MAINTENANCE SECTION MA CONTENTS MAINTENANCE MA-1 PREPARATION... 3 PERIODIC MAINTENANCE... 4

Transcription

1 T ST T TTS PRPRT... 3 PRPRT... 3 Special Service Tool...3 ommercial Service Tool...3 PR T... 4 R T... 4 xplanation of eneral aintenance...4 PR T... 6 ntroduction of Periodic aintenance...6 Schedule Schedule R US UR- TS...10 luids and ubricants...10 ngine il Recommendation...10 nti-reeze oolant ixture Ratio...11 T...12 RV TS...12 RV TS : xploded View...12 RV TS : hecking...12 RV TS : Tension djustment...12 T...12 T : nspection...12 T : raining...13 T : Refilling...13 T : lushing...15 RSRVR T P...15 RSRVR T P : nspection...15 RTR...16 RTR : nspection...16 U S...16 U S : nspection...17 R R TR...17 R R TR : Removal and nstallation : raining...17 : Refilling...17 TR...18 TR : Removal and nstallation...18 SPR PU...18 SPR PU : Removal and nstallation...19 SPR PU : nspection...19 VP VPR S...20 VP VPR S : nspection...20 SSS T...21 XUST SYST...21 XUST SYST : nspection...21 /T U...21 /T U : nspection...21 TRSR U...21 TRSR U : nspection...21 TRSR U : raining...21 TRSR U : Refilling...22 RT PRPR ST: 2 P RT PRPR ST: 2 P15 : nspection...22 RR PRPR ST: 2 P RR PRPR ST: 2 P26 : nspection...23 RR PRPR ST: 2S RR PRPR ST: 2S1410 : nspection...23 RT RT R : R RT RT R : R180 : nspection

2 RT RT R : R180 : raining RT RT R : R180 : Refilling RR RT R : R RR RT R : R230 : nspection RR RT R : R230 : raining RR RT R : R230 : Refilling WS ( WT TYP) WS ( WT TYP) : djustment R U V S R U V S : nspection R S S R S S : nspection R U R U : leeding rake System S R S R : nspection S R : ront isc rake S R : Rear isc rake STR R STR R : nspection PWR STR U S PWR STR U S : nspection X SUSPS PRTS X SUSPS PRTS : nspection RV ST RV ST : nspection Y T S, S T S, S T : ubricating ST T, US, RTRTRS, - RS USTRS ST T, US, RTRTRS, - RS USTRS : nspection SRV T SPTS (SS) SRV T SPTS (SS) RV TS RV TS : rive elts T T : Periodical aintenance Specification : Periodical aintenance Specification SPR PU SPR PU : Spark Plug R W R W : Road Wheel

3 < PRPRT > PRPRT PRPRT PRPRT Special Service Tool : Tool number (SPX-orth merica o.) Tool name escription V (-38956) il filter wrench Removing and installing oil filter a: 64.3 mm (2.531 in) ommercial Service Tool S-T375 : Tool name escription Power tool oosening nuts and bolts P0190 Spark plug wrench Removing and installing spark plug a : 14 mm (0.55 in) P0399ZZ -3

4 PR T R T xplanation of eneral aintenance R T : eneral maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform checks and inspections themselves or have their T dealers do them. UTS T V The maintenance items listed here should be performed from time to time, unless otherwise specified. tem Tires Wheel nuts Tire rotation Tire Pressure onitoring System (TPS) transmitter components Wheel alignment and balance Windshield Windshield wiper blades oors and engine hood amps S T V heck the pressure with a gauge often and always prior to long distance trips. djust the pressure in all tires, including the spare, to the pressure specified. heck carefully for damage, cuts or excessive wear. When checking the tires, make sure no nuts are missing, and check for any loose nuts. Tighten if necessary. Tires should be rotated every 12,000km (7,500 miles). f the vehicle is equipped with different sized tires in the front and rear, tires cannot be rotated. Replace the TPS transmitter grommet seal, valve core and cap when the tires are replaced due to wear or age. f the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. f the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. Reference page The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. tem Reference page Warning lamps and chimes Windshield wiper and washer Windshield defroster Steering wheel lean the windshield on a regular basis. heck the windshield at least every six months for cracks or other damage. Repair as necessary. WT-69 WT-63 WT-66 SU-7 RSU-6 heck for cracks or wear if they do not wipe properly. heck that all doors and the engine hood operate smoothly as well as the back door. lso make sure that all latches lock securely. ubricate if necessary. ake sure that the secondary latch keeps the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check lubrication frequently. ake sure that the headlamps, stop lamps, tail lamps, turn signal lamps, and other lamps are all operating properly and installed securely. lso check headlamp aim. lean the headlamps on a regular basis. ake sure that all warning lamps and chimes are operating properly. heck that the wipers and washer operate properly and that the wipers do not streak. heck that the air comes out of the defroster outlets properly and in sufficient quantity when operating the heater or air conditioner. heck that it has the specified play. heck for changes in the steering condition, such as excessive play, hard steering or strange noises. ree play: ess than 35 mm (1.38 in) -34-4

5 R T tem Seats heck seat position controls such as seat adjusters, seatback recliner, etc. to make sure they operate smoothly and that all latches lock securely in every position. heck that the head restrains move up and down smoothly and that the locks (if equipped) hold securely in all latched positions. heck that the latches lock securely for folding-down rear seatbacks. Reference page Seat belts heck that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. heck the belt webbing for cuts, fraying, wear or damage. -34 ccelerator pedal heck the pedal for smooth operation and make sure the pedal does not catch or require uneven effort. eep the floor mats away from the pedal. rakes heck that the brake does not pull the vehicle to one side when applied. rake pedal and booster heck the pedal for smooth operation and make sure it has the proper distance under it when depressed fully. heck the brake booster function. e sure to keep the floor mats away from the pedal. R-7 R-15 Parking brake utomatic transmission Park mechanism UR T V heck that the lever or pedal has the proper travel and make sure that the vehicle is held securely on a fairly steep hill when only the parking brake is applied. heck that the lock release button on the selector lever operates properly and smoothly. n a fairly steep hill check that the vehicle is held securely with the selector lever in the P (Park) position without applying any brakes. The maintenance items listed here should be checked periodically (e.g. each time you check the engine oil or refuel). tem P-3 Reference page Windshield washer fluid heck that there is adequate fluid in the tank. ngine coolant level heck the coolant level when the engine is cold. -12 Radiator and hoses heck the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. ake sure the hoses have no cracks, deformation, deterioration or loose connections. -16 rake fluid levels attery ake sure that the brake fluid level is between the X and lines on the reservoir(s). heck the fluid level in each cell. t should be between the X and lines. Vehicles operated in high temperatures or under severe conditions require frequent checks of the battery fluid level. -28 P-159 ngine drive belts ake sure that no belt is frayed, worn, cracked or oily. -12 ngine oil level Power steering fluid level and lines heck the level on the oil level gauge after parking the vehicle on a level spot and turning off the engine. heck the level on the dipstick with the engine off. heck the lines for improper attachment, leaks, cracks, etc. U-7-32 xhaust system ake sure there are no loose supports, cracks or holes. f the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it. -21 Underbody The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. t is very important to remove these substances, otherwise rust will form on the floor pan, frame, fuel lines and around the exhaust system. t the end of winter, the underbody should be thoroughly flushed with plain water, being careful to clean those areas where mud and dirt can easily accumulate. luid leaks heck under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. f you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. -5

6 PR T ntroduction of Periodic aintenance PR T : Two different maintenance schedules are provided, and should be used, depending upon the conditions in which the vehicle is mainly operated. fter 60,000 miles (96,000 km) or 48 months, continue the periodic maintenance at the same mileage/time intervals. Schedule 1 Schedule 2 Schedule 1 ollow Periodic aintenance Schedule 1 if the driving habits frequently include one or more of the following driving conditions: Repeated short trips of less than 5 miles (8 km). Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below freezing. perating in hot weather in stop-and-go rush hour traffic. xtensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door delivery use. riving in dusty conditions. riving on rough, muddy, or salt spread roads. Towing a trailer, using a camper or a car-top carrier. ollow Periodic aintenance Schedule 2 if none of driving conditions shown in Schedule 1 apply to the driving habits. mission ontrol System aintenance hassis and ody aintenance mission ontrol System aintenance hassis and ody aintenance -6-8 : SS TR SYST bbreviations: R = Replace. = nspect. orrect or replace if necessary. [ ]: t the mileage intervals only T PRT T TRV Reference Perform at number of miles, iles x 1, Section - kilometers or months, whichever comes first. onths ontent (km x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) Page or - Title rive belts T (1) -12 ir cleaner filter T (2) [R] -17 VP vapor lines * -20 uel lines * -17 uel filter T (3) ngine coolant* T (4) -13 ngine oil R R R R R R R R -17 ngine oil filter (Use genuine SS engine oil filter or equivalent.) Spark plugs (ridium-tipped type) ntake & exhaust valve clearance* T (5) R R R R R R R R -18 Replace every 105,000 miles (168,000 km) T PRT T TRV Reference Perform at number of miles, iles x 1, Section - kilometers or months, whichever comes first. onths ontent (km x 1,000) (54) (60) (66) (72) (78) (84) (90) (96) Page or - Title rive belts T (1) * -12 ir cleaner filter T (2) [R] -17 VP vapor lines * -20 uel lines * -17-6

7 PR T T PRT T TRV Reference Perform at number of miles, iles x 1, Section - kilometers or months, whichever comes first. onths ontent (km x 1,000) (54) (60) (66) (72) (78) (84) (90) (96) Page or - Title uel filter T (3) ngine coolant* T (4) -13 ngine oil R R R R R R R R -17 ngine oil filter (Use genuine SS engine oil filter or equivalent.) Spark plugs (ridium-tipped type) ntake & exhaust valve clearance* T: (1) fter 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km) or 12 months. Replace the drive belts if found damaged or if the auto belt tensioner reading reaches the maximum limit. (2) f operating mainly in dusty conditions, more frequent maintenance may be required. (3) aintenance-free item. or service procedures, refer to section. (4) irst replacement interval is 105,000 miles (168,000 km) or 84 months. fter first replacement, replace every 75,000 miles (120,000 km) or 60 months. Use only enuine SS ong ife ntifreeze/oolant (blue) or equivalent with proper mixture ratio of 50% antifreeze and 50% demineralized or distilled water. ixing any other type of coolant or the use of non-distilled water will reduce the life expectancy of the factory-fill coolant. (5) Periodic maintenance is not required. owever, if valve noise increases, inspect valve clearance. * aintenance items and intervals with * are recommended by T for reliable vehicle operation. The owner need not perform such maintenance in order to maintain the emission warranty or manufacturer recall liability. ther maintenance items and intervals are required. SSS Y T (5) R R R R R R R R -18 Replace every 105,000 miles (168,000 km) bbreviations: R = Replace. = nspect. orrect or replace if necessary. T PRT T TRV Reference Perform at number of miles, iles x 1, Section - kilometers or months, (km x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) Page or - ontent whichever comes first. onths Title rake lines & cables -28 rake fluid R R -28 rake pads & rotors Transfer fluid & differential gear oil utomatic transmission fluid Steering gear & linkage, axle & suspension parts Tire rotation T (3) rive shaft boots and propeller shaft (4W models) T (1) -30 R-16 R-18 R-16 R T (2) WT

8 PR T T PRT T TRV Reference Perform at number of miles, iles x 1, Section - kilometers or months, (km x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) Page or - ontent whichever comes first. onths Title xhaust system -21 n-cabin microfilter R R VT-17 T PRT T TRV Reference Perform at number of miles, iles x 1, Section - Page kilometers or months, (km x 1,000) (54) (60) (66) (72) (78) (84) (90) (96) or - ontent whichever comes first. onths Title rake lines & cables -28 rake fluid R R -28 rake pads & rotors Transfer fluid & differential gear oil utomatic transmission fluid Steering gear & linkage, axle & suspension parts Tire rotation T (3) rive shaft boots and propeller shaft (4W models) T: (1) f towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) fluid /oil at every 30,000 miles (48,000 km) or 24 months. (2) utomatic transmission fluid is maintenance-free. (3) Refer to Tire rotation under the eneral maintenance heading earlier in this section. Schedule 2 SS TR SYST T (1) -30 R-16 R-18 R-16 R T (2) WT xhaust system -21 n-cabin microfilter R R VT-17 T PRT Perform at number of miles, kilometers or months, whichever comes first. : bbreviations: R = Replace. = nspect. orrect or replace if necessary. [ ]: t the mileage intervals only iles x 1,000 (km x 1,000) onths 7.5 (12) 6 15 (24) 12 T TRV Reference Section - Page or - ontent Title rive belts T (1) * -12 ir cleaner filter [R] [R] -17 VP vapor lines * * -20 uel lines * * -17 uel filter T (2) ngine coolant* T (3) (36) (48) (60) (72) (84) (96) 48-8

9 PR T T PRT Perform at number of miles, kilometers or months, whichever comes first. ngine oil R R R R R R R R -17 ngine oil filter (Use genuine SS engine oil filter or equivalent.) T: (1) fter 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km) or 12 months. Replace the drive belts if found damaged or if the auto belt tensioner reading reaches the maximum limit. (2) aintenance-free item. or service procedures, refer to section. (3) irst replacement interval is 105,000 miles (168,000 km) or 84 months. fter first replacement, replace every 75,000 miles (120,000 km) or 60 months. Use only enuine SS ong ife ntifreeze/oolant (blue) or equivalent with proper mixture ratio of 50% antifreeze and 50% demineralized or distilled water. ixing any other type of coolant or the use of non-distilled water will reduce the life expectancy of the factory-fill coolant. (4) Periodic maintenance is not required. owever, if valve noise increases, inspect valve clearance. * aintenance items and intervals with * are recommended by T for reliable vehicle operation. The owner need not perform such maintenance in order to maintain the emission warranty or manufacturer recall liability. ther maintenance items and intervals are required. SSS Y bbreviations: R = Replace. T: (1) utomatic transmission fluid is maintenance-free. (2) Refer to Tire rotation under the eneral maintenance heading earlier in this section. R R R R R R R R -18 Spark plugs (ridium-tipped type) Replace every 105,000 miles (168,000 km). -19 ntake & exhaust valve clearance* T PRT Perform at number of miles, kilometers or months, whichever comes first. iles x 1,000 (km x 1,000) onths T (4) iles x 1,000 (km x 1,000) onths 7.5 (12) (12) 6 15 (24) (24) 12 T TRV 22.5 (36) (48) (60) (72) 36 T TRV 52.5 (84) (96) 48 Reference Section - Page or - ontent Title -12 = nspect. orrect or replace if necessary. Reference Section - Page or - ontent Title rake lines & cables -28 rake fluid R R -28 rake pads & rotors Transfer fluid & differential gear oil 22.5 (36) (48) (60) (72) (84) (96) 48 utomatic transmission fluid T (1) Steering gear & linkage, axle & suspension parts Tire rotation T (2) rive shaft boots and propeller shaft (4W models) -30 R-16 R-18 R-16 R WT xhaust system -21 n-cabin microfilter R R R R VT-17-9

10 R US URTS < PR T > R US URTS luids and ubricants : ngine oil rain and refill apacity (pproximate) US measure mp measure iter With oil filter change 6-7/8 qt 5-3/4 qt 6.5 Without oil filter change 6-4/8 qt 5-1/2 qt 6.2 ry engine (engine overhaul) 8 qt 6-3/4 qt 7.6 Recommended luids/ubricants ngine oil with P ertification ark *1 Viscosity S 5W-30 ooling system With reservoir tank 15-6/8 qt 13-1/8 qt 14.9 enuine SS ong ife ntifreeze/ Reservoir tank 1 qt 7/8 qt 1.0 oolant (blue) or equivalent utomatic transmission fluid 10-5/8 qt *9 8-3/4 qt* * 9 enuine SS atic S T * 2 Power steering fluid 1-1/8 qt 7/8 qt 1.0 enuine SS PS or equivalent* 3 rake fluid Transfer fluid 3-1/8 pt 2-5/8 pt 1.5 ifferential gear oil *1: or further details, see ngine il Recommendation. *2: Using automatic transmission fluid other than enuine SS atic S T will cause deterioration in driveability and automatic transmission durability, and may damage the automatic transmission, which is not covered by the T new vehicle limited warranty. *3: XR V type T may also be used. *4: vailable in mainland U.S.. through an T dealer. *5: Using transfer fluid other than enuine SS Transfer luid will damage the transfer, which is not covered by the T new vehicle limited warranty. See an T retailer for recommended transfer fluid. *6: or hot climates, Viscosity S 90 is suitable for ambient temperatures above 0 (32 ) *7: See an T dealer for service for synthetic oil. *8: Using ydraulic Suspension fluid other than enuine SS ydraulic Suspension fluid will damage the ydraulic Suspension, which is not covered by the T new vehicle limited warranty. See an T retailer for recommended hydraulic suspension fluid. *9: The fluid capacity is the reference value. ngine il Recommendation ront 1-5/8 pt 1-3/8 pt 0.75 Rear 3/3/4 pt 3-1/8 pt 1.75 Suspension fluid enuine SS Super eavy uty rake luid* 4 or equivalent T 3 (US - VSS o. 116) enuine SS Transfer luid for TX90 transfer* 5 enuine SS ifferential il ypoid Super -5 80W-90 or P -5, Viscosity S 80W-90* 6 enuine SS ifferential il Synthetic 75W-90 or P -5 synthetic gear oil, Viscosity S 75W-90* 7 enuine SS ydraulic Suspension luid* 8 ulti-purpose grease o. 2 (ithium soap base) : SS recommends the use of an energy conserving oil in order to improve fuel economy. Select only engine oils that meet the merican Petroleum nstitute (P) certification and nternational ubricant Standardization and pproval ommittee (S) certification and S viscosity standard. These oils have the P certification mark on the front of the container. ils which do not have the specified quality label should not be used as they could cause engine damage. -10

11 R US URTS 1. P certification mark 2. P service symbol nti-reeze oolant ixture Ratio : The engine cooling system is filled at the factory with a high-quality, year-round, anti-freeze coolant solution. The anti-freeze solution contains rust and corrosion inhibitors. Therefore, additional cooling system additives are not necessary. or outside temperatures down to: enuine SS nti-freeze oolant or equivalent S1514 emineralized water or distilled water % 50% When adding or replacing coolant, be sure to use only enuine SS ong ife ntifreeze/oolant (blue) or equivalent with the proper mixture ratio of 50% anti-freeze and 50% demineralized or distilled water. ixing any other type of coolant or the use of non-distilled water will reduce the life expectancy of the factory-fill coolant. -11

12 T RV TS RV TS : xploded View T : P3264ZZ 1. rive belt 2. Power steering oil pump pulley 3. lternator pulley 4. rankshaft pulley 5. / compressor 6. dler pulley 7. ooling fan pulley 8. Water pump pulley 9. rive belt auto-tensioner. Possible use range. Range when new drive belt is installed. ndicator. View RV TS : hecking : WR: e sure to perform the these steps when engine is stopped. heck that the indicator () (notch on fixed side) of each auto-tensioner is within the possible use range (). T: heck the each auto-tensioners indication when the engine is cold. When new drive belts is installed, the indicator (notch on fixed side) should be within the range () in the figure. Visually check all drive belts for wear, damage or cracks. f the indicator (notch on fixed side) is out of the possible use range or drive belts are damaged, replace drive belts. RV TS : Tension djustment : Refer to -132, "rive elts". T T : nspection : V -12

13 T heck if the reservoir tank engine coolant level is within the to X when the engine is cool. : X : djust the engine coolant level if necessary. WR: ever remove reservoir tank cap when engine is hot. To check for leakage, apply pressure to the cooling system with the radiator cap tester and radiator cap tester adapter (commercial service tool) (). Testing pressure WR: ever remove radiator cap and reservoir tank cap when engine is hot. Serious burns could occur from high-pressure engine coolant escaping from water inlet. igher test pressure than specified may cause radiator damage. T: n a case that engine coolant decreases, fill radiator with engine coolant. f anything is found, repair or replace damaged parts. T : raining : Refer to -23, "Radiator". P0102ZZ P3432ZZ : WR: ever remove radiator cap and reservoir tank cap when engine is hot. Serious burns could occur from high-pressure engine coolant escaping from radiator. Wrap a thick cloth around the caps. Slowly turn them a quarter of a turn to release built-up pressure. arefully remove the caps by turning it all the way. 1. pen radiator drain plug (1) at the bottom of radiator, and then remove radiator cap and reservoir tank cap. 2 : ront under cover : Vehicle front P3430ZZ When draining all of engine coolant in the system, open water drain plug on cylinder block. Refer to -103, "Setting". 2. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing. 3. heck drained engine coolant for contaminants such as rust, corrosion or discoloration. f contaminated, flush the engine cooling system. Refer to -15, " T : lushing". T : Refilling : nstall reservoir tank if removed, and radiator drain plug. e sure to clean drain plug and install with new -ring. Refer to -13, "xploded View". -13

14 T : 1.96 m (0.2 kg-m, 17 in-lb) f water drain plug on cylinder block is removed, close and tighten it. Refer to -107, "isassembly and ssembly". 2. heck that each hose clamp is firmly tightened. 3. Remove air relief plug (1) on heater hose. 2. ngine cover : Vehicle front 4. ill radiator, and reservoir tank, to specified level. Pour engine coolant through engine coolant filler neck slowly of less than 3 (2-5/8 lmp qt) a minute to allow air in system to escape. Use enuine SS ong ife ntifreeze/oolant or equivalent mixed with water (distilled or demineralized). Refer to -10, "luids and ubricants". P3429ZZ ngine coolant capacity (With reservoir tank at X level) : Refer to -23, "Periodical aintenance S pecification". P0412ZZ Reservoir tank engine coolant capacity (t X level) :Refer to -23, "Periodical aintenance Sp ecification". : X : P0102ZZ 5. When engine coolant overflows air relief hole on heater hose, install air relief plug with clamp. Then refill radiator with engine coolant. 6. nstall radiator cap. 7. nstall reservoir tank cap. 8. Warm up engine until opening thermostat less than 3,000 rpm. heck thermostat opening condition by touching radiator hose (lower) to see a flow of warm water. Watch water temperature gauge so as not to overheat engine. 9. Stop the engine and cool down to less than approximately 50 (122 ). ool down using fan to reduce the time. f necessary, refill radiator up to filler neck with engine coolant. 10. Refill reservoir tank to X level line with engine coolant if necessary. 11. Repeat steps 6 through 10 two or more times with reservoir tank cap installed until engine coolant level no longer drops. -14

15 T 12. heck cooling system for leakage with engine running. 13. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to 3,000 rpm with heater temperature controller set at several position between and WR. Sound may be noticeable at heater unit. 14. Repeat step 13 three times. 15. f sound is heard, bleed air from cooling system by repeating step 4, and steps from 6 to 14 until engine coolant level no longer drops. T : lushing 1. nstall reservoir tank if removed, and radiator drain plug. e sure to clean drain plug and install with new -ring. Refer to -13, "xploded View". : 1.96 m (0.2 kg-m, 17 in-lb) : f water drain plug on cylinder block is removed, close and tighten it. Refer to -107, "isassembly and ssembly". 2. Remove air relief plug (1) on heater hose. 2. ngine cover : Vehicle front P3429ZZ 3. ill radiator and reservoir tank with water until water spills from the air relief holes, then close air relief plugs with clamp. ill radiator and reservoir tank with water and reinstall caps. 4. Run the engine and warm it up to normal operating temperature. 5. Rev the engine two or three times under no-load. 6. Stop the engine and wait until it cools down. 7. rain water from the system. Refer to -13, " T : raining". 8. Repeat steps 1 through 7 until clear water begins to drain from radiator. RSRVR T P RSRVR T P : nspection heck valve seat of reservoir tank cap. - heck if valve seat () is swollen to the extent that the edge of the metal plunger () cannot be seen when watching it vertically from the top. - heck if valve seat has no soil and damage. : P0108ZZ -15

16 T Pull negative-pressure valve to open it, and check that it close completely when released. - heck that there is no dirt or damage on the valve seat of reservoir tank cap negative-pressure valve. - heck that there are no unusualness in the opening and closing conditions of negative-pressure valve. S967 heck reservoir tank cap relief pressure. - When connecting reservoir tank cap to the radiator cap tester (commercial service tool) and the radiator cap tester adapter (commercial service tool) (), apply engine coolant to the cap seal surface. Standard and limit : Refer to -23, "Radiator". P0109ZZ Replace reservoir tank cap if there is an unusualness related to the above three. When installing reservoir tank cap, thoroughly wipe out the water inlet filler neck to remove any waxy residue or foreign material. RTR RTR : nspection : heck radiator for mud or clogging. f necessary, clean radiator as per the following: e careful not to bend or damage radiator fins. When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan shroud. Then tape harness and connectors to prevent water from entering. 1. pply water by hose to the back side of the radiator core vertically downward. 2. pply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from radiator. 4. low air into the back side of radiator core vertically downward. Use compressed air lower than 490 kpa (4.9 bar, 5 kg/cm 2, 71 psi) and keep distance more than 30 cm (11.8 in). 5. low air again into all the radiator core surfaces once per minute until no water sprays out. U S -16

17 U S : nspection T nspect fuel lines, fuel filler cap and fuel tank for improper attachment, leakage, cracks, damage, loose connections, chafing or deterioration. : ngine : uel line : uel tank f necessary, repair or replace damaged parts. R R TR R R TR : Removal and nstallation : P0129ZZ : RV T: The viscous paper type filter does not need cleaning between replacement intervals. Replace the air filter as necessary for periodic maintenance. Refer to -6, "ntroduction of Periodic aintenance". 1. Unhook clips, and lift air cleaner case (upper). 2. Remove air cleaner filter from air cleaner case. STT nstall is the reverse order of removal. : raining : WR: e careful not to burn yourself, as the engine and engine oil may be hot. Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. f skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up the engine, and check for any oil leaks. 2. Stop the engine and wait for at least 10 minutes. 3. Remove drain plug and oil filler cap to drain the old oil. : Refilling 1. nstall drain plug with new washer. e sure to clean drain plug and install with new washer. Tightening torque 2. Refill with new engine oil. ngine oil specification and viscosity: Refer to -10, "luids and ubricants". : Refer to -54, "xploded View". : ngine oil capacity : Refer to U-17, "Periodical aintenance Specification". The refill capacity depends on the engine oil temperature and drain time. Use these specifications for reference only. lways use oil level gauge to determine the proper amount of engine oil in engine. -17

18 T 3. Warm up the engine and check area around drain plug and oil filter for engine oil leakage. 4. Stop the engine and wait for 10 minutes. 5. heck the engine oil level. Refer to U-7, "nspection". TR TR : Removal and nstallation RV 1. Remove front under cover. 2. rain engine oil. Refer to -17, " : raining". 3. Remove oil filter using oil filter wrench [SST: V ( )]. WR: e careful not to burn yourself, as the engine and engine oil may be hot. The oil filter is equipped with a pressure relief valve. Use enuine SS oil filter or equivalent. When removing, prepare a shop cloth to absorb any engine oil leaks or spills. o not allow engine oil to adhere to the drive belts. ompletely wipe off any engine oil that adheres to the engine and the vehicle. STT 1. Remove foreign materials adhering to the oil filter seal mating surface. 2. pply clean engine oil to the oil filter seal circumference of the new oil filter as shown. : W0388 S Screw on the oil filter manually until it touches the installation surface, then tighten it by 2/3 turn as shown. r tighten to specification. il filter : 17.7 m (1.8 kg-m, 13 ft-lb) S Refill engine with new engine oil. Refer to -17, " : Refilling". 5. nspect engine for oil leaks. Refer to U-7, "nspection". 6. nstall front under cover. SPR PU -18

19 SPR PU : Removal and nstallation RV T 1. Remove engine cover. Refer to -25, "xploded View". 2. Remove ignition coil. Refer to -29, "xploded View". 3. Remove spark plug with a spark plug wrench (commercial service tool). a : 14 mm (0.55 in) : STT ote the following item, installa is the reverse order of removal. nstall ignition coil marked with an identification mark () on cylinder o. 5, 6, 7 and 8. : ngine front P0030ZZ SPR PU : nspection SPT TR RV Use the standard type spark plug for normal condition. Spark plug (Standard type) ever drop or impact spark plug. ever use a wire brush for cleaning. f plug tip is covered with carbon, use spark plug cleaner to clean. leaner air pressure : Refer to -132, "Spark Plug". : ess than 588 kpa (5.9 bar, 6 kg/cm 2, 85 psi) leaning time : ess than 20 seconds P3471ZZ : S773 easure spark plug gap. When it exceeds the limit, replace spark plug even if it is within the specified replacement mileage. Refer to -132, "Spark Plug". -19

20 T Spark plug gap adjustment is not required between replacement intervals. VP VPR S VP VPR S : nspection P0031ZZ : Visually inspect VP vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration. 2. nspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc. Refer to -532, "nspection". -20

21 SSS T XUST SYST XUST SYST : nspection SSS T heck exhaust pipes, muffler and mounting for improper attachment, leakage, cracks, damage or deterioration. f damage is found, repair or replace damaged parts. : /T U /T U : nspection U heck transaxle surrounding area (oil seal and plug etc.) for fluid leakage. f anything is found, repair or replace damaged parts and adjust / T fluid level. Refer to T-95, "djustment". S211 : TRSR U TRSR U : nspection U heck transfer surrounding area (oil seal, drain plug, and filler plug etc.) for fluid leakage. U V 1. Remove filler plug (1) and gasket. Then check that fluid is filled up from mounting hole for the filler plug. ever start engine while checking fluid level. 2. Set a new gasket onto filler plug (1), and install it on transfer and then tighten to the specified torque. Specified torque ever reuse gasket. TRSR U : raining : 33 m (3.4 kg-m, 24 ft-lb) 1. Run the vehicle to warm up the transfer unit sufficiently. 2. Stop the engine. S1912ZZ : P0295ZZ :

22 SSS T 3. Remove the drain plug (1) and drain transfer fluid. 4. Set a new gasket onto drain plug (1), and install it to transfer and tighten to the specified torque. Specified torque ever reuse gasket. : 33 -m (3.4 kg-m, 24 ft-lb) TRSR U : Refilling P0245ZZ : Remove filler plug (1). ill up with new transfer fluid up to mounting hole for the filler plug. luid grade and Viscosity luid capacity arefully fill the fluid. (ill up for approximately 3 minutes.) 2. eave the vehicle for 3 minutes, and check the fluid level again. 3. Set a new gasket onto filler plug, and install it on transfer and tighten to the specified torque. Specified torque : Refer to -10, "luids and ubricants". : Refer to -124, "eneral Specifications". : 33 -m (3.4 kg-m, 24 ft-lb) ever reuse gasket. 4. Perform learning of transfer fluid viscosity. Refer to -47, "Work Procedure". RT PRPR ST: 2 P15 RT PRPR ST: 2 P15 : nspection P0295ZZ : S heck the propeller shaft tube surface for dents or cracks. f damaged, replace propeller shaft assembly. VRT f vibration is present at high speed, inspect propeller shaft runout first. 1. With a dial indicator, measure propeller shaft runout at runout measuring points by rotating final drive companion flange with hands. : Vehicle front Propeller shaft runout : Refer to -133, "Propeller Shaft Runout". 2. f runout still exceeds specifications, separate propeller shaft at final drive companion flange; then rotate companion flange 90, 180, 270 degrees and install propeller shaft. 3. heck runout again. f runout still exceeds specifications, replace propeller shaft assembly. 4. heck the vibration by driving vehicle. RUUT SUR PT

23 Propeller shaft runout measuring point (Point ). : Vehicle front SSS T imension : mm ( in) : mm ( in) : mm (10.02 in) RR PRPR ST: 2 P26 RR PRPR ST: 2 P26 : nspection : S heck the propeller shaft tube surface for dents or cracks. f damaged, replace propeller shaft assembly. VRT f vibration is present at high speed, inspect propeller shaft runout first. 1. With a dial indicator, measure propeller shaft runout at runout measuring points by rotating final drive companion flange with hands. : Vehicle front Propeller shaft runout 2. f runout still exceeds specifications, separate propeller shaft at final drive companion flange; then rotate companion flange 90, 180, 270 degrees and install propeller shaft. 3. heck runout again. f runout still exceeds specifications, replace propeller shaft assembly. 4. heck the vibration by driving vehicle. RUUT SUR PT Propeller shaft runout measuring point (Point ). : Vehicle front : Refer to -140, "Propeller Shaft Runout". P0321ZZ 0161 imension : mm ( in) : mm ( in) : mm (27.70 in) RR PRPR ST: 2S1410 RR PRPR ST: 2S1410 : nspection : S heck the propeller shaft tube surface for dents or cracks. f damaged, replace propeller shaft assembly. VRT P0320ZZ -23

24 SSS T f vibration is present at high speed, inspect propeller shaft runout first. 1. With a dial indicator, measure propeller shaft runout at runout measuring points by rotating final drive companion flange with hands. Propeller shaft runout : Refer to -147, "Propeller Shaft Runout". 2. f runout still exceeds specifications, separate propeller shaft at final drive companion flange; then rotate companion flange 90, 180, 270 degrees and install propeller shaft. 3. heck runout again. f runout still exceeds specifications, replace propeller shaft assembly. 4. heck the vibration by driving vehicle. RUUT SUR PT Propeller shaft runout measuring range : Vehicle front RT RT R : R180 RT RT R : R180 : nspection P0320ZZ : heck that oil is not leaking from the front final drive assembly or around it. V Remove filler plug (1) and check oil level from filler plug mounting hole as shown in the figure. ever start engine while checking oil level. Set a gasket on filler plug (1) and install it on final drive assembly. Refer to -164, "xploded View". ever reuse gasket. RT RT R : R180 : raining P0312ZZ : Stop engine. -24

25 SSS T 2. Remove drain plug (1) and drain gear oil. 3. Set a gasket on drain plug (1) and install it to final drive assembly and tighten to the specified torque. Refer to -164, "xploded View". ever reuse gasket. RT RT R : R180 : Refilling 1. Remove filler plug (1). ill with new gear oil until oil level reaches the specified level near filler plug mounting hole. P0313ZZ : il grade and Viscosity il capacity : Refer to -10, "luids and ubricants". : Refer to -185, "eneral Specifications". 2. fter refilling oil, check oil level. Set a gasket to filler plug (1), then install it to final drive assembly. Refer to -164, "xploded View". ever reuse gasket. RR RT R : R230 RR RT R : R230 : nspection heck that differential gear oil is not leaking from the rear final drive assembly or around it. V Remove filler plug (1) and check oil level from filler plug mounting hole as shown in the figure. ever start engine while checking oil level. Set a gasket on filler plug (1) and install it on final drive assembly. Refer to -203, "xploded View". ever reuse gasket. P0312ZZ : RR RT R : R230 : raining 1. Stop the engine. P0415ZZ :

26 SSS T 2. Remove drain plug (1) and drain gear oil. 3. Set a gasket on drain plug (1) and install it to final drive assembly and tighten to the specified torque. Refer to -203, "xploded View". ever reuse gasket. RR RT R : R230 : Refilling P0392ZZ : Remove filler plug (1). ill with new gear oil until oil level reaches the specified level near filler plug mounting hole. il grade and viscosity il capacity : Refer to -10, "luids and ubricants". : Refer to -222, "eneral Specification". 2. fter refilling oil, check oil level. Set a gasket to filler plug (1), then install it to final drive assembly. Refer to -203, "xploded View". ever reuse gasket. WS ( WT TYP) WS ( WT TYP) : djustment P0415ZZ : WS ( WT TYP) Preparation efore djustment Using releasing agent, remove double-faced adhesive tape from the road wheel. e careful not to scratch the road wheel during removal. fter removing double-faced adhesive tape, wipe clean traces of releasing agent from the road wheel. Wheel alance djustment f a tire balance machine has adhesion balance weight mode settings and drive-in weight mode setting, select and adjust a drive-in weight mode suitable for road wheels. 1. Set road wheel on tire balance machine using the center hole as a guide. Start the tire balance machine. 2. When inner and outer unbalance values are shown on the tire balance machine indicator, multiply outer unbalance value by 5/3 to determine balance weight that should be used. Select the outer balance weight with a value closest to the calculated value above and install to the designated outer position of, or at the designated angle in relation to the road wheel. ever install the inner balance weight before installing the outer balance weight. efore installing the balance weight, always to clean the mating surface of the road wheel. -26

27 SSS T a. ndicated unbalance value 5/3 = balance weight to be installed alculation example: 23 g (0.81 oz) 5/3 = g (1.35 oz) 37.5 g (1.32 oz) balance weight (closer to calculated balance weight value) T: ote that balance weight value must be closer to the calculated balance weight value. xample: g (1.23 oz) g (1.32 oz) b. nstalled balance weight in the position. When installing balance weight (1) to road wheels, set it into the grooved area () on the inner wall of the road wheel as shown in the figure so that the balance weight center () is aligned with the tire balance machine indication position (angle) (). lways use genuine SS adhesion balance weights. alance weights are non-reusable; always replace with new ones. ever install more than four sheets of balance weight. S054 c. f calculated balance weight value exceeds 50 g (1.76 oz), install two balance weight sheets in line with each other as shown in the figure. ever install one balance weight sheet on top of another. 3. Start the tire balance machine again. 4. nstall drive-in balance weight on inner side of road wheel in the tire balance machine indication position (angle). ever install more than two balance weight. 5. Start the tire balance machine. heck that the inner and outer residual unbalance value is within the allowable unbalance value. f either residual unbalance value exceeds limit, repeat installation procedures. P0040ZZ P0033 llowable unbalance value ynamic (t flange) : Refer to WT-69, "Road Wheel". Static (t flange) : Refer to WT-69, "Road Wheel". R U V S -27

28 SSS T R U V S : nspection : heck that the fluid level in the sub tank is within the specified range (X lines). Turn the ignition switch and depress the brake pedal 20 times or more to check brake fluid level. T: Since brake fluid is in the accumulator in pressurized condition, the reservoir tank brake fluid level should be lower than the X line. Visually check for any brake fluid leakage around the reservoir tank. heck the brake system for any leakage if the fluid level is extremely low (lower than ). heck the brake system for fluid leakage if the warning lamp remains illuminated even after the parking brake is released. heck the sub tank for the mixing of foreign matter (e.g. dust) and oils other than brake fluid. R S S R S S : nspection : heck brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. 2. epress the brake pedal with a force of 490 (50 kg, 110lb) and hold down the pedal for approx. 5 seconds with the engine running. heck for any fluid leakage. Retighten the applicable connection to the specified torque and repair any abnormal (damaged, worn or deformed) part if any brake fluid leakage is present). R U R U : leeding rake System SR389 : leed air in the following order: motor/accumulator assembly front right brake front left brake rear left brake and rear right brake. The V warning lamp, S warning lamp and brake warning lamp turn and T 118 may be detected in self-diagnosis result for S with SUT- when the brake pedal is excessively operated, such as air bleeding. This is not a system malfunction because this occurs due to the temporary decrease in accumulator fluid pressure. The system returns to normal condition when the accumulator fluid pressure reaches the specified pressure with the ignition switch and the V warning lamp, S warning lamp, and brake warning lamp turn. fter these steps, erase selfdiagnosis results for S with SUT-. - T other than 118 is detected: Refer to R-51, "T ndex". T: When the ignition switch is, the brake warning lamp may turns even when the parking brake pedal is released with the brake fluid within the specified level. This indicates the decrease in accumulator fluid pressure. TR/UUTR SSY f the brake fluid adheres to the brake caliper assembly and disc rotor, quickly wipe it off. ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. ever operate the brake pedal with the reservoir cap removed. ailure to do this may cause the scattering of brake fluid. ever operate the brake pedal excessively during the work procedure. onitor the fluid level in the reservoir tank while performing the air bleeding. -28

29 SSS T leed air in the following order: motor/accumulator assembly front right brake front left brake rear left brake and rear right brake. 1. Turn the ignition switch. 2. epress the brake pedal 20 times or more. 3. heck that there is no foreign material in the reservoir tank, and refill with new brake fluid. ever reuse drained brake fluid. ever allow oils other than brake fluid to enter the reservoir tank. 4. Turn the ignition switch. T: The motor is activated and automatically stops. 5. Turn the ignition switch. 6. epress the brake pedal 20 times or more. T: The pressure loss in the accumulator results in a large brake pedal stroke. n addition to this, the brake pedal depression becomes lighter in initial stage. 7. Repeat steps 4 to 6 for 5 times. 8. Turn the ignition switch to check that the time between motor activation and automatic stop is less than 18 seconds. f the time is 18 seconds or more, repeat from Step 4 to 8. RT R f the brake fluid adheres to the brake caliper assembly and disc rotor, quickly wipe it off. ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. ever operate the brake pedal with the reservoir cap removed. ailure to do this may cause the scattering of brake fluid. ever operate the brake pedal excessively during the work procedure. onitor the fluid level in the reservoir tank while performing the air bleeding. leed air in the following order: motor/accumulator assembly front right brake front left brake rear left brake and rear right brake. 1. Turn the ignition switch. 2. epress the brake pedal 20 times or more. T: The pressure loss in the accumulator results in a large brake pedal stroke. n addition to this, the brake pedal depression becomes lighter in initial stage. 3. heck that there is no foreign material in the reservoir tank, and refill with new brake fluid. ever reuse drained brake fluid. ever allow oils other than brake fluid to enter the reservoir tank. 4. Turn the ignition switch. 5. onnect a vinyl tube to the bleed valve. 6. epress the brake pedal and loosen the bleeder valve. 7. Repeat steps 1 to 6 until all of the air is out of the brake line and tighten the air bleeder to the specified torque with the brake pedal depressed. Refer to R-36, "R PR SSY : xploded View". 8. heck that no drag feel is present for the front disc brake. Refer to R-39, "R PR SSY : nspection". 9. heck each item of brake pedal. djust it if the measurement value is not the standard. Refer to R-7, "nspection and djustment". RR R f the brake fluid adheres to the brake caliper assembly and disc rotor, quickly wipe it off. ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. ever operate the brake pedal with the reservoir cap removed. ailure to do this may cause the scattering of brake fluid. -29

30 SSS T ever operate the brake pedal excessively during the work procedure. onitor the fluid level in the reservoir tank while performing the air bleeding. leed air in the following order: motor/accumulator assembly front right brake front left brake rear left brake and rear right brake. 1. Turn the ignition switch. 2. epress the brake pedal 20 times or more. T: The pressure loss in the accumulator results in a large brake pedal stroke. n addition to this, the brake pedal depression becomes lighter in initial stage. 3. heck that there is no foreign material in the reservoir tank, and refill with new brake fluid. ever reuse drained brake fluid. ever allow oils other than brake fluid to enter the reservoir tank. 4. Turn the ignition switch. 5. onnect a vinyl tube to the bleed valve. 6. epress the brake pedal and loosen the bleeder valve. 7. epress and hold the brake pedal depression to discharge 100 cc of brake fluid before tightening the air bleeder to the specified torque. Refer to R-42, "R PR SSY : xploded View". T: Since brake fluid is conveyed by the motor, the brake pedal is not necessarily depressed. 8. Release the brake pedal. 9. Repeat steps 1 to 8 until all of the air is out of the brake line and tighten the air bleeder to the specified torque with the brake pedal depressed. Refer to R-42, "R PR SSY : xploded View". 10. heck that no drag feel is present for the rear disc brake. Refer to R-45, "R PR SSY : nspection". 11. heck each item of brake pedal. djust it if the measurement value is not the standard. Refer to R-7, "nspection and djustment". R U V USTT TR R 1. Turn the ignition switch. 2. epress the brake pedal 20 times or more. T: The pressure loss in the accumulator results in a large brake pedal stroke. n addition to this, the brake pedal depression becomes lighter in initial stage. 3. djust brake fluid level to the reservoir tank X line. ever adjust with the ignition switch. 4. Turn the ignition switch. 5. heck that the reservoir tank brake fluid level is 4 12 mm ( in) lower than the X line. T: Since brake fluid is in the accumulator in pressurized condition, the reservoir tank brake fluid level should be lower than the X line. S R S R : nspection P0769ZZ : S RTR heck condition, wear, and damage. PR heck for leakage. -30