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F300-HD_Engine-MA-Maintenance

F300-HD_Engine-MA-Maintenance.pdf

DAIHATSU

F300

MAINTENANCE

MAINTENANCE SCHEDULE MA-2 MAINTENANCE OPERATIONS MA-3 COLD ENGINE OPERATIONS MA-3 HOT ENGINE OPERATIONS MA-8

WN88E-MAO01

MA-1


MAINTENANCE

MAINTENANCE SCHEDULE

O Check 0... Change or replacement

x 1,000 km

1 5 1015 20 25 30,35 4045 50 55 60 65170 75 80 857909501

(MONTHS) Years -(3) (6) (9) 1 (3) (6)(9) 2 (3) (6) (9) 3 (3)(6) (9) 4 (3) (6) (9) 5

- Distributor cap. rotor Damage

O O

O O O

Spark plug Cleaning Engine ;

O O

O O O

Battery Electrolyte leve!

OOOOOOOOOOOOOOOOOOOO

- wife harness ' Fghfness Clamps

OOOOO

OOOOOO

- Air cleaner element” Cleaning

0000

000.00

Valve clearance Clearance

O O

OOOOOOOOOOOOOOOOOOOOO

engine

- Fuel filter Change

HD-E engine

Damage Engine Fuei lines & Connec- Crack

mms Tughtness

Leakage

O O

O O O O

Carburetor - Idle speed

(HD-C engine) Acceleration

O

O O O O

O O O O

Chang'e (Long life coolant)

OOOO

OOOO

OOOOOOO

Blow-by gas - Connection ventilation hose Damage

Throttle positioner Operation

O

O O O

Spark control system - Operation

O

O O O

- Charcoal canister - Operation

O

O O O O

in case of driving on dusty roads, clean every 2,500 km (1,500 miles) and replacie every 20,000 km (12,000 miles). ' in case of severe drivino condition. renlgm :mam : nm i... 1° M.

MA-2


MAINTENANCE

MAINTENANCE OPERATIONS

COLD ENGINE OPERATIONS 1.

nun-nr nr nlannanm H l5|JUULlUl I UI UIDU IULlI.Ul DGP dl IU IULUI . Visually inspect the distributor for cracks, wear or damage. ( nw

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2. Inspection and cleaning of spark plugs

(1) If there are traces of oil, remove it with gasoline before

the spark plug is cleaned by the spark plug cleaner.

SPARKPLUG

p gaUge' ga ing a rv- “S de 98 he 9 ufet Maas (2)

Txghtening Torque of Spark Plug: 1.5 - 2.2 kg-m

(10.8 - 15.9 it-Ib)

3. Check of battery electrolyte level ; _ if

(1) Visually check the electrolyte level between the upper

line and the lower line. 7' J (2) lf the electrolyte level is below the lower level, replenish gg; _“lyke

distilled water up to the upper level.

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WNSBE-MAOO6

MA-3


MAINTENANCE

4, _C__heck of wiring harness clamp

Visually check that the wiring harness is suitable clamp, damaged.

Cleaning of air cleaner filter element (1) Remove the air cleaner filter element from the air cleaner

case. (2) Clean the element with compressed air. First blow from the back side thoroughly. Then, blow off the front side of

the element.

CAUTION: The air pressure to be used forthis cleaning operation shculd not exceed 4.0 (56.9 psi)

(3) Install the air cleaner filter element in the air cleaner.

Engine oil change (See page LU-4)

Becommended oil grade: API grade SE, SF Oil capacity

When only engine oil is changed: 3.3 liter When engine oil is changed and oil filter is replaced:

3.5 liter

Engine oil filter replacement (1) Remove the oil filter, using the following SST.

SST: 09228-87201 -O00 NOTE: Since the oil flows out during the replacement, receive the oil with an adequate container.

(2) Inspect and clean the oil filter installation surface.

MA-4

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WNSBE-MANS


MAINT

(3) Apply clean engine oil to the gasket of a new oil filter. (4) Installation of oil filter

ENANCE

Screw in the oil filter lightly by hand until the oil seal sur- i

face contacts the oil cooler.

Then, tighten the oil filter one more turn, using the SST.

8. Fuel filter replacement

Carburetor installed engine: Disconnect the hose clamp. Then, replace the fuel filter.

EFI installed engine:

Loosen the union bolt slowly and pull it out. WARNING:

wise, the fuel may be splashed.

9. Inspection of fuel lines and connecti

_ lnsnection of fuel lines and connections

Visually inspect the fuel lines for cracks, leakage, loose con- nections, or deformation.

10. Inspection of auto choke system (Only for HD-C)

Check that choke valve is completely closed when cold en- gine.

Then, start the engine, check that choke valve is gradually opened in accordance with the warning-up condition of the engine.

MA-5

3 us

Efnission


MAINTENANCE

Check of engine coolant (1) Check of cooling system for leakage

Apply a pressure of 1.2 kg/cmz (17 psi) to the cooling system by means of a radiator tester. Ensure that the pressure does not drop. WARNING: Never remove the radiator tester when the coolant tempera- ture ls still high.

(2) Check of coolant level

Check to see if the coolant level is between the LOW and FULL lines of the resen/e tank. lf the coolant level is near the low level or below the low level, add the coolant up to the full level.

12. inspection of drive belt

(1) Visually check the V belt for separation of the adhesive

rubber above and below the core, core separation from the belt side, severed core, separation of the rib from the adhesive rubber, cracks or separation of the ribs, torn or worn ribs or cracks in the inner ridges of the ribs.

(2) Measure the amount ofthe drive belt deflection when the

midpoint of the drive belt between the alternator and the water pump pulley is pushed with a force of 10 kg (2.20 Ib) Specified Bolt Deflection

New belt: 5.0 - 7.0 mm (0.20 - 0.28 inch) Used belt: 6.0 - 8.0 mm (0.24 - 0.31 inch)

NOTE: - “New belt” refers to a belt which has been used on a run

ning engine for less than five minutes.

- After installing a new belt, run the engine for about five

minutes and then recheck the tension.

MA-6

Water pump pulley

Alternator pulley


MAINTENANCE

13. Inspection of blow-by gas recirculating system

Check the hose, connections for cracks, leak or damage.

14. Inspection of charcoal canister

(1) Disconnect the rubber hoses and remove the charcoal

canister. HD-E: (2) Blow air of 3 kg/cm2 (43 psi) into the pipe while hold

ing the pipe closed. Ensure that air flows smooth from the pipe

HD-C (Only for GCC Specmcations) Plug the pipe and with your fingers and blow com- pressed air of 3 kg/cm (43 psi) through the pipe © (fuel tank side). v Check that the air comes out of the bottom pipe 0 Check that no activated charcoal comes out. NOTE:

Do not attempt to wash the charcoal canister.

(3) Install the charcoal canister and reconnect the rubber

hose. -


MAINTENANCE

15. Removal cf timing belt

(See page EM-21.)

HOT ENGINE OPERATIONS

_ :

Adjustment of ignition timing (1) Connect the tachometer to the ignition coil. (2) With the engine idling as specified, use a timing light to

check the timing. ' Ignition timing: 3° 1 2° BTDC/850 rpm (3) if necessary, loosen the distributor bolts and turn the dis

tributor to align the marks. Re-check the timing after tightening the distributor.

NOTE:

- Disconnect the vacuum hose of sub-diagram from the

vacuum advancer of distributor and close the vacuum hose during test.

- The ignition coil has no terminal for extemai connection.

Hence, insert an adequatejumper cord from the backside of the connector attached to the ignition coil. Then, con- nect the_ other ent! of the jumper cord to the measuring terminal of the tachometer. - For the purpose of connecting tachometer, the SST for

connecting to the distributor wire is available. SST: 09991 -87703-000

CAUTION: - Never allow the tachometer terminal to touch ground as it oould result in damage to the ignitor and/or ignition ooll. - As some tachumeters are not compatible with this igni

tion system, it is imperative to confirm the compatibility of your meter before it is used.


MAINTENANCE

Adjustment of valve clearances (See page EM-9) NOTE: The valve clearance adjustment is performed normally when the engine is in a hot condition. “Hot engine condition” denotes a condition in which the cool- ing water temperature is 75 - 85 °C (167 - and the en- gine oil temperature is above 65°C (149°F).

Valve clearances (Hot condition)

Intake: 0.20 - 0.30 mm (0.0078 - 0.0118 inch) Exhaust: 0.28 - 0.38 mm (0.0110 - 0.0150 inch)

idle speed adjustment (1) Preparation to be made prior to idle adjustment 0 Warm up the engine thoroughly. v All accessory switches are turned OFF.

On those vehicle equipped with a day-lamp system, set

the lamp control switch to the first stage with head lamps turned OFF.

0 The air cleaner element is installed. 0 All vacuum hoses are connected. (2) Connect the tachometer to the distributor.

(See page MA-8) (3) Adjustment 0 Carburetor equipped vehicle

Adjust the throttle adjusting screw so that the engine idle speed may become the specified valve. Engine Idle Speed: 850 :t 50 rpm

EFI equipped vehicle

Remove the idle adjusting screw cap from the throttle body. Then, set the idle speed by turning the idle speed adjusting screw.

Engine Idle Speed: 850 :t 50 rpm

MA-9

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MAINTENANCE

4. Inspection of throttle positioner system

Carburetor equipped vehicle (1) Warm up the engine. (2) Raise the engine speed to approximately 2500 rpm and hold the engine speed at 2500 rpm for five seconds. Measure that the dashpot shaft is fully stretched. (3) Close the throttle valve quickly. (4) Make sure the time required for the engine speed to drop

from 1500 rpm to 1200 rpm. Specified Time: 0.5 - 5.0 second NOTE: Dashpot touch engine speed: 1500 i 50 rpm

0 EFI equipped vehicle (1) Warm up the engine. (2) Raise the en_gine speed to approximately 3500 rpm and hold the engine speed at 3500 rpm for five seconds. Ensure that the dashpot lever should be fully extended. (3) Close the throttle valve quickly.

(4) Measure the time required forthe engine speed to drop

from 1800 rpm to idle speed (850 i 50 rpm). Specified Time: 1.0 - 5.0 seconds NOTE: Dashpct touch engine speed: 1800 i 100 rpm

5. Inspection of spark control system

(1) Disconnect the vacuum hose of main and sub diagram from the vacuum advancer of distributor, and close the

vacuum hose. Using a timing light, check the ignition ad- vance timing. while engine speed is being raised.

(2) Dis-connect the plug from vacuum hose.

Connect the Mitgvac to the vacuum advancer of dis- tributor, check the ignition advancetiming, while vacuum is applied.

MA-10

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