MA-1

MAINTENANCE

GENERAL NOTES:
There are two separate maintenance schedules,
namely A and B, which apply to different driving
conditions. Find out how the vehicle is driven, select the appropriate schedule and service the vehicle accordingly.

Every service item in the periodic maintenance list

must be performed.
Next to the columns of periods in the schedule,
. reference pages have been added for easy access to
service data and procedures necessary for each
operation.
The service interval for scheduled maintenance
is determined by the odometer reading or time
interval, whichever comes first, shown in the
schedule.
Maintenance services after the last period should
be performed at the same interval as before unless
otherwise noted.
Skipping even one item in the list can cause the
engine to run poorly and increase exhaust emissions.

MA-2
MAINTENANCE

MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE
SCHEDULE A

CONDITIONS:
Towing a trailer, using a camper or car top carrier.
Repeated short trips of less than 8 km (5 miles) with outside temperature remaining below
freezing.
Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to
-door delivery use.
Operating on dusty, rough, muddy or salt spread roads.
Maintenance operation: A = Check and adjust if necessary.
R = Replace, change or lubricate.
I = Inspect and correct or replace if necessary.

System

Service interval
(Use odometer
reading or months,
whichever
comes first)

Maintenance services beyond 96,000 km (60,000 miles) should continue to be performed at the same intervals
shown for each maintenance schedule.

Maintenance items
ENGINE

See page
(item No.)

x 1,000 km
x 1,000 miles

3.75

11.25

18.75

22.5

26.25

33.75

37.5

41.25

Drive belt

MA-7
(item 1)
A: Every 72 months
I: First period 96,000 km (60,000 miles) a 72 months.
I: After that every 12,000 km (7,500 miles) or 12 months.

Engine oil and oil filter

Engine coolant

EVAP
BRAKES

CHASSIS

Idle speed

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

R: Every 6 months
R: First period 72,000 km (45,000 miles) or 36 months.
R: After that every 48,000 km (30,000 miles) or 24 months.

Exhaust pipes and mountings

IGNITION

52.5 56.25

Timing belt (1)

Valve clearance

FUEL

48.75

Months

MA-9
(item 6)
MA-9
(item 7)

I: Every 24 months
A: First period. 12,000 km (1.500 miles) or 12 months, second period 24,000 km (15,000 miles) or 24 months.
A: After that every 24,000 km (15,000 miles) or 24 months.

MA-10
(item 11)
MA-1 1
(item 13)

Air filter (2)

I: Every6 months
R: Every 36 months

MA-8
(item 3, 4)

Fuel lines and connections (3)

I: Every 36 months

MA-10
(item 10)

Fuel tank cap gasket

R: Even 72 months

MA-10
(item 9)

Spark plugs
*

R: Every 36 months

MA-8
(item 5)

Charcoal canister

I: Every 72 months

MA-9
(item 8)

Brake linings and drums (4)

1: Every 12 months

MA-14
(item 16)

Brake pads and discs

i: Every 12 months

MA-14
(item 15)

Brake line pipes and hoses

I: Every 24 months

MA-13
(item 14)

I: Every 12 months

MA-15
(item 17)

Steering linkage
SRS airbag

I: First period 10 years.

I: After that every 2 years.

MA-15
(item 18)
MA-16
(item 20)

Drive shaft boots

I: Every 12 months

Ball joints and dust covers

I: Every 12 months

Transaxle oil

R: Every 24 months

Steering gear housing oil (5)

I: Even 24 months

MA-16
(item 19)

Rear wheel bearing

I: Every 48 months

MA-19
(item 24)

Bolts on body (6)

I: Every 12 months

MA-19
(item 26)

MA-16
(item 21)
MA-17 ,
MA-18

(item 22, 23)

MA-3
MAINTENANCE

MAINTENANCE SCHEDULE

 and * marks indicates maintenance which is part of the warranty conditions for the Emission
Control Systems. The warranty period is in accordance with the owners guide or the warranty
booklet.
: California and New York specification vehicles
*: Other specification vehicles
(1) Applicacable to vehicles operated under conditions of extensive idling and/or low speed driving
for long distances such as police, taxi or door-to-door 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 oil leaks from steering gear housing.
(6) Applicable only when operating mainly on rough, muddy roads. The applicable parts are listed
below. For other usage conditions, refer to SCHEDULE B.
Bolts for seat installation.

MA-4
MAINTENANCE

MAINTENANCE SCHEDULE

SCHEDULE B
CONDITIONS:
Conditions others than those listed for SCHEDULE A.
Maintenance operation: A = Check and adjust if necessary.
R = Replace, change or lubricate.
I = Inspect and correct or replace if necessary.

System

Service interval
(Use odometer reading or
months, whichever comes first)
Maintenance items

ENGINE

Maintenance services beyond 96,000 km (60,000 miles) should continue to be

performed at the same intervals shown for each maintenance schedule.
x 1,000 km
x 1,000 miles

22.5

37.5

52.5

Valve clearance
Drive belt

A: Every 72 months
I: First period 96,000 km (60,000 miles) or 72 months.
I: After that every 12,000 km (7,500 miles) or 12 months.

Engine oil and oil filter

Engine coolant

R: Every 12 months
R: First period 72,000 km (45,000 miles) or 36 months.
R: After that every 48,000 km (30,000 miles) or 24 months.

Exhaust pipes and mountings

FUEL
Idle speed

Months

I: Every 36 months
A: First period, 12,000 km (7,500 miles) or 12 months,
second period 24,000 km (15,000 miles) or 24 months.
A: After that every 24,000 km (15,000 miles) or 24 months.

See page
(item No.)

MA- 11 (item 12)

MA-7 (item 2)
MA-9 (item 6)
MA-9 (item 7)
MA-10 (item 11)
MA-1 1 (item 13)

Air filter

R: Every 36 months

MA-8 (item 4)

Fuel lines and connections (1)

I: Every 36 months

MA-10 (item 10)

Fuel tank cap gasket

R: Every 72 months

MA-10 (item 9)

IGNITION

Spark plugs
*

R: Every 72 months

MA-8 (item 5)

EVAP

Charcoal canister

I: Every 72 months

MA-9 (item 8)

BRAKES

Brake linings and drums (2)

I: Every 24 months

MA-14 (item 16)

Brake pads and discs

I: Every 24 months

MA-14 (item 15)

Brake line pipes and hoses

I: Every 24 months

MA-13 (item 14)

Steering linkage

I: Every 24 months

CHASSIS

SRS airbag

I: First period 10 years. I: After that every 2 years.

MA-15 (item 17)

MA-15 (item 18)

Drive shaft boots

I: Every 24 months

MA-16 (item 20)

Ball joints and dust covers

I: Every 24 months

MA-16 (item 21)

Transaxle oil (3)

I: Every 24 months

MA-17 (item 22)

Steering gear housing oil (4)

I: Every 24 months

MA-16 (item 19)

Rear wheel bearing

I: Every 48 months

MA-19 (item 24)

Bolt on body (5)

I: Every 12 months

MA-19 (item 25)

 and * marks indicates maintenance which is part of the warranty conditions for the Emission
Control Systems. The warranty period is in accordance with the owners guide or the warranty
booklet.
: California and New York specification vehicles
*: Other specification vehicles
(1) Includes inspection of fuel tank band and vapor vent system.
(2) Also applicable to drum lining for parking brake.
(3) Check for leakage.
(4) Check for oil leaks from steering gear housing.
(5) The applicable parts are listed below.
Bolts for seat installation.

MA-5
MAINTENANCE

PREPARATION

PREPARATION
SST (SPECIAL SERVICE TOOLS)
09043-38100 Hexagon 10 mm Wrench

A/T oil pan drain plug

RECOMMENDED TOOLS
09200-00010 Engine Adjust Kit

EQUIPMENT
Belt tension gauge
Dial indicator
Micrometer
Mirror

Brake hose

Steel square
Tachometer
Torque wrench
Vernier calipers

COOLANT
Capacity

Item
Engine coolant (w/ Heater)

M/T
A/T

4.9 liters (5.2 US qts, 4.3 Imp. qts)

5.4 liters (5.7 US qts, 4.8 Imp. qts)

Classification
Ethylene-glycol base

MA-6
MAINTENANCE

PREPARATION

LUBRICANT
Item
Engine oil
Drain and refill
w/ Oil filter change
w/o Oil filter change
Manual transaxle oil
Automatic transaxle fluid
Transmission
Drain and refill
Differential
Wheel bearing grease

Capacity

Classification
API grade SG or SH, Energy- Conserving II
multigrade engine oil or ILSAC multigrade
engine oil and recommended viscosity oil

2.7 liters (2.9 US qts, 2.4 Imp. qts)

2.5 liters (2.6 US qts, 2.2 Imp. qts)
2.4 liters (2.5 US qts, 2.1 Imp. qts)

API GL-4 or GL-5

SAE 75W-90
ATF DEXRON
II

2.5 liters (2.6 US qts, 2.2 Imp. qts)

1.4 liters (1.5 US qts, 1.2 Imp. qts)
Lithium base multipurpose (NLGI No.2)

MA-7
MAINTENANCE

MAINTENANCE OPERATIONS

MAINTENANCE OPERATIONS
ENGINE
Cold Engine Operations
1. REPLACE TIMING BELT
(a) Remove the timing belt.
(See pages EM-15 to EM-18)
(b) Install the timing belt.
(See pages EM-22 to EM-26)
2. INSPECT DRIVE BELTS
(a) 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.

(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
Generator
Used belt
100 20 lbf
New belt
160 20 lbf
PS
Used belt
100 20 lbf
New belt
160 25 lbf
A/C
Used belt
110 20 lbf
New belt
165 15 lbf
PS and A/C
Used belt
100 20 lbf
New belt
160 20 lbf
If necessary, adjust the drive belt tension.

MA-7
MAINTENANCE

MAINTENANCE OPERATIONS

MAINTENANCE OPERATIONS
ENGINE
Cold Engine Operations
1. REPLACE TIMING BELT
(a) Remove the timing belt.
(See pagesto EM-15 to18)
(b) Install the timing belt.
(See pages EM-22 to EM-26)
2. INSPECT DRIVE BELTS
(a) 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.

(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
Generator
Used belt
100 20 lbf
New belt
160 20 lbf
PS
Used belt
100 20 lbf
New belt
160 25 lbf
A/C
Used belt
110 20 lbf
New belt
165 15 lbf
PS and A/C
Used belt
100 20 lbf
New belt
160 20 lbf
If necessary, adjust the drive belt tension.

MA-8
MAINTENANCE

MAINTENANCE OPERATIONS

HINT:
New belt refers to a belt which has been used
less than 5 minutes on a running engine.
Used belt refers to a belt which has been used
on a running engine for 5 minutes or more.
After replacing the drive belt, check that it fits
properly in the ribbed grooves, especially in the
places difficult to see.
Check by hand to confirm that the belt has not
slipped out of the groove on the bottom of the
pulley.
After installing a new belt, run the engine for
approx. 5 minutes and then recheck the tension.

3. INSPECT AIR FILTER

(a) Visually check that the air filter is not excessively
dirty, damaged or oily.
If necessary, replace the air filter.
(b) Clean the air filter with compressed air.
First blow from the upper side thoroughly, then blow
off the lower side of the air filter.
4. REPLACE AIR FILTER
Replace the air filter with a new one.
5. REPLACE SPARK PLUGS
(a) Disconnect the high - tension cords at the rubber
boot. Do not pull on the high-tension cords.
NOTICE: Pulling on or bending the cords may damage the
conductor inside.

(b) Remove the 4 spark plugs.

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

Correct electrode gap:
1.1 mm (0.043 in.)
Recommended spark plugs:
W16REXR-U1 1 for ND
BPR5EY11 for NGK
(d) Reinstall the 4 spark plugs.
Torque: 18 N
m (180 kgf
cm. 13 ft
lbf)

(e) Reconnect the high-tension cords.

MA-9
MAINTENANCE

MAINTENANCE OPERATIONS

6. REPLACE ENGINE OIL AND OIL FILTER

(See Lubrication System on page EG-235 )
Oil grade:
API grade SG or SH, Energy-Conserving ll
multigrade engine oil or ILSAC multigrade engine
oil.
Recommended viscosity is as shown in the
illustration.
Drain and refill capacity:
w/ Oil filter change
2.7 liters (2.9 US qts, 2.2 Imp. qts)
w/o Oil filter change
2.5 liters (2.6 US qts, 2.4 Imp. qts)

7. REPLACE ENGINE COOLANT

(See Cooling System on page EG-21 1 )
Coolant capacity (w/ Heater):
M/T
4.9 liters (5.2 US qts, 4.3 Imp.qts)
A/T
5.4 liters (5.7 US qts, 4.8 Imp.qts)
HINT:
Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturers
directions.
Using coolant which includes more than 50 %
ethylene-glycol (but not more than 70 %) is
recommended.
NOTICE:
Do not use a alcohol type coolant.
The coolant should be mixed with demineralized
water or distilled water.

8. INSPECT CHARCOAL CANISTER

(a) Remove the charcoal canister.
(b) Visually inspect the canister case.
(c) Check for crogged each port and stuck check valve.
Using low compressed air (4.71 kPa (48 gf/cm2,
0.68 psi)), blow into port A and check that air
flows without resistance from the other ports.

MA-10
MAINTENANCE

MAINTENANCE OPERATIONS

Blow low compressed air (4.71 kPa (48 gf/cm2,

0.68 psi)) into port B and check that air does not
flow from the other ports.
If operation is not as specified, replace the charcoal
canister.

(d) Clean the filter in the canister.

Clean the filter by blowing 294 kPa (3 kgf/cm2, 43 psi)
of compressed air into port A while holding port B
closed.
NOTICE:

Do not attempt to wash the canister.

No activated carbon should come out.
(e) Reinstall the charcoal canister.

9. REPLACE GASKET IN FUEL TANK CAP

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

10. INSPECT FUEL LINES AND CONNECTIONS

Visually check the fuel lines for cracks, leakage, loose
connections, deformation or tank band looseness.
11. INSPECT EXHAUST PIPES AND MOUNTINGS
Visually check the pipes, hangers and connections for
severe corrosion, leaks or damage.

MA-1 1
MAINTENANCE

MAINTENANCE OPERATIONS

Hot Engine Operations

12. ADJUST VALVE CLEARANCE
(a) Warm up the engine to normal operating temperature.
(b) Stop the engine and remove the cylinder head cover.
(c) Adjust the valve clearance.
(See Engine Mechanical on page EG-49 )
Valve clearance (Hot):
0.20 mm (0.008 in.)
(d) Reinstall the cylinder head cover.
13. ADJUST IDLE SPEED
(a) Preparation
Engine at normal operating temperature
Air cleaner installed
All pipes and hoses of air induction system connected
All vacuum lines properly connected
HINT: All vacuum hoses for EGR system, etc. should
be properly connected.
MFI system wiring connectors fully plugged
All accessories switched OFF
Ignition timing set correctly
Transmission in neutral position

(b) Disconnect the VSV connector for idle-up.

(c) Connect a tachometer to the engine.

Connect the tester probe of a tachometer to terminal
IG
of the data link connector 1.
NOTICE:
NEVER allow the tachometer terminal to touch
ground as it could result in damage to the igniter
and/or ignition coil.
As some tachometers are not compatible with this
ignition system, we recommend that you confirm
the compatibility of your unit before use.

MA-12
MAINTENANCE

MAINTENANCE OPERATIONS

(d) Race the engine at 2,500 rpm for approx. 2 minutes.

(e) Adjust the idle speed by turning the idle speed adjusting screw.
Idle speed (w/ Cooling fan OFF):
M/T
750 rpm
A/T
800 rpm

(f) Reconnect the VSV connector for idle-up.

(g) Disconnect the tachometer.

MA-13
MAINTENANCE

MAINTENANCE OPERATIONS

BRAKES
14. INSPECT BRAKE LINE PIPES AND HOSES
HINT: Check in a well lighted area. Check the entire
circumference and length of the brake hoses using a
mirror as required. Turn the front wheels fully right or
left before checking the front brake.
(a) Check all brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
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.

MA-14
MAINTENANCE

MAINTENANCE OPERATIONS

15. INSPECT BRAKE PADS AND DISCS FOR FRONT

AND REAR
(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 to
see if it is contacting the disc rotor. If so, the disc pad
should be replaced.

(b) Check the disc for wear.

Minimum disc thickness:
17.0 mm (0.669 in.)

(c) Check the disc for runout.

Maximum disc runout:
0.09 mm (0.0035 in.)

16. INSPECT BRAKE LININGS AND DRUMS FOR

PARKING BRAKE
(a) Check the lining-to-drum contact condition and
lining wear.
Minimum lining thickness:
1.0 mm (0.039 in.)

MA-15
MAINTENANCE

MAINTENANCE OPERATIONS

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

Maximum drum inside diameter:
181 mm (7.126 in.)
(c) Clean the brake parts with a damp cloth.
NOTICE: Do not use compressed air to clean the
brake parts.
If necessary, adjust the parking brake.

CHASSIS
17. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay.
Maximum 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 damaged.

Boot clamps are not loose.

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 or front passenger airbag assembly, see page
RS-16 and be sure to perform the operation in the
correct order.

MA-16
MAINTENANCE

MAINTENANCE OPERATIONS

Before disposing of the steering wheel pad or front

passenger airbag assembly must first be deployed
by using SST (See page RS-93 ).
19. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.

20. INSPECT DRIVE SHAFT BOOTS

Inspect the drive shaft boots for clamp looseness,
grease leakage or damage.

21. INSPECT BALL JOINTS AND DUST COVERS

(a) Inspect the ball joints for excessive looseness.

Jack up the front of the vehicle and place a

wooden block with a height of 180 - 200 mm
(7.09 - 7.87 in.) under one front tire.

Lower the jack until there is about half a load on

one front coil spring. Place stands under the
vehicle for safety.

Make sure the front wheels are in a straightforward position and block the wheel with chocks.

Move the lower arm up and down, and check that

the ball joint has no excessive play.
Maximum ball joint vertical play:
0 mm (0 in.)
If there is play, replace the ball joint.

(b) Check the dust cover for damage.

MA-17
MAINTENANCE

MAINTENANCE OPERATIONS

22. INSPECT TRANSAXLE OIL (FLUID)

A. Inspect manual transaxle oil
(a) Visually check the transaxle for oil and leakage.
If leakage is found, check for the cause and repair.
(b) Remove the filler plug, and feel inside the hole with
your finger. Check that the oil comes to within 5 mm
(0.20 in.) of the bottom edge of the filler hole.
If the level is low, add oil until it begins to run out of
the filler hole.
Transaxle oil:
See item 23 (A)
(c) Reinstall the filler plug securely.

B. Inspect automatic transaxle fluid

Transmission
(a) Visually check the transmission for fluid and leakage.
If leakage is found, check for the cause and repair.
(b) Check the fluid level with the engine idling and shift
lever at P position.
If the level is low, add fluid.
Transmission fluid:
See item 23 (B)
Differential
(a) Visually check the differential for fluid and leakage.
If leakage is found, check for the cause and repair.
(b) Remove the filler plug, and feel inside the hole with
your finger. Check that the fluid comes to within 5 mm
(0.20 in.) of the bottom edge of the filler hole.
If the level is low, add fluid until it begins to run out of
the filler hole.
Differential fluid:
See item 23 (C)
(c) Reinstall the filler plug securely.

MA-18
MAINTENANCE

MAINTENANCE OPERATIONS

23. REPLACE TRANSAXLE OIL (FLUID)

A. Replace manual transaxle oil
(a) Remove the filler and drain plugs, and drain the oil.
(b) Reinstall the drain plug securely.

(c) Add new oil until it begins to run out of the filler hole.
Transaxle oil:
Oil grade
API GL-4 or GL-5
Viscosity
SAE 75W-90
Capacity:
2.4 liters (2.5 US qts, 2.1 Imp.qts)
(d) Reinstall the filler plug securely.
B. Replace automatic transaxle fluid
Transmission
(a) Using SST, remove the drain plug, and drain the fluid.
09043-38100
(b) Reinstall the drain plug securely.

(c) With the engine OFF, add new fluid through the
dipstick tube.
Transaxle fluid:
ATF DEXRON II
Drain and refill capacity:
2.5 liters (2.6 Us qts, 2.2 Imp.qts)
(d) Start the engine and shift the selector into all positions from P through L, and then shift into P.
(e) With the engine idling, check the fluid level. Add fluid
up to the COOL level on the dipstick.
(f) Recheck the fluid level with the normal temperature
(70 - 80C (158 - 176F)) and add as necessary.
NOTICE: Do not overfill. The transmission and differential are separate units.

MA-19
MAINTENANCE

MAINTENANCE OPERATIONS

Differential
(a) Remove the filler plug.
(b) Using SST, remove the drain plug, and drain the fluid.
09043-38100
(c) Reinstall the drain plug securely.

(d) Add new fluid until it begins to run out of the filler
hole.
Differential fluid:
ATF DEXRONII
Capacity:
1.4 liters (1.5 US qts, 1.2 Imp.qts)
(e) Reinstall the filler plug securely.

24. REPACK REAR WHEEL BEARINGS

(a) Change rear wheel bearing grease.

Remove the hub and inner and outer bearings.

Clean in solvent and inspect the bearings for
damage.

Pack the bearings and axle hubs with multipurpose grease.

Wheel bearing grease grade:
Lithium base multipurpose grease (NLGI No.2)
(b) Install inner bearing and new oil seal.
(c) Install the hub and adjust the wheel bearing preload.
(See page SA-43 )
Preload (while turning):
Add frictional force plus
0-1 1.8 N (0-1.2 kgf, 0-2.6 lbf)

25. TIGHTEN BOLTS ON BODY

Tighten the front seat mounting bolts.
Torque: 37 N
m (375 kgf
cm, 27 ft
lbf)

MA-20
MAINTENANCE

MAINTENANCE OPERATIONS

26. 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.
27. 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.
28. 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
Folding-down rear seat backs lock securely
(b) Be sure to deliver a clean car. Especially check:

Steering wheel

Shift lever knob

All switch knobs

Door handles

Seats

MA-21
MAINTENANCE

GENERAL MAINTENANCE
There are some maintenance and inspection items which are considered to be the
owners responsibility. They can be performed by the owner or be can have them
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:

OUTSIDE VEHICLE
1. TIRES
(a) Check the pressure with a gauge. Adjust if
necessary.
(b) Check for cuts, damage, uneven or excessive wear.
2. WHEEL NUTS
When checking the tires, check the nuts
for looseness or for missing nuts. If necessary, tighten them.
3. TIRE ROTATION
It is recommended that tires be rotated
every 12,000 km (7,500 miles).
4. WINDSHIELD WIPER BLADES
Check for wear or cracks whenever they
do not wipe clean. Replace if necessary.
5. FLUID LEAKS
(a) Check underneath for leaking fuel, oil,
water or other fluid.
(b) If you smell gasoline fumes or notice any
leak, have the cause found and corrected.
6. DOORS AND ENGINE HOOD
(a) Check that all doors including the trunk lid
operate smoothly, and that all latches lock
securely.
(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, tail
lights, turn signal lights, and other lights
are all working.
(b) Check the headlight aim.

GENERAL MAINTENANCE

8. WARNING LIGHTS AND BUZZERS

Check that all warning lights and buzzers
function properly.
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.
13. REAR VIEW MIRROR
Check that it is mounted securely.
14. SUN VISORS
Check that they move freely and are mounted securely.
15. STEERING WHEEL
Check that it has specified freeplay. Be
alert for changes in steering condition,
such as hard steering, excessive freeplay
or strange noise.
16. SEATS
(a) Check that all front seat controls such as
seat adjusters, seatback recliner, etc. operate smoothly.
(b) Check that all latches lock securely in any
position.
(c) Check that the locks hold securely in any
latched position.
(d) Check that the head restraints move up
and down smoothly and that the locks
hold securely in any latched position.
(e) For fold - down rear seat backs, check
that the latches 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.
18. ACCELERATOR PEDAL
Check the pedal for smooth operation and
uneven pedal effort or catching.

MA-22
MAINTENANCE

19. CLUTCH PEDAL

(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper freeplay.
20. BRAKE PEDAL
(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.
21. BRAKES
At safe place, check that the brakes do not
pull to one side when applied.
22. PARKING BRAKE
(a) Check that the lever has the proper travel.
(b) On a safe incline, check that vehicle is held
securely with only the parking brake applied.
23. 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 P position and all brakes released.

UNDER HOOD
24. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the
tank.
25. ENGINE COOLANT LEVEL
Check that the coolant level is between
the FULL and LOW lines on the seethrough reservoir.
26. RADIATOR AND HOSES
(a) Check that the front of the radiator is
clean and not blocked with leaves, dirt or
bugs.
(b) Check the hoses for cracks, kinks, corrosion or lose connections.
27. BATTERY ELECTROLYTE LEVEL
Check that the electrolyte level of all battery cells is between the upper and lower
level lines on the case. If level is low, add
distilled water only.

GENERAL MAINTENANCE

28. BRAKE AND CLUTCH FLUID LEVELS

(a) Check that the brake fluid level is near the
upper level line on the see-through reservoir.
(b) Check that the clutch fluid level is within
5 mm (0.20 in.) of the reservoir hem.
29. ENGINE DRIVE BELTS
Check all drive belts for fraying, cracks,
wear or oiliness.
30. ENGINE OIL LEVEL
Check the level on the dipstick with the
engine turned OFF.
31. POWER STEERING FLUID LEVEL
Check the level in the dipstick.
The level should be in the HOT Or COLD
range depending on the fluid temperature.
32. AUTOMATIC TRANSAXLE 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 position.
(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 (70 - 80
C (158 176
F)).
If the level is at the low side, add fluid.
NOTICE: Do not overfill.
HINT: Wait about 30 minutes before che-

cking the fluid level after extended driving

at high speeds in hot weather, driving in
heavy traffic or with a trailer.
33. EXHAUST SYSTEM
Visually inspect for cracks, holes or loose
supports.
If any change in the sound of the exhaust
or smell of the exhaust fumes is noticed,
have the cause located and corrected.

MA-23
MAINTENANCE

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
SERVICE DATA
Engine

Drive belt tension

Generator

PS

A/C

PS and A/C

Spark plug
Recommended spark plug
Correct electrode gap
Firing order
Valve clearance
Idle speed (w/ Cooling fan OFF)

Brake

Chassis

Front brake
Pad thickness
Disc thickness
Disc runout
Rear brake
Lining thickness
Drum inside diameter

Steering linkage
Steering wheel freeplay
Ball joint
Vertical play

New belt

160
20 Ibf

Used belt

100
20 lbf

New belt

160
25 lbf

Used belt

100
20 lbf

New belt

165
15 lbf

Used belt

110
20 lbf

New belt

160
20 lbf

Used belt

100
20 Ibf

ND
NGK

M/T
A/T

W16EXR-U1 1
BPR5EY11
1.1 mm (0.043 in.)
1-3-4-2
0.20 mm (0.008 in.)
750 rpm
800 rpm

Limit
Limit
Limit

1.0 mm (0.039 in.)

17.0 mm (0.669 in.)
0.09 mm (0.0035 in.)

Limit
Limit

1.0 mm (0.039 in.)

181 mm (7.126 in.)

Limit

30 mm (1.18 in.)

Limit

0.3 mm (0.012 in.)

TORQUE SPECIFICATIONS
Part tightened

N
m

kgf
cm

Spark plug x Cylinder head

180

Front seat x Body

375

ft
lbf