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MA1

MAINTENANCE

SCHEDULE A
CONDITIONS:

MA2

MAINTENANCE SCHEDULE

Maintenance operation: A = Check and adjust if necessary;


R = Replace, change or lubricate;
I = Inspect and correct or replace if necessary

Towing a trailer, using a camper or car top carrier.


Operating on dusty, rough, muddy or salt spread roads.
Repeat short trips of less than 5 miles (8 km) with outside temperatures remain below freezing.
Extensive idling and/or low speed driving for long distance, such as police, taxi or doortodoor delivery use.

MA-4 (item 1)
MA-7 (item 12)
MA-4 (item 2)

MA-6 (item 11)


MA-5 (item 3, 4)
MA-6 (item 10)
MA-6 (item 9)
MA-5 (item 5)

MA-8 (item 16)


MA-7 (item 13)
MA-8 (item 17)
MA-9 (item 18)
MA-9 (item 20)
MA-10 (item 22)
MA-9 (item 19)
MA-10 (item 24)
MA-11 (item 25)
MA-11 (item 26)

* mark indicate maintenance which is part of the warranty conditions for the emission control system. The warranty period is in accordance with the owners guide or
the warranty booklet. (*: California specification vehicles.)
(1) Applicable to vehicles operated under conditions of extensive idling and / or low speed driving for long distances such as police, taxi or doortodoor delivery use.
(2) Applicable when operating mainly on dusty roads.
(3) Includes inspection of fuel tank band and vapor vent system.
(4) Also applicable to drum lining for parking brake. For other usage conditions, refer to SCHEDULE B.
(5) Check for leakage.
(6) Check for oil leaks from steering gear box.
(7) Applicable only when operating mainly on rough, muddy roads. The applicable parts are listed below. For other usage conditions, refer to SCHEDULE B.
Front and rear suspension member to cross body.
Strut bar bracket to body bolts.
Bolts for sheet installation.

Maintenance Schedule

MA-7 (item 14)

MA-6 (item 8)
MA-7 (item 14)

MAINTENANCE

MA-5 (item 6)
MA-6 (item 7)

SCHEDULE B
CONDITION:
Conditions other than those listed for SCHEDULE A.

MA-7 (item 12)


MA-4 (item 2)
MA-5 (item 6)
MA-6 (item 7)
MA-6 (item 11)
MA-5 (item 3)
MA-6 (item 10)
MA-5 (item 9)
MA-5 (item 5)
MA-6 (item 8)
MA-7 (item 14)
MA-8 (item 16)
MA-7 (item 13)
MA-8 (item 17)
MA-9 (item 18)
MA-9 (item 20)

MAINTENANCE

MA-7 (item 14)

MA-10 (item 22)

MA-11 (item 25)


MA-11 (item 26)

* mark indicate maintenance which is part of the warranty conditions for the emission control system. The warranty period is in accordance with the
owners guide or the warranty booklet. (*: California specification vehicles.)
(1) Includes inspection of fuel tank band and vapor vent system.
(2) Also applicable to lining drum for parking brake.
(3) Check for leakage.
(4) Check for oil leaks from steering gear box.
(5) The applicable parts are listed below.
Front and rear suspension member to cross body.
Strut bar bracket to body bolts.
Bolts for sheet installation.

Maintenance Schedule

MA-10 (item 24)

MA-9 (item 19)

MA3

MA4
MAINTENANCE

Maintenance Operations

MAINTENANCE OPERATIONS
ENGINE
Cold Engine Operations
1.

REPLACE TIMING BELT


(a) Remove the timing belt.
(See pages EM17 to 24)
(b) Install the timing belt.
(See pages EM27 to 36)

2.

INSPECT DRIVE BELT


HINT: A belt tensioner is used, so check that the belt tention
is not necessary.
(a) Remove the air duct.
(b) Visually check the belt for excessive wear, frayed cords,
etc. If necessary, replace the drive belt.
HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be
replaced.
(c) Check the belt tensioner operation.

Check that the belt tensioner moves downward


when point (A) is pressed down with approx. 10 kgf
of force.

Check the alignment of the belt tensioner pulley to


make sure the belt has not slipped off the pulley.
If necessary, replace the belt tensioner.

Check that the arrow mark on the belt tensioner


falls within area A of the scale.

If it is outside area A, replace the belt with a new one.


HINT: When the new belt is installed, it should lie within area
B. If not, the belt is not correct.

HINT:

After installing the belt, check that it fits properly in the


ribbed grooves.

Check by hand to confirm that the belt has not slipped


out of the groove on the bottom of the pulley.
(d) Install the air duct.

MA5
MAINTENANCE

3.

4.

5.

Maintenance Operations

INSPECT AIR FILTER


(a) Visually check that the air cleaner element is not
excessively damaged or oily.
If necessary, replace the air cleaner element.
(b) Clean the element with compressed air.
First blow from the inside thoroughly, then blow off the outside of the element.
REPLACE AIR FILTER
Replace the air cleaner element with a new one.
REPLACE SPARK PLUGS
(a) Disconnect the spark plug cords at the rubber boot.
DO NOT pull the cords.

(b) Using a 16 mm plug wrench, remove the spark plugs.

(c) Check the electrode gap of new spark plugs.


Correct electrode gap:
1.1 mm (0.043 in.)
Recommended spark plugs: ND
PK20R11
NGK
BKR6EP11

6.

HINT: If adjusting the gap of a new plug, bend only the base
of the ground electrode. DO NOT touch the tip. Never attempt
to adjust the gap on a used plug.
When installing a plug, properly install the plug cord into the
cord clamp.
REPLACE ENGINE OIL AND OIL FILTER
(See page LU5)
Oil grade: API grade SG, EnergyConserving II multi
grade. Recommended viscosity is as shown,
with SAE 5W30 being the preferred engine oil.
Engine oil capacity:
Drain and refill
w/o Oil filter change
5.0 liters (5.3 US qts, 4.4 lmp. qts)
w/o Oil filter change
5.3 liters (5.6 US qts, 4.7 lmp. qts)

Check for oil leakage

MA6
MAINTENANCE

7.

Maintenance Operations

REPLACE ENGINE COOLANT


(See page CO5)
Coolant capacity (w/ Heater)
10.6 liters (11.2 US qts, 9.3 lmp. qts)

HINT:

Use a good brand of ethyleneglycol base coolant,


mixed according to the manufacturers directions.

We recommend using coolant which contains more than


50 % ethyleneglycol
(but not more than 70 %) for your system.
8.

INSPECT CHARCOAL CANISTER


(a) Disconnect the hoses to the charcoal canister. Label the
hoses for correct reinstallation.
(b) Plug pipe A with your finger and blow compressed air
294 kPa (3 kgf/cm2, 43 psi) through pipe B (fuel tank
side).

Check that air comes out of the bottom pipe C


without resistance.

Check that no activated charcoal comes out.


If necessary, replace the charcoal canister.
HINT:
Do not attempt to wash the charcoal.
(c) Connect the hoses to the charcoal canister.

9.

REPLACE GASKET IN FUEL TANK CAP


(a) Remove the old gasket (Oring) from the fuel tank cap.
Do not damage the cap.
(b) Install the new gasket by hand.
(c) Inspect the cap for damage or cracks.
(d) Install the cap and check the torque limiter.

10. INSPECT FUEL LINES AND CONNECTIONS


(See page FI53)
Visually inspect the fuel lines for cracks, leakage, loose connections, deformation or tank bend looseness.

11. INSPECT EXHAUST PIPES AND MOUNTINGS


Visually inspect the pipes, hangers, and connections for severe corrosion, leaks or damage.

MA7
MAINTENANCE

Maintenance Operations

12. ADJUST VALVE CLEARANCE


(See page EM9)
Valve clearance (Cold):
Intake 0.15 0.25 mm (0.0059 0.0098 in.)
Exhaust 0.25 0.35 mm (0.0098 0.0138 in.)

BRAKES
13. INSPECT BRAKE LINE PIPES AND HOSES
HINT: Inspect in a well lighted area. Inspect the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before inspecting the front brake.
(a) Check all brake lines and hoses for:

Damage
Corrosion

Wear
Leaks

Deformation
Bends

Cracks
Twists
(b) Check all clamps for tightness and connections for
leakage.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.

14. INSPECT FRONT AND REAR BRAKE PADS AND DISCS


(See pages BR22 and BR31)
(a) Check the thickness of the disc brake pads and check
for irregular wear.
Minimum pad thickness: 1.0 mm (0.039 in.)

HINT: If a squealing or scraping noise comes from the brake


during driving, check the pad wear indicator. If there are
traces of the indicator contacting the disc rotor, the disc pad
should be replaced.
(b) Check the disc for wear or runout.
Minimum disc thickness:
Front: 26 mm (1.024 in.)
Rear:
15 mm (0.591 in.)
Maximum disc runout: 0.05 mm (0.0020 in.)

MA8
MAINTENANCE

Maintenance Operations

15. INSPECT PARKING BRAKE LININGS AND DRUMS


(See page BR37)
(a) Check the liningtodrum contact condition and lining
wear.
Minimum lining thickness: 1.0 mm (0.039 in.)

(b) Check the brake drum for scoring or wear.


Maximum drum inside diameter: 191 mm (7.520 in.)

(c) Clean the brake parts with a damp cloth.


HINT: Do not use compressed air to clean the brake parts.
(d) Settle the parking brake shoes and drum. When
performing the road test in item 26, do the following:

Depress the parking brake pedal with 15 kg (33 lb,


147 N) of force.

Drive the vehicle at approx. 30 mph (50 km/h) on a


safe, level and dry road.

Drive the vehicle for approx. \frb\1/4\fre\ mile (400


meters) in this condition.

Repeat this procedure 2 or 3 times.

Check parking pedal travel.


If necessary, adjust the parking brake.
16. INSPECT OR CHANGE BRAKE FLUID
(a) Visually inspect the master cylinder for leaks.
(b) Change brake fluid (See page BR5)

CHASSIS
17. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay.
Maximum steering wheel freeplay: 30 mm (1.18 in.)

With the vehicle stopped and pointed straight ahead, rock the
steering wheel gently back and forth with light finger pressure.

(b) Check the steering linkage for looseness or damage.


Check that:

Tie rod ends do not have excessive play.

Dust seals and boots are not damage.

Boot clamps are not loose.

MA9
MAINTENANCE

Maintenance Operations

18. INSPECT SRS AIRBAG


Visually inspect the steering wheel pad (airbag and inflater)

Use the diagnosis check to check if there are


abnormalities.

Check that there are no cuts, cracks or noticeable color


changes on the surface of the steering wheel pad or in
the center groove of the pad.

Remove the steering wheel pad from the vehicle and


check the wiring and steering wheel for damage and
corrosion due to rusting, etc.
If necessary, replace the steering wheel pad.
CAUTION:

For removal and replacement of the steering wheel pad,


see page AB16 and be sure to perform the operation in
the correct order.
Before disposing of the steering wheel pad, the airbag
must first be deployed using an SST.
(See page AB93 )

19. INSPECT STEERING GEAR HOUSING OIL


Check the steering gear box for oil leakage.
20. INSPECT LOWER BALL JOINTS AND DUST COVERS
(See page SA52)
(a) Jack up the front of the vehicle and support it with
stands.
(b) Make sure the front wheels are in a straightahead
position, and depress the brake pedal.
(c) Jack up the lower suspension arm until there is about
half a load on the front coil spring.
(d) Move the front wheel up and down and check that the
ball joint has no excessive play.
Maximum lower ball joint vertical play:
0.3 mm (0.012 in.)

If there is play, replace the ball joint.


(e) Inspect the dust cover for damage.
21. CHECK
AUTOMATIC
TRANSMISSION
AND
DIFFERENTIAL OIL
Visually check the automatic transmission and differential for
oil leakage.
If leakage is found, check for the cause and repair it.

MA10
MAINTENANCE

Maintenance Operations

22. REPLACE AUTOMATIC TRANSMISSION FLUID


(a) Remove the drain plug and drain the fluid.
(b) Reinstall the drain plug securely.
(c) With the engine OFF, add new fluid through the
dipstick tube.
Fluid: ATF Type TII or equivalent
Drain and refill capacity (Reference):
2.0 liters (2.1 US qts, 1.8 lmp. qts)

(d) Start the engine and shift the selector into all positions
from R through L, and then shift into P position.
(e) With the engine idling, check the fluid level. Add fluid up
to the COOL level on the dipstick.
(f) Check that the fluid level is in the HOT range at the
normal operating temperature (7080C or 158
176F) and add as necessary.
NOTICE: Do not overfill.

23. REPLACE DIFFERENTIAL OIL


(a) Remove the drain plug and drain the oil.
(b) Clean the drain plug.
(c) Reinstall drain plug securely.
(d) Add new oil until it begins to run out of the filler hole.
Differential oil
Oil grade: API GL5 or equivalent
Viscosity: SAE90
Capacity: 1.3 liters (1.4 US qts, 1.1 lmp. qts)

24. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY


Tighten the following parts:

Mount bolts of front seats


Torque:

Strut/stabilizer bar brackettobody mount bolts

Torque:

72 Nm (730 kgfcm, 53 ftlbf)

Front suspension lower crossmembertobody mount


nuts

Torque:

37 Nm (375 kgfcm, 27 ftlbf)

98 Nm (1,000 kgfcm, 72 ftlbf)

Rear suspension membertobody mount bolts

Torque: 180 Nm (1,840 kgfcm, 133 ftlbf)

MA11
MAINTENANCE

Maintenance Operations

25. BODY INSPECTION


(a) Check the body exterior for dents, scratches and rust.
(b) Check the underbody for rust and damage.
If necessary, replace or repair.
26. ROAD TEST
(a) Check the engine and chassis for abnormal noises.
(b) Check that the vehicle does not wander or pull to one
side.
(c) Check that the brakes work properly and do not drag.
(d) Perform settling of the parking brake shoes and drum.
27. FINAL INSPECTION
(a) Check the operation of the body parts:

Hood
Auxiliary catch operates properly
Hood locks securely when closed

Front and rear doors


Door locks operate properly
Doors close properly

Luggage compartment door


Door lock operates properly

Seats
Seat adjusts easily and locks securely in any position
Front seat back locks securely in any position
Foldingdown rear seat backs lock securely
(b) Be sure to deliver a clean car. Especially check:

Steering wheel

Shift lever knob

All switch knobs

Seats

MA12
MAINTENANCE

General Maintenance

GENERAL MAINTENANCE

8. WARNING LIGHTS AND BUZZERS

These are the maintenance and inspection items


which are considered to be the owners responsibility. They can be performed by the owner or he can
have then done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be
reasonable for the owner to perform.
Items and procedures for general maintenance are
as follows.

Check that all warning lights and buzzers function


properly.

OUTSIDE VEHICLE
1. TIRES
(a) Check the pressure with a gauge. Adjust if
necessary.
(b) Check for cuts, damage or excessive wear.

9. HORN
Check that it is working.
10. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
11. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
12. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet
when operating the heater or air conditioner at defroster mode.
13. REAR VIEW MIRROR

2. WHEEL NUTS
When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them.

Check that it is mounted securely.

3. TIRE ROTATION
It is recommended that tires be rotated every 7,500
miles (12,000 km).

Check that they move freely and are mounted securely.

4. WINDSHIELD WIPER BLADES


Check for wear or cracks whenever they do not wipe
clean. Replace if necessary.

Check that it has specified freeplay. Be alert for


changes in steering condition, such as hard steering, excessive freeplay or strange noise.

5. FLUID LEAKS

16. SEATS

(a) Check underneath for leaking fuel, oil, water or


other fluid.

(a) Check that all front seat controls such as seat


adjusters, seatback recliner, etc. operate smoothly.

(b) If you smell gasoline fumes or notice any leak,


have the cause found and corrected.

(b) Check that the seats lock securely in any


position.

6. DOORS AND ENGINE HOOD


(a) Check that all doors including the trunk lid
operate smoothly, and that all latches lock securely.

(c) Check that the seats are held securely in any


position.

(b) Check that the engine hood secondary latch


secures the hood from opening when the primary
latch is released.

INSIDE VEHICLE
7. LIGHTS
(a) Check that the headlights, stop lights,
taillights, turn signal lights, and other lights are all
working.
(b) Check the headlight aiming.

14. SUN VISORS

15. STEERING WHEEL

(d) Check that the head restraints move up and


down smoothly and that they lock securely in any
position.
(e) For foldingdown rear seat backs, check that
they lock securely.
17. SEAT BELTS
(a) Check that the seat belt system such as buckles,
retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed,
worn or damaged.

MA13
MAINTENANCE

General Maintenance

18. ACCELERATOR PEDAL


Check the pedal for smooth operation and uneven
pedal effort or catching.

27. BRAKE FLUID LEVELS

19. BRAKE PEDAL (See page BR4)

28. ENGINE DRIVE BELT

(a) Check the pedal for smooth operation.


(b) Check that the pedal has the proper reserve
distance and freeplay.
(c) Check the brake booster function.

Check that the brake fluid level is near the upper level line on the seethrough reservoir.

Check drive belt for fraying, cracks, wear or oiliness.


29. ENGINE OIL LEVEL
Check the level on the dipstick with the engine
turned off.

20. BRAKES

30. POWER STEERING FLUID LEVEL

At a safe place, check that the brakes do not pull to


one side when applied.

Check the level on the dipstick.

21. PARKING BRAKE (See page BR7)


(a) Check that the pedal has the proper travel.
(b) On a safe incline, check that vehicle is held
securely with only the parking brake applied.
22. AUTOMATIC TRANSMISSION PARK
MECHANISM
(a) Check the lock release button of the selector
lever for proper and smooth operation.
(b) On a safe incline, check that vehicle is held
securely with the selector lever in the P position
and all brakes released.

The level should be in the HOT or COLD range


depending on the fluid temperature.
31. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking and
foot brake applied, shift the selector into all positions
from P to L, and then shift into P.
(c) Turn and pull out the dipstick and wipe off the
fluid with a clean rag. Reinsert the dipstick fully and
check that the fluid level is in the HOT range.
(d) Perform this check with the fluid at normal
driving temperature (7080C or 158176F).

UNDER HOOD

If the level is at the low side, add fluid.

23. WINDSHIELD WASHER FLUID

Fluid type: ATF Type TII or equivalent


NOTICE: Do not overfill.

Check that there is sufficient fluid in the tank.


24. ENGINE COOLANT LEVEL
Check that the coolant level is between the LEVEL
lines on the seethrough reservoir at normal temperature (20C, 68F)

HINT: Wait about 30 minutes before checking the


fluid level after extended driving at high speeds in
hot weather, driving in heavy traffic or with a trailer.
32. EXHAUST SYSTEM

25. RADIATOR AND HOSES

Visually inspect for cracks, holes or loose supports.

(a) Check that the front of the radiator is clean


and not blocked with leaves, dirt or bugs.

If any change in the sound of the exhaust or smell


of the exhaust fumes is noticed, have the cause located and corrected.

(b) Check the hoses for cracks, links, rot or


loose connections.
26. BATTERY ELECTROLYTE LEVEL
Check the indicator.
When the indicator color is blue, the condition is satisfactory. A red color indicates that distilled water
must be added, and white indicates that charging is
necessary.

MA14
MAINTENANCE

Service Specifications

SERVICE SPECIFICATIONS
ENGINE
Drive belt tension
Coolant capacity (w/ Heater)
Engine oil capacity (Drain and refill) w/ Oil filter change
w/o Oil filter change
Spark plug
Type
ND
NGK
Gap
Firing order
Valve clearance (Cold)
Intake
Exhaust

A belt tensioner is used, so check that the belt


tension is not necessary.
10.6 liters
11.2 US qts
9.3 lmp. qts
5.3 liters
5.6 US qts
4.7 lmp. qts
5.0 liters
5.3 US qts
4.4 lmp. qts
PK20R11
BKR6EP11
1.1 mm
0.043 in.
18436572
0.150.25 mm
0.00590.0098 in.
0.250.35 mm
0.00980.0138 in.

CHASSIS
Front and rear brake
Pad thickness
Disc thickness

Front
Rear

Disc runout
Parking brake
Lining thickness
Drum inside diameter
Limit
Front axle and suspension
Lower ball joint vertical play
Limit
Steering wheel freeplay
Torque specifications
Front seat mount bolts
Strut/stabilizer bar bracket X Body
Front suspension lower crossmember X Body
Rear suspension member X Body

Limit
Limit
Limit
Limit

1.0 mm
26.0 mm
15.0 mm
0.05 mm

0.039 in.
1.024 in.
0.591 in.
0.0020 in.

Limit

1.0 mm
191.0 mm

0.039 in.
7.520 in.

0.3 mm
30 mm (1.18 in.) or less

0.012 in.

37 Nm (375 kgfcm, 27 ftlbf)


72 Nm (730 kgfcm, 53 ftlbf)
98 Nm (1,000 kgfcm, 72 ftlbf)
180 Nm (1,840 kgfcm, 133 ftlbf)

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