120
Oil level
Do not start the engine while the oil level is being checked.
40 N-m (4.1 kgm; 29.5 ft-lb)

1. Filler plug
2. Fill to this level NMT197

Oil change
1. Completely empty the oil.
40 N-m (4.1 kgm; 29.5 ft-lb)

1. Drain plug
NMT197

2. Re-fill and check the level.

40 N-m (4.1 kgm; 29.5 ft-lb)
Oil capacity:
Without power take-off: 2.7 l (2.37 [Link])

2. Filler plug
NMT197

MA-44
 STEERING SYSTEM

STEERING SYSTEM PFP:_

Checking the level in the power steering fluid reservoir

RESERVOIR LOCATION

CABSTAR.E-100 CABSTAR.E-100
(Left hand drive) (Right hand drive)

0498MA 0499MA

CABSTAR.E-120 CABSTAR.E-120
(Chassis cab/ Left hand drive) (Chassis cab/ Right hand drive)

0524MA 0499MA

CABSTAR.E-120 CABSTAR.E-120
(Double cab/ Left hand drive) (Double cab/ Right hand drive)

0526MA 0527MA

The oil level must be checked with the oil cold.

1. Clean the dipstick cap.
2. With the engine idling, check that the level is between the two
marks on the dipstick.
When adding oil, do not exceed the "MAX" mark.
NOTE:
When checking the oil level, prevent dust or dirt from entering the
reservoir. The power steering will not operate correctly if the quantity
of oil is insufficient or if the oil is dirty.
Use recommended oil only.
See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND FLU- 0027MA
IDS".

MA-45
 STEERING SYSTEM

WARNING:
The power steering fluid is poisonous and must therefore be kept in its original container.
BLEEDING THE HYDRAULIC POWER STEERING SYSTEM
Check the system for leaks. See ST-5, "Check for leaks in the power steering system" of the CABSTAR.E Wor-
shop Manual.

MA-46
 FRONT AXLE AND SUSPENSION

FRONT AXLE AND SUSPENSION PFP:_

Checking front axle and suspension parts CIADFHEJ

1. Holding the tyre as shown in the figure, move the front wheels in the direction of the arrows.
Check whether any parts of the suspension are loose, worn or damaged. Tighten any loose joints and
change all worn parts.
See Section FA of this Workshop Manual.
2. Check the shock absorbers for defects and oil leaks. TL 45

0113FA

SFA240

3. Clean and grease the shafts of each hub using the grease TL 45
nipples.

0048ST

MA-47
 FRONT AXLE AND SUSPENSION

4. Clean and grease the pins fixing the front springs. TL 45

5. Check the tightness of nuts and bolts.
TL 45
Nuts fixing U-bolts:
186 N-m (19 kgm; 137.2 ft-lb)

Lower nut fixing shock absorber:

80÷90 N-m (8.2÷9.2 kgm; 59÷66.4 ft-lb)

Upper nut fixing shock absorber: 0101FA

25 N-m (2.6 kgm; 18.4 ft-lb)

TL 28/ 32/ 34/ 35

Lower nut fixing shock absorber:
74.9÷103 N-m (7.6÷10.5 kgm; 55.3÷76.0 ft-lb)

Upper nut fixing shock absorber:

15.7÷21.7 N-m (1.6÷2.2 kgm; 11.6÷16.0 ft-lb)
6. Check suspension ball joints for grease leakage and dust covers
for cracks or other damage

SMA241

MA-48
 REAR AXLE AND SUSPENSION

REAR AXLE AND SUSPENSION PFP:_

Checking rear axle and suspension parts CIADFBBI

1. Check the rear axle casing for dents, cracks and damage. To
replace it, see Section RA of the CABSTAR.E Workshop Manual

0023RA

2. Check the shock absorbers for defects and oil leaks.

0015RA

3. Check the tightness of nuts and bolts.

Nuts fixing U-bolts:
All models.
116 N-m (11.8 kgm; 85.6 ft-lb)

Upper and lower nuts fixing shock absorbers:

86 N-m (8.8 kgm; 63.4 ft-lb)

MA-49
 BRAKE AND CLUTCH SYSTEMS

BRAKE AND CLUTCH SYSTEMS PFP:_

Brake and clutch fluid level CIAHBBAI

1. Remove the cap (1) by pulling it outward and check the brake
and clutch fluid level in the reservoir (2).
2. The level must be between the "MAX" and "MIN" marks on the
reservoir. If it is below the "MIN" mark or if the warning light
comes on, top up to the "MAX" mark.
CAUTION:
● Use new brake fluid. Low quality or dirt fluid could cause
problems in the brake and clutch systems.
● Low quality fluids damage the brakes and reduce braking
capacity. 0317MA
● Do not spill fluid onto painted surfaces since it will damage
the paintwork. Wash immediately with water if this happens.
WARNING:
Brake and clutch fluid is poisonous and must therefore always be kept in its original container.
Changing the brake and clutch liquid CIAIGABA

1. Change the brake fluid.

To change the brake liquid of the system, use the same procedure as when purging the hydraulic circuit. This
operation must be performed for a single wheel at a time. (See BR-6, "HYDRAULIC BRAKING SYSTEM" in
Section BR of this Manual.)

WARNING:
Never re-use brake fluid since its properties change due to oxidation and the presence of foreign
bodies and dirt.
Properties of recommended brake fluid:
See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND FLUIDS".
2. Check the brake fluid level.
3. Check for leaks.
Checking the brake system CIAGAIBH

1. Check that the connections are correct and there are no leaks,
scratches, wear, deformations, etc.

0276MA

Checking the brake servo vacuum system CIACGCBJ

1. Check the state of the vacuum hoses and connections.

2. Check the tightness of the hoses and vacuum pump (depressor).

MA-50
 BRAKE AND CLUTCH SYSTEMS

Checking the disc brakes

Check the state of the disc brake components.
BRAKE DISCS
Check its state and thickness.
Standard thickness: 24 mm (0.94 inches)
Minimum thickness: 21 mm (0.82 inches)

0316BR

BRAKE CALLIPER
Check its operation and for leaks.

0470BR

BRAKE PADS
Check for wear and damage.
Standard thickness: 18 mm (0.70 inches).
Minimum thickness: 9 mm (0.35 inches)

0317BR

Consult section “BR” of the Workshop Manual to replace the brake pads.

MA-51
 BRAKE AND CLUTCH SYSTEMS

Checking the drum brakes CIAICGAH

Check the state of the drum brake parts.

BRAKE CYLINDER
Check for leaks.

0473BR

DRUM
Check the state of the inner surface.

Standard interior diameter: 280 mm (11,2 inches)

Maximum inner diameter: 282 mm (11.10inches)

0472BR

BRAKE LINING (SHOE)

Check for wear and damage.
Standard thickness:
Primary shoe: 8.95 mm (0.35 inches)
Secondary shoe: 3.95 mm (0.15 inches)
Minimum thickness: 1.52 mm (0.059 inches)
Consult secion “BR” of the Workshop Manual to replace the brake
linings.

0471BR

CHECKING BRAKE LINING WEAR

Remove the inspection plug and check the wear of the shoe.

0404MA

MA-52
 WHEELS AND TYRES

WHEELS AND TYRES PFP:_

Checking the state of the tyres CIAIGEIC

1. Check the wear of the tread; if it has worn unevenly, fit the most
worn tyre on the inside of the twin wheels until it can be
replaced.
2. Replace tyres that are worn or defective.
3. The illustration shows a tyre close to the approximate location of
the band wear indicators.

0205MA

4. Remove pebbles, glass and other foreign bodies trapped in the tyre's tread.
5. Check the tread and sidewalls for cracks, holes, separations or damage.
6. Check the tyre's valve for leaks.

CAUTION:
● Whenever a wheel is changed (and especially if they are twins) make certain that the tyres fitted
are of the same make, size, type and degree of wear and that they are correctly inflated.
● When the wheels have run the first 1000 km (600 miles) (after replacement or removal), retighten
the wheel nuts to the torque specified in the aside MA-54, "Fitting the wheels".
● Never fit a wheel that has not been balanced beforehand.
● The wheel must be balanced off the vehicle. Balancing the rear wheels when they are fitted to the
vehicle could cause damage to the transmission (differential, transmission shaft or gearbox)..
● Do not fit deformed tyres or wheel rims, even if they have been repaired. Either may have
structural imperfections, with the consequent risk that this implies for driving.
● When a tyre is replaced, use another of the same kind and size and loading capacity as the one
originally fitted. The use of tyres other than those recommended or the mixed use of tyres of
different makes will affect driving, brake response, handling, the distance between the bodywork
and the tyres, the free space for snow chains, speedometer precision, orientation of the lights,
height of the bumpers and reprogramming of the ECM and the instrument panel. Some of these
faults might cause an accident

MA-53
 WHEELS AND TYRES

Swapping of tyres CIAGBJIB

Single wheel on rear axle.

Tightening torque for wheel nuts:
CABSTAR.E-100 (28, 32, 34):
184 ÷ 220 N-m (18.8 ÷ 22.4 kgm; 135.7 ÷ 162.3 ft-lb)

0429MA

Twin wheels on rear axle.

Tightening torque for wheel nuts:
CABSTAR.E-100/120 (35):
144 ÷ 216 N-m (14.7 ÷ 22.0 kgm; 106.2 ÷ 159.3 ft-lb)

Tightening torque for wheel nuts:

CABSTAR.E-100/120 (45/ GE, GE HD):
273 N-m (27.8 kgm; 201.4 ft-lb)

0428MA

Fitting the wheels

The wheels must be kept clean and, before they are fitted to their hubs, the holes in the wheel rims for the
wheel nuts must be completely clean so that both surfaces fit together perfectly. The wheel studs have a right-
hand thread.
Tighten the wheel nuts in opposite pairs to a torque of:
CABSTAR. E -
100 100/ 120
28/ 32/ 34 35* 45*/GE* and GE HD*
N-m 181 ÷ 216 265 ÷ 324
FRONT kgm 18.5 ÷ 22 27 ÷ 33
ft-Ib 133.5 ÷ 159,3 195.5 ÷ 239
N-m 184 ÷ 220 144 ÷ 216 273 0062RA
REAR kgm 18,8 ÷ 22,4 14,7 ÷ 22 27,8
ft-Ib 135.7 ÷ 162.3 106,2 ÷ 159,3 201,4
* Twin wheels

WARNING:
Never place yourself under a vehicle that is supported by a jack only.
Always use safety trestles.
CAUTION:
When replacing a tyre, take special care not to damage the bead, wheel rim and bead seating.

MA-54
 WHEELS AND TYRES

Tyres CIABCIGB

TYRE PRESSURES
PRESION (bar) (kg/cm2; psi2)
MODEL RIM (Size) TUBELESS WHEELS
FRONT REAR
CABSTAR.E-100 (28) 6J-15 195/70 R15 3.5 (3.6; 51) 4.25 (4.3; 61)
CABSTAR.E-100 (32) 6J-15 205/70 R15 4.0 (4.1; 58.3) 4.5 (4.6; 64)
CABSTAR.E-100 (34) 6J-15 215/70 R15 4.5 (4.6; 64) 2.7 (2.8; 38)
CABSTAR.E-100/120 (35 GE) ** 5J-15 195/70 R15 4.5 (4.6; 64) 2.75 (2.8; 38)
CABSTAR.E-100 (45 GE)/ 120 (45/ 45 GE) ** 51/ 2J-15 185/75 R16 5.0 (5.1; 73) 5.0 (5.1; 73)
CABSTAR.E-100/120 (45 GE HD) ** 5.00E 16 6.00 R16* 4.5 (4.6; 64) 4.5 (4.6; 64)
* With inner tube
** Twin wheels

MA-55
 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM PFP:_

CAUTION:
Before starting to work on or repair the vehicle, make sure that the ignition switch is off and then
disconnect the battery earth strap.
Battery CIAHHAEA

The battery is on the left beam (Chassis cabin models, left hand
Chassis cab
drive), the right beam (Chassis cabin models right hand drive) or
inside the trap below the rear seats (Double cabin models).

0386EL

LOW MAINTENANCE
Check the electrolyte level
Check the electrolyte level in each cell. Add only distilled water so Double cab
that the level covers the top of the plates. Do not exceed this level.

0487EL

MAINTENANCE FREE
These batteries do not need periodical checking of the electrolyte or the addition of distilled water. However, to
prevent possible damage, it is best to check the level at least once a month.
The use of batteries other than NISSAN ones is not recommended.
MA-56
 ELECTRICAL SYSTEM

TECHNICAL DATA
MODEL CABSTAR. E-100 CABSTAR. E-120
Type Maintenance free
Voltage V 12
Capacity Ah 90 75

MA-57
 ELECTRICAL SYSTEM

Pre-heating glow plugs CIABHIFH

TD-30 T ENGINE
Consult the chapter EC-98, "DTC P0380, DTC P0381, DTC 0382 GLOW CONTROL SYSTEM / BD-30 Ti/BD-
30 T" in Section "EC" of this Workshop Manual.
Air heater CIAJEHBJ

BD-30 TI ENGINE
Consult the chapter EC-98, "DTC P0380, DTC P0381, DTC 0382 GLOW CONTROL SYSTEM / BD-30 Ti/BD-
30 T" in Section "EC" of this Workshop Manual.

MA-58
 BODYWORK

BODYWORK PFP:_

Checking the safety belts, buckles, retractors, anchorings and adjuster CIAJGDGF

FRONT BELTS

0410MA

0405MA 0406MA

0409MA 0407MA 0408MA

MA-59
 BODYWORK

REAR BELTS

0411MA

0405MA 0406MA

0409MA 0408MA

MA-60
 TECHNICAL DATA AND CHARACTERISTICS / BD-30 T

TECHNICAL DATA AND CHARACTERISTICS / BD-30 T PFP:00045

Technical data EXS00B01

INSPECTION AND ADJUSTMENT

Valve clearances
Unit: mm (inches)
Intake
Hot 0.25 ± 0.1 (0.009 ± 0.003)
Exhaust

Drive belt movement

Unit: mm (inches)
Used belt movement:
New belt movement:
Limit Movement after adjustment
6 (0.23) 13 (0.51) 7.5 (0.29)
Applied force 98N (10 Kg; 72.3lb)

Oil capacity (approximate)

Unit: l (Imp qt)
Filter included 7.2 (18 5/8)

Cooling system Capacity (approximate)

Unit: l (Imp qt)
15 (26 3/8)

Pressures
Unit: kPa (bar; kg/cm2; lb/psi)
Safety pressure of the stopper of the expansion tank 59 ÷ 98 (0.59 ÷ 0.98; 0.6 ÷ 1.0; 8 ÷ 14)
Cooling system leaks test pressure 157 (1.57; 1.6; 22)

TIGHTENING TORQUES
Components N-m kgm kgm
Adjustment screw lock nut (valve clearances) 15 ÷ 20 1.5 ÷ 2.0 11.1 ÷ 14.8
Oil drain plug 20 ÷ 29 2÷3 14.8 ÷ 21.4
Intake manifold nuts and bolts 16 ÷ 22 1.6 ÷ 2.2 11.8 ÷ 16.2
Exhaust manifold nuts 31 ÷ 38 3.2 ÷ 3.9 22.9 ÷ 28.0
Rocker cover bolts 9 ÷ 11 0.9 ÷ 1.1 6.6 ÷ 8.1
Cylinder block drain plug 20 ÷ 29 2.0 ÷ 3.0 14.8 ÷ 21.4
Fixing of injector to cylinder head 39 ÷ 44 4.0 ÷ 4.5 28.8 ÷ 32.5

Injectors
Injector pressure rating
bar kPa kg/cm2 psi
Used injector (mín.) 252 25.200 257 3.655
New injector 270 27.000 275 3.910

Idling speed
Unit: rpm
Idle speed with the engine at normal running temperature and air conditioning turned off 725 ± 25
Idle speed with air conditioning turned on 825 ± 25
Maximum engine speed 4.225 ± 25

MA-61
 TECHNICAL DATA AND CHARACTERISTICS / BD-30 TI

TECHNICAL DATA AND CHARACTERISTICS / BD-30 TI PFP:00045

Technical data
INSPECTION AND ADJUSTMENT
Valve clearances
Unit: mm (inches)
Intake
Hot 0.25 ± 0.1 (0.009 ± 0.003)
Exhaust

Drive belt movement

Unit: mm (inches)
Used belt movement:
New belt movement:
Limit Movement after adjustment
6 (0.23) 13 (0.51) 7.5 (0.29)
Applied force 98N (10 Kg; 72.3lb)

Oil capacity (approximate)

Unit: l (Imp qt)
Filter included 7.2 (18 5/8)

Cooling system Capacity (approximate)

Unit: l (Imp qt)
15 (26 3/8)

Pressures
Unit: kPa (bar; kg/cm2; lb/psi)
Safety pressure of the stopper of the expansion tank 59 ÷ 98 (0.59 ÷ 0.98; 0.6 ÷ 1.0; 8 ÷ 14)
Cooling system leaks test pressure 157 (1.57; 1.6; 22)

TIGHTENING TORQUES
Components Nm kgm kgm
Adjustment screw lock nut (valve clearances) 15 ÷ 20 1.5 ÷ 2.0 11.1 ÷ 14.8
Oil drain plug 20 ÷ 29 2÷3 14.8 ÷ 21.4
Intake manifold nuts and bolts 16 ÷ 22 1.6 ÷ 2.2 11.8 ÷ 16.2
Exhaust manifold nuts 31 ÷ 38 3.2 ÷ 3.9 22.9 ÷ 28.0
Rocker cover bolts 9 ÷ 11 0.9 ÷ 1.1 6.6 ÷ 8.1
Cylinder block drain plug 20 ÷ 29 2.0 ÷ 3.0 14.8 ÷ 21.4
Fixing of injector to cylinder head 39 ÷ 44 4.0 ÷ 4.5 28.8 ÷ 32.5

Injectors
Injector pressure rating
bar kPa kg/cm2 psi
Used injector (mín.) 252 25.200 257 3.655
New injector 270 27.000 275 3.910

Idling speed
Unit: rpm
Idle speed with the engine at normal running temperature and air conditioning turned off 725 ± 25
Idle speed with air conditioning turned on 825 ± 25
Maximum engine speed 4.225 ± 25

MA-62