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GROUP 0
GENERAL
CONTENTS
AC305590
AC305593
AC305594 AC305596
If any of the following parts are removed, they must In accordance with the instructions in this manual,
be replaced with new parts. apply the specified lubricants in the specified loca-
• Oil seals tions during assembly and installation.
• Gaskets (except rocker cover gasket)
• Packings BRAKE FLUID
M6001000900025
• O-rings
• Lock washers
• Split pins
• Self-locking nuts
PARTS
M6001000600024
AC305285
ACX00880AD
and the lighting switch. (If this is not done, there Refer to the "M.U.T.-III OPERATING INSTRUC-
is the possibility of semiconductor parts being TIONS" for instructions on handling the M.U.T.-III.
damaged.) AC302297
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS
M6001001100022
If oil or grease gets onto the oxygen sensor, it will
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats. 16-pin
GROUP 1
PRE-DELIVERY
INSPECTION
CONTENTS
Model
Chassis number
Engine number Before Road Test
Distance Travelled km 17. Seat adjusters and seat back latches
Owner 18. Choke system and inhibitor switch
Date of inspection
19. Idle control knob
Place of inspection
20. Instrument panel controls
Inspector
21. Meters, gauges, warning lamps and indication lamps
Body colour
22. Air conditioning, heater and defroster systems
Symbols to be used 23. Wipers and washers
24. Operation of service brakes and parking brakes
Needs Needs
Good A T 25. Clutch operation
adjustment retightening
26. Operation of seat belts, shoulder belts and retractors
Needs
Needs
Needs replenishment Road Test
C L X replenishment
cleaning of lubricant,
of repair 27. Engine performance and exhaust gas
water, etc.
28. Transmission in all ranges
INSPECTION PROCEDURE
29. Brakes
First Step
30. Steering control
1. Connection of the dark current connector
31. Vibration and rattles
Body
32. Electrical equipment
2. Wrap film
3. Exterior
After Road Test
4. Operation of door locking systems and door hinges
33. Idle speed
5. Operation of door mirrors, windows and sunroof
34. Ignition timing
Under Hood
35. Radiator coolant level
6. Engine oil level
36. Hoses, fluid lines and connections located under hood
7. Brake master cylinder fluid level
37. Manual transmission and transfer (4WD) oil level
8. Clutch master cylinder fluid level
38. Automatic transmission fluid level
9. Washer fluid level
39. Engine, transmission, steering gear box and
10. Battery condition and connections differential for leaks
11. Power steering fluid level 40. Front and rear differential oil levels
12. Electrical wiring 41. Hoses, fluid lines and connections located under vehicle
Under Vehicle Final Steps
13. Tyre and spare tyre pressures 42. Headlamp aiming
14. Suspension system 43. Equipment
15. Steering linkage and split pins 44. Exterior and interior
16. Under body 45. Owner instructions
AC401525
AC306353
PRE-DELIVERY INSPECTION
PAINTWORK TERMS
1-5
PAINTWORK TERMS
M6010200100032
FIRST STEP
1. CONNECTION OF DARK CURRENT
CONNECTOR
M6010300100073
Connecting Procedure
Junction block
Storage connector
AC311576AB
BODY
2. WRAP FILM To protect the exterior finish of vehicles prior to
M6010400100025 dealer delivery, a protective coating is used. The
coating is a thin white resin film. It is applied to all
painted exterior horizontal surfaces of the vehicle
and is held in place with a tacky adhesive backing.
AC305606
PRE-DELIVERY INSPECTION
BODY
1-7
Removal procedure
Peel off slowly from corners keeping parallel to the body. When
Wrap film removal the body temperature is high, lower it to 50ºC or less by
sprinkling water so that adhesive may not remain on the body.
Water washing
AC306352 AB
Wrapping work
No. Process Operation Content
1 Continuous peeling of film The film is peeled off.
2 Water rinse Sand and dust are removed from the vehicle body and it
is dried thoroughly.
3 Parts where the film is to be reapplied are There should be no leftover adhesive, swelling or
checked. discoloration of the paint film, or other defects.
4 Treatment of parts where film is to be Treat the defects on the parts where film is to be
reapplied. reapplied. If a solvent is used to remove leftover
adhesive, wipe off the solvent thoroughly.
5 Reapplication 1. Basically, the parts where the film is to be applied
should be the same as the film that is to be applied.
2. Apply the film from the lower portion of the body,
working upward progressively. Apply pressure using
a plastic squeegee or similar tool.
3. As necessary, cut the film at the various parts such as
windshield washer nozzles, hood and trunk lid.
CAUTION
1. Apply the film with the body at a temperature of 10 − 40°C. (Workability is good in this temperature
range.)
2. If the outside surface of the film (the side with no adhesive) is brought into direct contact with the
paint film and left in that state, it may result in loss of paint gloss, so make sure the film does not
get folded under or otherwise make contact with the paint film.
3. Air bubbles and wrinkles do not have a particularly bad influence on the pain film, but every effort
should be made to prevent air bubbles from being trapped under the film by applying pressure
from the centre of the film outward toward the edges during application.
4. To prevent intrusion of rainwater, be sure to press down the overlapping portions and cut ends of
the film securely.
1-8 PRE-DELIVERY INSPECTION
BODY
3. EXTERIOR 3. Open the door, operate the lock lever and close
M6010400200022 the door to check the lock.
4. Partially close the door to check the open-door
detent.
5. Unlock each door with the key to check lock
operation.
6. Verify that all doors can be locked by the lock
buttons.
NOTE:
Adjust and lubricate the door latches, strikers and
AC305607 locks as required.
AC305607
1. Door mirrors
AC210253AB
Check that the mirror operate properly.
1. Open each door to check the release mechanism 2. Door windows
and ease of operation. Close all door windows to the fully closed position
2. Close the door to check the latch and striker. to check ease of operation.
PRE-DELIVERY INSPECTION
UNDER HOOD
1-9
3. Power windows 4. Slide window
Check that the door windows operate when the Close the slide window to the fully closed position
respective switches are operated. Check that to check operation.
when the lock switches are depressed, the 5. Sunroof
respective door windows can no more be opened
Close the sunroof to the fully closed position to
or closed.
check operation.
UNDER HOOD
6. ENGINE OIL LEVEL 8. CLUTCH MASTER CYLINDER FLUID
M6010500100022
LEVEL
M6010500300048
MAX
MIN
AC305611 AB
Check that the oil level is between "MAX" and "MIN". AC305613
If it is at or below MIN, add the necessary amount of Check the fluid level.
the specified engine oil referring to GROUP 2, Peri- If it is below the "MIN" mark, replenish fresh brake
odic Inspection and Maintenance P.2-3. fluid up to the "MAX" mark.
7. BRAKE MASTER CYLINDER FLUID Specified Brake Fluid: DOT4+
LEVEL 9. WASHER FLUID LEVEL
M6010500200041 M6010500400023
AC305612 AC305614
Check the fluid level. Check the fluid level; if it is low, replenish the washer
If it is below the "MIN" mark, replenish fresh brake fluid at the up to MAX mark.
fluid up to the "MAX" mark. 1. Windshield washer reservoir
Specified Brake Fluid: DOT4+ 2. Rear window washer reservoir
1-10 PRE-DELIVERY INSPECTION
UNDER VEHICLE
10. BATTERY CONDITION AND 2. If the fluid is added, start the engine and turn the
CONNECTIONS steering wheel from stop to stop several times to
M6010500500020 expel air from the system.
Specified gear oil: Automatic transmission
fluid DEXRON II
AC305615
AC305616
UNDER VEHICLE
13. TYRE AND SPARE TYRE PRESSURES 1. Tyre specification
M6010600100029 Check the correct tyre specification.
2. Tyre pressures
Adjust each tyre pressure.
NOTE:
Recommended pressure is shown on the tyre pres-
sure label.
3. Valve stem extensions
Verify that the valve stem extensions are installed
where necessary.
AC305618 4. Install the wheel covers, wheel rings and hub
caps.
PRE-DELIVERY INSPECTION
UNDER VEHICLE
1-11
14. SUSPENSION SYSTEM 15. STEERING LINKAGE AND SPLIT PINS
M6010600200026 M6010600300023
AC305609 AC305604
Check to be sure that each installation bolt and nut is 1. Steering linkage retaining nuts and split pins
tightened. If split pins are used, make sure that they Check visually and by feel that the steering
are properly installed. linkage retaining nuts are correctly tightened and
1. Lower arm, Upper arm the split pins are correctly installed.
2. Stabilizer bar 2. Tie rods and relay rod
3. Strut assembly Check that the tie rods and relay rod of the
REMOVE FRONT SPRING RESTRAINTS steering linkage are not bent and that the tie rod
end lock nuts are securely tightened.
Spring 3. Steering components
restraints (1) Check that each of the steering components is
tightened.
(2) Check the tie rod end, nuts and split pins for
proper installation.
(3) Check the condition of bellows-type dust
seals.
4. Split pins
AC305605 Check the front axle nuts and rear wheel spindle
With the vehicle correctly positioned on the nuts for split pins.
sub-frame contact points, and the suspension fully
extended, remove the rubber restraints from the front
16. UNDER BODY
M6010600400020
springs. Check under body and under body coating for dam-
CAUTION age.
It is very important that these restraints must be
removed during predelivery-inspection. Failure
to do so could cause ride and handling com-
plaints.
1-12 PRE-DELIVERY INSPECTION
BEFORE ROAD TEST
AC305622
M6010701100029
On models with an automatic transmission, be sure 1. Air conditioner
the engine starts in both "P" and "N" position, and (1) Operate the air conditioner system.
does not start in other positions. (2) Operate the air conditioner light.
(3) Operate the control lever in all ranges.
19. IDLE CONTROL KNOB (4) Operate the blower motor switch in all ranges.
M6010700300020
Verify that the diesel engine revolution increases
when the idle control knob is pulled out.
AC305624
PRE-DELIVERY INSPECTION
BEFORE ROAD TEST
1-13
23. WIPERS AND WASHERS
M6010700700028
AC305629
AC305630AC
1. Service brakes
(1) Turn up the carpet, etc under the brake pedal.
Check the clearance between the brake pedal
and the toeboard when the brake pedal is
depressed. If the clearance does not meet the
specifications, check for air in the system,
brake fluid leakage, and/or a malfunction of
the pedal itself.
Clearance between the brake pedal and the
toeboard:
Standard value: 70 mm or more
1-14 PRE-DELIVERY INSPECTION
ROAD TEST
AC305631
ROAD TEST
27. ENGINE PERFORMANCE AND (2) Verify that no black smoking is emitted from
EXHAUST GAS the end of the exhaust pipe (diesel-powered
M6010800100023 vehicles).
AC305633
1. Engine performance
AC305634
Check the engine for proper performance and
accelerator pedal for smooth operation.
1. Manual transmission
2. Exhaust system
Check the transmission in all forward ranges and
(1) Check the exhaust system components for in reverse.
gas leaks.
PRE-DELIVERY INSPECTION
ROAD TEST
1-15
30. STEERING CONTROL
M6010800400024
Button
AC305635 AB
AC305636
2. Automatic transmission
(1) Make sure shift indicator lines up properly in 1. Check for excessive play or looseness.
all ranges. 2. Check the steering wheel centre.
(2) Depress the accelerator completely to check
that the manual kickdown is operating 31. VIBRATION AND RATTLES
M6010800500021
correctly. 1. Locate squeaks, rattles and unusual vibrations.
(3) Stop the vehicle on a steep incline. 2. Verify that no noise occurs from the engine,
Put the automatic transmission in "P" position transmission, axle and body.
and slowly release the service brakes to see if
"P" position lock holds. If it does not hold, the 32. ELECTRICAL EQUIPMENT
transmission requires further service. M6010800600028
29. BRAKES
M6010800300027
1. Service Brake
Put the vehicle in gear and apply the brakes while
the vehicle is in motion. Be sure brake operation
is smooth and positive.
2. Parking Brake
(1) Stop the vehicle on a steep incline.
With the service brakes firmly applied, place AC305637
the transmission in "N" position, and set the
parking brakes. 1. Radio
(2) Slowly release the service brakes to see if the Tune the radio to a local broadcasting station and
parking brakes will hold. check the following:
(1) Operate the volume, tone, balance and fader
controls, etc.
(2) Pull out the pushbuttons, dial another station
and set each pushbuttons.
(3) Operate the AM/FM switch.
2. Tape player
Insert a cassette tape in the tape player and
check as follows:
(1) Check the operation of the tape feeder and
rewind.
(2) Check the ejection.
(3) Check the operation of volume, tone, balance
and fader controls, etc.
1-16 PRE-DELIVERY INSPECTION
AFTER ROAD TEST
AC305643
TYPE 1 TYPE2
LEVEL
M6010900600070
8 mm Gear oil
Upper
limit
Lower
limit
AC305646 AB
FINAL STEPS
42. HEADLAMP AIMING 44. EXTERIOR AND INTERIOR
M6011000100042 M6011000300046
Screen
Headlamp
Level surface
AC305648 AB AC305650
Check condition for headlamp aiming. Finally check and clean the exterior and interior.
NOTE: 1. Wash the vehicle to remove all traces of road
For headlamp aiming procedures, refer to the Work- grime and other dirt on the vehicle as a result of
shop Manual for that model. new vehicle preparations.
2. Clean exterior and interior glass surface.
43. EQUIPMENT 3. Remove all protective covers.
M6011000200049
4. Remove undercoat overspray, excess window
sealer, and excess weatherstrip adhesive.
5. Verify that the secondary key can not unlock the
glove box and tailgate/boot lid (if so equipped).
6. Remove shipping and inspection stickers.
GROUP 2
PERIODIC
INSPECTION AND
MAINTENANCE
CONTENTS
of error.
5. Hold the microphone to the middle of the drive
<Setting procedure> belt between the pulleys (at the place indicated by
(1) Press down the "MASS" button till the belt the arrow), about 10 − 15 mm away from the rear
mass select display appears. surface of the belt and so that it is perpendicular
(2) Press the "UP" or "DOWN" button to select "01 to the belt (within an angle of ± 15 °).
1.5GT 0.9" and press the "MEASURE" button 6. Press the "MEASURE" button.
to decide it.
Check to ensure that "M 000.9 g/m" is
displayed.
2-8 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT
Crankshaft
pulley AK305689 AB
MB992081
Nut for alternator
pivot bolt
AC310987AB
(3) Press the "WIDTH" button to change to the 6. Press the "MEASURE" button.
belt width input display. 7. Gently tap the middle of the belt between the
(4) Press number keys 0, 1, 0, and 0 sequentially, pulleys (the place indicated by the arrow) with
and press the "SELECT" button to apply them. your finger as shown in the illustration, and check
Check to ensure that "W 010.0 mm/R" that the vibration frequency of the belt is within the
appears on the display. standard value.
(5) Press the "SPAN" button to change to the NOTE: To take the measurement repeatedly, fillip
span length input display. the belt again.
(6) Press number keys 0, 1, 0, and 0 sequentially, 8. After the completion of the measurement, press
and press the "SELECT" button to apply them. and hold the "POWER" button to turn off the
Check to ensure that "S 0100 mm" appears on power supply.
the display.
4. Press "Hz" button twice to change the display to <When using the vehicle communication
the frequency display (Hz). interface (V.C.I.)>
CAUTION 1. Connect the special tool belt tension meter set
• The temperature of the surface of the belt (MB991668) to the special tool V.C.I. (MB991824)
should be as close as possible to normal tem- 2. Connect the special tool V.C.I. (MB991824) to the
perature. diagnosis connector.
• Do not let any contaminants such as water or 3. Turn the ignition switch to the "ON" position and
oil get onto the microphone. select "Belt Tension Measurement" from the menu
• If strong gusts of wind blow against the screen.
microphone or if there is loud sources of 4. Hold the microphone to the middle of the drive
noise nearby, the values measured by the belt between the pulleys (at the place indicated by
microphone may not correspond to actual the arrow), about 10 − 20 mm away from the rear
values. surface of the belt and so that it is perpendicular
• If the microphone is touching the belt while to the belt (within an angle of ± 15 °).
the measurement is being made, the values
measured by the microphone may not corre- Water pump 10 – 20 mm
pulley
spond to actual values. 15˚
• Do not take the measurement while the vehi- 15˚
cle's engine is running.
MB991668
Water pump 10 – 15 mm (Microphone)
pulley
Crankshaft
15˚ Alternator pulley
pulley
15˚
MB992080 AK402044AC
(Microphone)
Crankshaft 5. Gently tap the middle of the belt between the
Alternator pulley pulleys (the place indicated by the arrow) with
pulley
your finger as shown in the illustration, and check
AK600562AB that the vibration frequency of the belt is within the
standard value.
5. Hold the microphone to the middle of the drive
belt between the pulleys (at the place indicated by
the arrow), about 10 − 15 mm away from the rear
surface of the belt and so that it is perpendicular
to the belt (within an angle of ± 15 °).
PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT
2-11
CAUTION ALTERNATOR DRIVE BELT TENSION
1. The temperature of the surface of the belt ADJUSTMENT <4G1>
should be as close as possible to normal tem-
perature. Alternator fixing nut
2. Do not let any contaminants such as water or
oil get onto the microphone.
3. If strong gusts of wind blow against the
microphone or if there is loud sources of Adjusting bolt
noise nearby, the values measured by the
microphone may not correspond to actual
values.
Nut for alternator
4. If the microphone is touching the belt while pivot bolt AKX01155AE
the measurement is being made, the values
measured by the microphone may not corre- 1. Loosen the nut of the nut for alternator pivot bolt.
spond to actual values. 2. Loosen the alternator fixing nut.
5. Do not take the measurement while the vehi- 3. Use the adjusting bolt to adjust the belt tension
cle's engine is running. and belt deflection to the standard values.
<When using the tension gauge> Standard value:
Items When When
Water pump adjusted replaced
pulley
Vibration frequency 231 − 255 308 − 344
Hz
Tension Tension N 441 − 539 785 − 981
Gauge
Deflection mm 6.6 − 7.5 4.1 − 5.0
(Reference)
Alternator
pulley Crankshaft 4. Tighten the nut of the nut for alternator pivot bolt.
pulley
AK402045AC Tightening torque: 44 ± 10 N⋅m
Use a belt tension gauge to check that the belt ten- 5. Tighten the alternator fixing nut.
sion is within the standard value. Tightening torque: 23 ± 2 N⋅m
6. Tighten the adjusting bolt.
<Belt deflection check>
Tightening torque: 5.0 ± 1.0 N⋅m
Water pump Deflection
pulley
A2. CHECK INTAKE AIR HOSE FOR
Approximately DAMAGE (VEHICLES WITH
100 N
TURBOCHARGER)
M6020200500075
Alternator
pulley Crankshaft Air intake hose
pulley
AK402046AC
BREATHER HOSE
AC310830AC
<134, 135>
<4G1>
Ventilation hose
PCV valve
Breather hose
AC311577AC
AC404368AB
<4G1>
1. Remove the ventilation hose from the PCV
Ventilation hose (Positive crankcase ventilation) valve.
2. Remove the PCV valve from the rocker cover.
3. Reinstall the PCV valve at the ventilation hose.
4. Start the engine and run at idle.
<134, 135>
Breather hose
AC404365AB
AK402735 AB
Radiator hose
AC310828AC
<4G1>
AK300022 AF
<4G1>
PCV valve
Radiator hose
AC404366AB
AK402736AB
1. Insert a thin rod into the PCV valve from the side Radiator
shown in the illustration (rocker cover installation condenser
side), and move the rod back and forth to check tank
that the plunger moves.
Radiator hose
2. If the plunger does not move, there is clogging in AC400555AC
the PCV valve. In this case, clean or replace the
PCV valve. 1. Check entire circumference and length of hoses,
using a mirror as required.
A5. REPLACE SPARK PLUGS 2. Check that hoses installed in grommets pass
M6020200800076
After removing old spark plugs, install new ones and through the centre of the grommets.
tighten them at the specified torque. 3. Check all clamps for tightness and connections
for leakage.
2-14 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS INSIDE THE ENGINE COMPARTMENT
AC305655
Reserve tank
3. Loosen the drain plug, remove the radiator can
AC310829AC
and drain the coolant.
4. Feed fresh water into the cooling system through
<4G1> the filler port of the radiator in order to wash the
cooling system, and then tighten the drain plug.
5. Drain the coolant from the reserve tank.
6. Install the reserve tank.
Reserve tank
AC404367AB
AC305656
MB991871
Air hose
Oil filter
AC402237AB
AC400551AB
MB995110 AC311579
Outlet
Outlet
AC312910AC
CAUTION
After connecting the fuel return tube <4G1> fuel
vapour control line tube <134, 135, 4G1>or fuel
main tube, slightly pull it to ensure that it is
installed securely. Also confirm that there is a
AC313226AB play approximately 3 mm.
Fuel tank pump
7. Install the fuel tank cap wrench (special tool Fuel main tube
and gauge assembly
MB991991) as shown in the figure. connector
8. Align the mating marks in the following procedure.
6˚
AC400557AC
FRONT SUSPENSION
Deterioration
and sagging
Noise and
oil leakage
Bends and
damage
Cracks, bends
and dents Cracks, bends
and dents
REAR SUSPENSION
Noise and
oil leakage
Deterioration
and sagging
Cracks, bends
and dents
AC313282AB
2-22 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS UNDER THE VEHICLE
B2. CHECK SUSPENSION ARM BALL B4. CHECK STEERING LINKAGE FOR
JOINTS FOR PLAY, AND DUST COVERS DAMAGE AND LOOSE CONNECTIONS
FOR DAMAGE (INCLUDING SEALS AND BOOTS)
M6020300200059 M6020300500050
Dust cover
AC305662
AC305661
AC311888AB
0 - 5 mm
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque.
Filler plug
Tightening torque: 43 ± 3 N⋅m
Transmission oil
AC311891AB
4. Fill the specified transmission oil until the level
1. Remove the filler plug. comes to the lower portion of filler plung hole.
2. Check that the oil level is with in 0 - 5 mm from the Transmission oil:
lower edge of the filler plug hole. Castrol BOT 328 Produced by Burmach Oil
Technology GmbH (or exact equivalents):
3. Check that the transmission oil is not noticeably
SAE 75W - 90 API GL-4 full synthetic oil
dirty, and that it has a suitable viscosity.
Quantity: 1.75L
4. Tighten the filler plug to the specified torque.
Tightening torque: 43 ± 3 N⋅m 5. Tighten the filler plug to the specified torque.
Tightening torque: 43 ± 3 N⋅m
B6. CHANGE GEAR OIL IN MANUAL
TRANSMISSION (include Automated B7. CHECK EXHAUST PIPE
manual transmission) CONNECTIONS FOR GAS LEAKAGE,
M6020300800051 AND CHECK PIPE INSTALLATION
M6020301200074
<Left side view>
1. Confirm that the exhaust pipe does not interfere
with any body components.
2. Check the exhaust pipe for damage by stones,
etc.
Filler plug 3. Start the engine and check for gas leaks from the
exhaust pipe connections.
AC311889AB
AC312518AB
AC306798
2-26 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS OUTSIDE THE VEHICLE
Compensator
AC001079 AB
AC102503AD
Standard value:
Standard value: −1°00’ ± 0° 45’ (Left/right
Item Specifications deviation within 30’
Standard High-ground NOTE: .
suspension suspension 1. For vehicles with aluminium wheel, we recom-
Camber −0°30' ± 0° −0°15' ± 0° mend that a compensator be used to measure
30'* 30'* the camber.
2. Camber is preset at the factory and cannot be
Caster 2°40' ± 0° 30'* 2°30' ± 0° 30'* adjusted.
Kingpin inclination 13°20' ± 0° 13°00' ± 0° 30'
30' D2. CHECK FRONT AND REAR WHEEL
BEARINGS FOR PLAY
M6020500900063
<Front>
1. Remove the disc brake caliper and suspend it
with a wire.
2. Remove the brake disc from the front hub.
PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS OUTSIDE THE VEHICLE
2-27
Vehicles with
rear drum brake
AC209503AC AC208743 AC
<Rear>
1. For vehicles with drum brake, remove the brake AC311430 AB
drum.
2. For vehicles with disc brake, remove the caliper 3. Check the bearing's axial play. Place a dial gauge
assembly, and suspend the caliper assembly with against the hub surface; then move the hub in the
a wire and remove the brake disc. axial direction and check whether or not there is
axial play.
Limit: 0.05 mm
4. If the play exceeds the limit, replace the rear hub
assembly.
Brake booster
Hydraulic unit
AC403774AB
Front disc brake
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
2-28 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS OUTSIDE THE VEHICLE
D4. CHECK BRAKE PADS AND DISCS BRAKE DISC RUN-OUT CHECK
FOR WEAR 1. Remove the brake assembly, and then hold it with
M6020500400411 wire.
2. Temporarily install the disc with the hub nut.
AC102396AF
ACX00668AF
A
3. Using a micrometer, measure disc thickness at
eight positions, approximately 45° apart and 10
mm in from the outer edge of the disc.
Standard value: ACX00708AE
<Front> 24.0 mm (except 4G1), 25.8 mm (4G1)
<Rear> 10.0 mm 2. Measure the thickness of the brake lining at
Limit: several places.
<Front> 21.5 mm (except 4G1), 23.5 mm (4G1) Standard value (A):
<Rear> 8.0 mm <Leading> 4.6 mm
<Trailing> 3.3 mm
4. If the disc thickness is less than the limits, replace
Limit (A): 0.5 mm
it with a new one.
3. If the thickness of the brake lining is below the
limit, replace the shoe and lining assemblies on
both sides of the vehicle. Never replace only one
side.
PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS AFTER ENGINE IS WARMED UP
2-29
BRAKE DRUM INSIDE DIAMETER CHECK 2. Measure the inside diameter of the brake drum in
1. Remove the brake drum. two places or more.
Standard value: 203.0 mm
Limit: 204.4 mm
3. If the inside diameter exceeds the limit, or if it is
excessively worn or one side, replace the brake
A drum.
AC000893AD
AC404209AC
1. Check entire circumference and length of hoses 2. Check all clamps for tightness and connections
and pipes. for leakage.
Engine oil
pan drain
Engine oil pan plug gasket
drain plug
AC404572 AB
Engine oil
pan side
<639>
AC402262AD
AC404573AB
A/C compressor
E3. CHECK ENGINE IDLING SPEED
M6020600500471
MB991910
ACX00395AG
Diagnosis
connector
4. Use the commercially-available tool to remove the
engine oil filter.
5. Clean the filter bracket side mounting surface.
MB991824
MB991827 AC311450AB
O-ring
AC103250AD 3. Connect the M.U.T.-III to the diagnosis connector.
<134>
<639 engine>
AC206895
No.1 Ignition coil
MB991910
Diagnosis
AC613107AB connector
<135>
MB991824
8. If the idle speed is outside the standard value, 1. Before inspection, set the vehicle to the
inspect the MPI system (Refer to WORKSHOP pre-inspection condition.
MANUAL GROUP 13 − Troubleshooting). 2. Turn the ignition switch to "LOCK" (OFF) position.
9. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-III.
PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS AFTER ENGINE IS WARMED UP
2-33
AC206895 7. Run the engine at 2,500 r/min for 2 minutes.
8. Set the CO, HC tester.
MB991910 9. Check the CO contents and the HC contents at
idle.
Standard value
CO contents: 0.5% or less
HC contents: 100 ppm or less
Diagnosis
connector 10.If there is a deviation from the standard value,
check the following items:
• Diagnosis output
MB991824 • Fuel pressure
• Injector
• Ignition coil, spark plug
• Evaporative emission control system
• Compression pressure
NOTE: Replace the three way catalyst when the
CO and HC contents are not within the standard
value, even though the result of the inspection is
MB991827 AC311450AB normal on all items.
11.Turn the ignition switch to the "LOCK" (OFF)
3. Connect the M.U.T.-III to the diagnosis connector. position and then remove the M.U.T.-III.
<134>
E5. CHECK VALVE CLEARANCE
No.1 Ignition coil
(EXCEPT VEHICLES WITH AUTO-LASH
ADJUSTER)
M6020600900275
Timing mark
CAUTION
Paint mark
Turn the crankshaft always clockwise.
12 teeth
Paint mark (120 degrees)
6.5 teeth
(65 degrees)
Paint mark
Timing mark
AK604593AB
Paint mark
65˚ AK604594AB
Paint mark
8. Turn the crankshaft clockwise 240 degrees, and
Timing mark align the paint mark against the upper face of the
AK604592AB cylinder head as shown in Figure.
5. Turn the crankshaft clockwise 130 degrees, and Exhaust valve side
No.2
align the paint mark against the upper face of the
cylinder head as shown in Figure.
Exhaust valve side
No.3
No. 3
Intake valve side AK305588 AF
Timing mark
AK604595AB AK304938 AB
10.Apply the paint mark to the 5.5th tooth (55 14.Using a micrometer, measure the thickness of the
degrees) clockwise from the timing mark on the removed valve tappet.
exhaust camshaft sprocket.
Top view Under view
Paint mark Timing mark Identification mark
AK604596AB
15.Calculate the thickness of the newly installed
11.Turn the crankshaft clockwise 240 degrees, and valve tappet through the following equation.
align the paint mark against the upper face of the A: thickness of newly installed valve tappet
cylinder head as shown in Figure.
B: thickness of removed valve tappet
Exhaust valve side
No.1 C: measured valve clearance
Equation
Intake valve: A = B + (C − 0.22 mm)
Exhaust valve: A = B + (C − 0.30 mm)
NOTE: The valve tappet ranges 2.70 − 3.30 mm
and has 31 types per 0.02 mm. The thickness
below a decimal point is stamped on the reverse
No. 2 side of the valve tappet.
Intake valve side AK305588 AE Example: In case of 2.90 mm, "90" is stamped.
16.Install the valve tappet selected through the
12.Check the valve clearance with the arrow shown
procedure 15, and put the camshaft in position.
in Figure. If deviated from the standard value,
For the camshaft installation, refer to
make note for the valve clearance.
WORKSHOP MANUAL.
13.If the valve clearance is deviated from the
17.Remove any liquid gasket remaining on the
standard value, remove the camshaft and the
cylinder head cover, the timing chain case and the
valve tappet. For the camshaft removal, refer to
cylinder head.
WORKSHOP MANUAL.
2-36 PERIODIC INSPECTION AND MAINTENANCE
OPERATIONS AFTER ENGINE IS WARMED UP
CAUTION
Turn the crankshaft always clockwise.
Exhaust valve side
No. 1 No. 3
AK304933AB
OTHERS
F1. CHECK BODY CONDITION FOR Drive the vehicle and check for conditions.
DAMAGE 1. Check free play of steering wheel.
M6020700100027 2. Check efficiency of service brakes and parking
1. Check underbody coating for damage. brakes system.
2. Check body painting for damage. 3. Check driveability of engine.
F2. ROAD TEST 4. Check condition of instruments, gauges
M6020700200091 indicators, exterior lamps, heater and ventilators.
5. Check abnormal noise of each part.
6. Check the tyres for wear and for the correct air
pressure.
AC404799