MAINTENANCE SECTION MA CONTENTS MAINTENANCE MA-1 SERVICE INFORMATION... 3

Transcription

1 T ST T TTS SRV RT... 3 RUTS... 3 recaution for Supplemental Restraint System (SRS) "R " and "ST LT R-T- SR"...3 recaution ecessary for Steering Wheel Rotation fter attery isconnect...3 RRT... 4 Special Service Tool...4 ommercial Service Tool...4 RL T... 6 xplanation of eneral aintenance...6 eneral aintenance...6 R T... 8 ntroduction of eriodic aintenance...8 Schedule Schedule R LUS LUR- TS...14 R QR ngine il Recommendation...15 nti-freeze oolant ixture Ratio...16 T (R20)...17 RV LTS...17 RV LTS : omponent...17 RV LTS : hecking rive elts...17 RV LTS : Tension djustment...17 LT...17 LT : nspection...17 LT : hanging ngine oolant...19 UL LS...21 UL LS : hecking uel Line...21 R LR LTR...21 R LR LTR : omponent...21 R LR LTR : hanging ir leaner ilter...22 L...22 L : nspection...22 L : hanging ngine il...23 L LTR...24 L LTR : Removal and nstallation...24 SR LU...25 SR LU : omponent...26 SR LU : Removal and nstallation...26 V VR LS...28 V VR LS : hecking V Vapor Line...28 T (QR25 )...29 RV LT...29 RV LT : hecking rive elts...29 RV LT : Tension djustment...29 LT...29 LT : nspection...29 LT : hanging ngine oolant...31 UL LS...33 UL LS : hecking uel Line...33 R LR LTR...33 R LR LTR : Removal and nstallation...34 L...35 L : nspection...35 L : hanging ngine il...36 L LTR...37 L LTR : Removal and nstallation

2 SR LU SR LU : Removal and nstallation V VR LS V VR LS : hecking V Vapor Line SSS Y T hanging n-cabin icrofilter hecking xhaust System hecking VT luid hanging VT luid hecking lutch luid Level and Leaks hecking lutch System hanging /T il - RS694R hecking /T il - RS694R hanging /T il - RS652 and RS hecking /T il - RS652 and RS alancing Wheels Rotation hecking rake luid Level and Leaks hecking rake Line and ables hanging rake luid hecking isc rake xle and Suspension arts rive Shaft Lubricating Locks, inges and ood Latch hecking Seat elts, uckles, Retractors, nchors and djusters

3 SRV RT RUTS RUTS recaution for Supplemental Restraint System (SRS) "R " and "ST LT R-TSR" : The Supplemental Restraint System such as R and ST LT R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SRS and S section of this Service anual. WR: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized SS/T dealer. mproper maintenance, including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag odule, see the SRS section. o not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. When working near the irbag iagnosis Sensor Unit or other irbag System sensors with the gnition or engine running, T use air or electric power tools or strike near the sensor(s) with a hammer. eavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. When using air or electric power tools or hammers, always switch the gnition, disconnect the battery, and wait at least 3 minutes before performing any service. recaution ecessary for Steering Wheel Rotation fter attery isconnect -3 : T: This rocedure is applied only to models with ntelligent ey system and TS (SS T-TT SYS- T). Remove and install all control units after disconnecting both battery cables with the ignition knob in the L position. lways use SULT- to perform self-diagnosis as a part of each function inspection after finishing work. f T is detected, perform trouble diagnosis according to self-diagnostic results. or models equipped with the ntelligent ey system and TS, an electrically controlled steering lock mechanism is adopted on the key cylinder. or this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible. f steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation. RT RUR 1. onnect both battery cables. T: Supply power using jumper cables if battery is discharged. 2. Use the ntelligent ey or mechanical key to turn the ignition switch to the position. t this time, the steering lock will be released. 3. isconnect both battery cables. The steering lock will remain released and the steering wheel can be rotated. 4. erform the necessary repair operation. 5. When the repair work is completed, return the ignition switch to the L position before connecting the battery cables. (t this time, the steering lock mechanism will engage.) 6. erform a self-diagnosis check of all control units using SULT-.

4 RRT Special Service Tool RRT : The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. Tool number (ent-oore o.) Tool name V (-38956) il filter wrench escription Removing and installing oil filter a: 64.3 mm (2.531 in) S-T375 V (-23688) ngine coolant refractometer hecking concentration of ethylene glycol in engine coolant W ( ) Radiator cap tester adapter dapting radiator cap tester to radiator cap and radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) S-T564 V (-45695) oolant Refill Tool Refilling engine cooling system L ( ) Radiator cap tester adapter dapting radiator cap tester to radiator cap and radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) ommercial Service Tool S-T564 :

5 RRT (ent-oore o.) Tool name ower tool escription Loosening bolts and nuts 0190 Spark plug wrench Removing and installing spark plug

6 RL T xplanation of eneral aintenance eneral aintenance RL 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 they can have their SS dealers do them. UTS T VL The maintenance items listed here should be performed from time to time, unless otherwise specified. tem Tires Wheel nuts 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 specified pressure. 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. Reference page WT-27, "Tire" WT-8, "Rotation" Windshield lean the windshield on a regular basis. heck the windshield at least every six months for cracks or other damage. Repair as necessary. Tire rotation Tires should be rotated every 12,000 km (7,500 miles). WT-8, "Rotation" Tire pressure monitoring system (TS) transmitter components Wheel alignment and balance Windshield wiper blades oors and engine hood Lamps Replace the TS transmitter grommet seal, valve core and cap when the tires are replaced due to wear or age. f the vehicle pulls 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. WT-25, "Transmitter (ressure Sensor)" SU-18, "Wheel lignment (Unladen*)" and -45, "alancing Wheels" 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 trunk lid and back hatch. lso make sure that all latches lock securely. Lubricate 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. -50, "Lubricating Locks, inges and ood Latch" S T VL The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. tem Warning lamps and chimes Windshield wiper and washer Windshield defroster Steering wheel Seats Reference page 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 conditioning. heck that it has the specified play. e sure to check for changes in the steering condition, such as excessive play, hard steering or strange noises. ree play: Less than 35 mm (1.38 in) heck seat position controls such as seat adjusters, seat back recliner, etc. to make sure they operate smoothly and that all latches lock securely in every position. heck that the head restraints 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 seat backs. -6

7 RL T tem Seat belts ccelerator pedal 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. 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. Reference page S-8, "Seat elt nspection" lutch pedal ake sure the pedal operates smoothly and check that it has the proper free play. -43 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 floor mats away from the pedal. -46 and -47 arking brake VT (ark) position mechanism heck that the lever 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. n a fairly steep hill check that the vehicle is held securely with the selector lever in the position without applying any brakes. -4 UR T VL The maintenance items listed here should be checked periodically (e.g. each time you check the engine oil or refuel). tem Reference page Windshield washer fluid ngine coolant level / condenser, radiator and hoses heck that there is adequate fluid in the tank. heck the coolant level when the engine is cold. heck the front of the condenser and radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. ake sure the radiator hoses have no cracks, deformation, deterioration or loose connections rake and clutch fluid levels ake sure that the brake and clutch fluid levels are between the X and lines on the reservoirs. -46 and -43 attery 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. ngine drive belts ake sure that no belt is frayed, worn, cracked or oily ngine oil level heck the level on the dipstick after parking the vehicle on a level spot and turning off the engine 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. -41 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. -7

8 R T ntroduction of eriodic aintenance R 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 eriodic aintenance Schedule 1 if your driving habits frequently includes 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 eriodic aintenance Schedule 2 if none of the driving conditions shown in Schedule 1 apply to your driving habits. mission ontrol System aintenance hassis and ody aintenance mission ontrol System aintenance hassis and ody aintenance : mission ontrol System aintenance T RT erform at number of miles, kilometers or months, whichever comes first. iles x 1,000 (km x 1,000) onths rive belt T (1) bbreviations: R = Replace. = nspect. orrect or replace if necessary. [ ]: t the mileage intervals only 3.75 (6) (12) 6 T TRVL (18) 9 15 (24) (30) (36) (42) 21 ir cleaner filter T (2) [R] V vapor lines * 30 (48) 24 Reference Section - age or - ontent Title uel lines * uel filter T (3) ngine coolant T (4) ngine oil R R R R R R R R

9 R T T RT erform at number of miles, kilometers or months, whichever comes first. ngine oil filter (Use genuine SS oil filter or equivalent) iles x 1,000 (km x 1,000) onths 3.75 (6) (12) 6 T TRVL (18) 9 15 (24) (30) (36) (42) (48) 24 R R R R R R R R Reference Section - age or - ontent Title Spark plugs (ridiumtipped type) Replace every 105,000 miles (169,000 km) ntake and exhaust valve clearance * T (5) T RT erform at number of miles, kilometers or months, whichever comes first. rive belt ir cleaner filter iles x 1,000 (km x 1,000) onths T (1) T (2) bbreviations: R = Replace. = nspect. orrect or replace if necessary. [ ]: t the mileage intervals only (54) 27 T TRVL 37.5 (60) (66) (72) (78) (84) (90) 45 V vapor lines * uel lines * uel filter ngine coolant T (3) T (4) ngine oil R R R R R R R R ngine oil filter (Use genuine SS oil filter or equivalent) 60 (96) 48 R R R R R R R R * [R] R* Reference Section - age or - ontent Title

10 R T T RT erform at number of miles, kilometers or months, whichever comes first. Spark plugs (ridiumtipped type) ntake and exhaust valve clearance * iles x 1,000 (km x 1,000) onths T (5) (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, go to the L section. (4) fter 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months. (5) eriodic maintenance is not required. owever, if valve noise increases, inspect valve clearance. * aintenance items and intervals with * are recommended by SS 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. hassis and ody aintenance T RT erform at number of miles, kilometers or months, whichever comes first. iles x 1,000 (km x 1,000) onths (54) (6) 3 T TRVL 37.5 (60) (66) (72) (78) (84) 42 Replace every 105,000 miles (169,000 km) (90) (96) 48 Reference Section - age or - ontent Title bbreviations: R = Replace. = nspect. orrect or replace if necessary. L = Lubricate. 7.5 (12) (18) 9 T TRVL 15 (24) (30) (36) (42) (48) 24 Reference Section - age or - ontent Title rake lines & cables -47 rake pads, rotors, drums & linings -47 anual transaxle oil T (1) -43 (RS694R) -44 (RS652 and RS652) VT fluid T (2) -41 Steering gear & linkage, axle & suspension parts -49, - 49 Tire rotation T (3) -46 ront drive shaft boots -49 xhaust system -41 n-cabin microfilter R R

11 T RT erform at number of miles, kilometers or months, whichever comes first. R T bbreviations: R = Replace. = nspect. orrect or replace if necessary. L = Lubricate. (1) f towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil at every 30,000 miles (48,000 km) or 24 months. (2) f towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, inspect VT fluid deterioration with - SULT- every 60,000 miles (96,000 km), then change VT fluid S-2 if necessary. (Refer to VT section). f SULT- is not available, change (not just inspect) VT fluid S-2 every 60,000 miles (96,000 km). Using transmission fluid other than enuine SS VT luid S-2 will damage the VT, which is not covered by the SS new vehicle limited warranty. (3) Refer to Tire rotation under the RL T heading earlier in this section. Schedule 2 iles x 1,000 (km x 1,000) onths (54) 27 mission ontrol System aintenance 37.5 (60) (66) 33 T TRVL 45 (72) (78) (84) (90) (96) 48 Reference Section - age or - ontent Title rake lines & cables -47 rake pads, rotors, drums & linings -47 anual transaxle oil T (1) -43 (RS694R) -44 (RS652 and RS652) VT fluid T (2) -41 Steering gear & linkage, axle & suspension parts -49, -49 Tire rotation T (3) -46 ront drive shaft boots -49 xhaust system -41 n-cabin microfilter R R -40 T RT erform 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 TRVL rive belt T (1) * ir cleaner filter [R] [R] V vapor lines * * 22.5 (36) (48) (60) (72) (84) (96) 48 Reference Section - age or - ontent Title uel lines * * uel filter T (2) -11

12 R T T RT erform at number of miles, kilometers or months, whichever comes first. ngine coolant T (3) R* ngine oil R R R R R R R R ngine oil filter (Use genuine SS oil filter or equivalent.) Spark plugs (ridium-tipped type) ntake and exhaust valve clearance) * (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 belt if found damaged or if the auto belt tensioner reading reaches the maximum limit. (2) aintenance-free item. (3) fter 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months. (4) eriodic maintenance is not required. owever, if valve noise increases, inspect valve clearance. aintenance items and intervals with * are recommended by SS 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. hassis and ody aintenance T RT erform at number of miles, kilometers or months, whichever comes first. iles x 1,000 (km x 1,000) onths T (4) 7.5 (12) 6 iles x 1,000 (km x 1,000) onths 15 (24) 12 T TRVL 22.5 (36) (48) (60) (72) 36 R R R R R R R R Replace every 105,000 miles (169,000 km) 52.5 (84) (96) 48 Reference Section - age or - ontent Title bbreviations: R = Replace. = nspect. orrect or replace if necessary. L = Lubricate. 7.5 (12) 6 15 (24) 12 T TRVL 22.5 (36) (48) (60) (72) (84) (96) 48 Reference Section - age or - ontent Title rake lines & cables -47 rake pads, rotors, drums & linings -47 anual transaxle oil -43 (RS694R) -44 (RS652 and RS652) VT fluid T (1) -41 Steering gear & linkage, axle & suspension parts -49, -49 Tire rotation T (2) -46 ront drive shaft boots -49 xhaust system -41 n-cabin microfilter R R R R

13 R T (1) Using transmission fluid other than enuine SS VT luid S-2 will damage the VT, which is not covered by the S- S new vehicle limited warranty. (2) Refer to Tire rotation under the RL T heading earlier in this section. -13

14 R LUS LURTS < SRV RT > R LUS LURTS R20 : *1: or further details, see ngine il Recommendation. *2: f enuine SS gear oil is not available, L-4, Viscosity S 75W-80 may be used as a temporary replacement. owever, use enuine SS gear oil as soon as possible. *3: Using transaxle fluid other than enuine SS VT luid S-2 will damage the VT, which is not covered by the SS new vehicle limited warranty. *4: vailable in mainland U.S.. through a SS dealer. *5: or further details, see ir conditioner specification label. QR25 escription apacity (pproximate) Liter US measure mp measure uel /2 gal 12 1/8 gal ngine oil rain and refill With oil filter change Without oil filter change /8 qt 3 3/8 qt /8 qt 3 1/8 qt ry engine (engine overhaul) /8 qt 3 7/8 qt ooling system (with reservoir at max level) /8 qt 6 1/8 qt Recommended luids/lubricants Unleaded gasoline with an octane rating of at least 87 (R 91) ngine oil with ertification ark *1 Viscosity S 5W-30 enuine SS Long Life nti-freeze oolant or equivalent anual transaxle fluid (T) /4 pt 3 1/2 pt enuine SS gear oil (XT4447 +) 75W-80, enuine SS gear oil (TL8997) 75W-80 or equivalent *2 VT fluid /4 qt 6 3/8 qt enuine SS VT luid S-2 *3 rake and clutch fluid enuine SS Super eavy uty rake luid *4 or equivalent T 3 (US VSS o. 116) ulti-purpose grease L o. 2 (Lithium soap base) Windshield washer fluid /4 qt 3 1/8 qt enuine SS Windshield Washer oncentrate leaner & nti-reeze or equivalent ir conditioning system refrigerant 0.50 ± 0.05 kg 1.10 ± 0.11 lb 1.10 ± 0.11 lb -134a (R-134a) *5 ir conditioning system oil 150 m 5.03 fl oz 5.3 fl oz SS / System Lubricant Type S or equivalent *5 : escription apacity (pproximate) Liter US measure mp measure uel /2 gal 12 1/8 gal ngine oil rain and refill With oil filter change Without oil filter change /2 qt 3 3/4 qt /4 qt 3 1/2 qt ry engine (engine overhaul) /8 qt 4 1/2 qt ooling system (with reservoir at max level) /T models VT models /4 qt 7 1/2 qt 6 1/8 qt 6 1/4 qt Recommended luids/lubricants Unleaded gasoline with an octane rating of at least 87 (R 91) ngine oil with ertification ark *1 Viscosity S 5W-30 enuine SS Long Life nti-freeze oolant or equivalent -14

15 R LUS LURTS escription anual transaxle fluid (T) /8 pt 3 pt enuine SS anual Transmission (T) Q ulti 75W-85 or L-4 viscosity S 75-W-85 VT fluid /8 qt 6 5/8 qt enuine SS VT luid S-2 *2 rake and clutch fluids enuine SS Super eavy uty rake luid or equivalent, T 3 (US VSS o. 116) *3 ulti-purpose grease L o. 2 (Lithium soap base) Windshield washer fluid /4 qt 3 1/8 qt enuine SS Windshield Washer oncentrate leaner & nti-freeze or equivalent ir conditioning system refrigerant 0.50 ± 0.05 kg 1.10 ± 0.11 lb 1.10 ± 0.11 lb -134a (R-134a) *4 ir conditioning system oil *1: or further details, see " ngine il Recommendation. *2: Using transaxle fluid other than enuine SS VT luid S-2 will damage the VT, which is not covered by the SS new vehicle limited warranty. *3: vailable in mainland U.S.. through a SS dealer. *4: or further details, see ir conditioner specification label. ngine il Recommendation apacity (pproximate) Liter US measure mp measure 150 m 5.03 fl oz 5.3 fl oz Recommended luids/lubricants SS / System Lubricant Type S or equivalent *4 : SS recommends the use of an energy conserving oil in order to improve fuel economy. Select only engine oils that meet the merican etroleum nstitute () certification and nternational Lubricant Standardization and pproval ommittee (LS) certification and S viscosity standard. These oils have the 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. S certification mark 2. service symbol T-RZ LT XTUR RT The engine cooling system is filled at the factory with a high-quality, long life, 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: When adding or replacing coolant, be sure to use only enuine SS Long Life nti-freeze coolant or equivalent with the proper mixture ratio of 50% anti-freeze and 50% demineralized water or distilled water. -15 enuine SS Long Life ntifreeze coolant nti-freeze coolant mixture ratio emineralized water or distilled water % 50 %

16 R LUS LURTS < SRV RT > ther types of coolant solutions may damage your cooling system. nti-freeze oolant ixture Ratio : The engine cooling system is filled at the factory with a high-quality, long life, year-round, anti-freeze coolant solution. The anti-freeze solution contains rust and corrosion inhibitors. Therefore, additional cooling system additives are not necessary. aximum outside temperature enuine SS nti-freeze oolant or equivalent emineralized water or distilled water % 50% When adding or replacing coolant, be sure to use only a enuine SS Long Life nti-reeze coolant or equivalent with the proper mixture ratio. The use of other types of coolant solutions may damage the engine cooling system. -16

17 T (R20) RV LTS RV LTS : omponent T (R20) : enerator 2. rive belt auto tensioner 3. rankshaft pulley 4. / compressor (models with /) dler pulley (models without /) 5. Water pump 6. rive belt. llowable use range. Range when new drive belt is installed. ndicator RV LTS : hecking rive elts : WR: nspect the drive belt only when the engine is stopped. T: n vehicles not equipped with /, there is an idler pulley in the position for the drive belt routing. ake sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range. T: heck the drive belt auto-tensioner indicator (notch) when the engine is cold. When the new drive belt is installed, the range of possible use should be as shown. Visually check entire belt for wear, damage or cracks. f the indicator is out of allowable use range or belt is damaged, replace the drive belt. RV LTS : Tension djustment elt tension is not manually adjustable, it is automatically adjusted by the drive belt auto-tensioner. LT LT : nspection : : WR: ever remove the radiator cap when the engine is hot. Serious burns could occur from high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap. Slowly push down and turn it a quarter turn to allow built-up pressure to escape. arefully remove the cap by pushing down and turning it all the way. L SYST SS heck hoses for the following: mproper attachment Leaks racks amage Loose connections hafing eterioration RSRVR LVL -17

18 T (R20) < SRV RT > heck if the reservoir tank engine coolant level is within the to X range when the engine is cool. djust the engine coolant level as necessary. S412 L SYST R LS To check for leaks, apply pressure to the cooling system using Tool. Tool number : ( ) Testing pressure : 157 ka (1.6 kg/cm 2, 23 psi) WR: ever remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. igher pressure than specified may cause radiator damage. W0568 RTR 1. nspect the radiator cap. Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket. Replace the cap if deposits of waxy residue or other foreign material are on the black rubber gasket or the metal retainer. T: Thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material. 2. ull the negative-pressure valve to open it and check that it closes completely when released. heck that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. heck that there are no abnormalities in the opening and closing conditions of the negative-pressure valve. S heck radiator cap relief pressure using Tool. Tool number : ( ) Standard: ka ( kg/cm 2, psi) Limit: 59 ka (0.6 kg/cm 2, 9 psi) When connecting the radiator cap to the tester, apply water or coolant to the cap seal surface. Replace the radiator cap if there is an abnormality in the negative-pressure valve, or if the open-valve pressure is outside of the standard values. W0570 RTR -18

19 T (R20) heck radiator for mud or clogging. f necessary, clean radiator as follows. e careful not to bend or damage the radiator fins. When radiator is cleaned without removal, remove all surrounding parts such as cooling fan shroud and horns. Then tape the harness and electrical connectors to prevent water from entering. 1. pply water by hose to the back side of the radiator core, with the hose pointed 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 the radiator. 4. low air into the back side of radiator core, with the air hose pointed vertically downward. Use compressed air lower than 490 ka (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. 6. heck for leaks. LT : hanging ngine oolant : WR: To avoid being scalded, do not change the engine coolant when the engine is hot. Wrap a thick cloth around radiator cap and carefully remove the cap. irst, turn the cap a quarter of a turn to release built-up pressure. Then push down and turn the cap all the way to remove. e careful not to allow engine coolant to contact drive belt. R LT 1. Remove the engine undercover using power tool. 2. pen the radiator drain plug (1) at the bottom of the radiator, and remove the radiator filler cap. This is the only step required when partially draining the cooling system (radiator only). ront erform this step when engine is cold. o not spill engine coolant on drive belt ollow this step for heater core removal/replacement only. isconnect the upper heater hose at the engine side and apply moderate air pressure [ ka (15 psi, kg/cm 2 ) maximum air pressure] into the hose for 30 seconds to blow the excess coolant out of the heater core. 4. When draining all of the coolant in the system, remove the reservoir tank and drain the coolant, then clean the reservoir tank before installation. 5. When draining all of the coolant in the system for engine removal or repair, open the drain plug on the cylinder block. Refer to -74, "omponent". 6. heck the drained engine coolant for contaminants such as rust, corrosion or discoloration. f the coolant is contaminated, flush the engine cooling system. ollow the "LUS L SYS- T" procedure. RLL LT 1. nstall the radiator drain plug. nstall the reservoir tank and cylinder block drain plug, if removed for a total system drain or for engine removal or repair. The radiator must be completely empty of coolant and water. pply sealant to the threads of the cylinder block drain plugs. Use enuine igh erformance Thread Sealant or equivalent. Refer to -42, "Recommended hemical roduct and Sealant". Radiator drain plug : Refer to -15, "omponent". ylinder block drain plug : Refer to -182, "Removal and nstallation". 2. f disconnected, reattach the upper radiator hose at the engine side. -19

20 T (R20) < SRV RT > 3. Set the vehicle heater controls to the full T and heater position. Turn the vehicle ignition with the engine as necessary to activate the heater mode. 4. nstall the Tool by installing the radiator cap adapter onto the radiator neck opening. Then attach the gauge body assembly with the refill tube and the venturi assembly to the radiator cap adapter. Tool number : V (-45695) 5. nsert the refill hose into the coolant mixture container that is placed at floor level. ake sure the ball valve is in the closed position. Use enuine SS Long Life nti-freeze coolant or equivalent, mixed 50/50 with distilled water or demineralized water. Refer to -16, "nti-freeze oolant ixture Ratio". ngine coolant capacity (with reservoir tank) : Refer to nstall an air hose to the venturi assembly, the air pressure must be within specification. ompressed air supply pressure The compressed air supply must be equipped with an air dryer. 7. The vacuum gauge will begin to rise and there will be an audible hissing noise. uring this process open the ball valve on the refill hose slightly. oolant will be visible rising in the refill hose. nce the refill hose is full of coolant, close the ball valve. This will purge any air trapped in the refill hose. 8. ontinue to draw the vacuum until the gauge reaches 28 inches of vacuum. The gauge may not reach 28 inches in high altitude locations, use the vacuum specifications below based on the altitude above sea level. 9. When the vacuum gauge has reached the specified amount, disconnect the air hose and wait 20 seconds to see if the system loses any vacuum. f the vacuum level drops, perform any necessary repairs to the system and repeat steps 6-8 to bring the vacuum to the specified amount. Recheck for any leaks. 10. lace the coolant container (with the refill hose inserted) at the same level as the top of the radiator. Then open the ball valve on the refill hose so the coolant will be drawn up to fill the cooling system. The cooling system is full when the vacuum gauge reads zero. o not allow the coolant container to get too low when filling, to avoid air from being drawn into the cooling system. 11. Remove the Tool from the radiator neck opening. 12. ill the cooling system reservoir tank to the specified level and install the radiator cap. Run the engine to warm up the cooling system and top up the system as necessary. LUS L SYST : ka ( kg/cm 2, psi) LL0058 ltitude above sea level Vacuum gauge reading m (328 ft) : 28 inches of vacuum 300 m (984 ft) : 27 inches of vacuum 500 m (1,641 ft) : 26 inches of vacuum 1,000 m (3,281 ft) : inches of vacuum LL ill radiator and reservoir tank with water and reinstall radiator cap. -20

21 T (R20) 2. Run engine until it reaches normal operating temperature. 3. Rev the engine two or three times under no-load. 4. Stop the engine and wait until it cools down. 5. rain water from the cooling system. 6. Repeat steps 1 through 5 until clear water begins to drain from the radiator. UL LS UL LS : hecking uel Line nspect fuel lines, fuel filler cap and fuel tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. f necessary, repair or replace damaged parts. : R LR LTR R LR LTR : omponent S803 : ir cleaner filter 2. ir cleaner holder 3. ir cleaner case 4. ir duct 5. ass air flow sensor 6. ir duct (nlet) 7. ir duct/battery tray 8. ir duct 9. rommet 10. Resonator. To electric throttle control actuator W

22 T (R20) < SRV RT > R LR LTR : hanging ir leaner ilter : RVL 1. Unclip the tabs () of both ends of the air cleaner cover (1). W Remove the air cleaner filter and holder assembly from the air cleaner case. 3. Remove the air cleaner filter from the holder. ST TR RVL t is necessary to replace it at the recommended intervals, more often under dusty driving conditions. Refer to -8. STLLT nstallation is in the reverse order of removal. L L : nspection : L LVL T: efore starting engine, park vehicle on a level surface and check the engine oil level. f engine is already started, stop it and allow 10 minutes before checking. 1. ull out oil level gauge and wipe it clean. 2. nsert oil level gauge and make sure the engine oil level is within the range () as shown. 3. f it is out of range, add oil as necessary. L R heck engine oil for white milky or excessive contamination. f engine oil becomes milky, it is highly probable that it is contaminated with engine coolant. Repair or replace damaged parts. L L heck for engine oil leakage around the following areas: il pan (upper and lower) il pan drain plug il pressure switch il filter ntake valve timing control solenoid valve ront cover -22 W0776

23 T (R20) ating surface between cylinder block and cylinder head ating surface between cylinder head and rocker cover rankshaft oil seals (front and rear) il filter (for intake valve timing control) L RSSUR WR: e careful not to burn yourself, as engine oil may be hot. or /T models, put the gearshift lever in the eutral "" position and apply the parking brake securely. or VT models, put the selector lever in the ark position. 1. heck engine oil level. 2. Remove undercover using power tool. 3. isconnect harness connector at oil pressure switch (1), and remove oil pressure switch using a suitable tool. il pan (lower) (2) : ront o not drop or shock oil pressure switch nstall oil pressure gauge and hose. Tool number : ST ( ) : ST ( ) W Start engine and warm it up to normal operating temperature. 6. heck oil pressure with engine running under no-load. Refer to LU-10, "il ressure". T: When engine oil temperature is low, engine oil pressure becomes high. f difference is extreme, check oil passage and oil pump for oil leaks. 7. fter the inspections, install oil pressure switch as follows: a. Remove old liquid gasket adhering to oil pressure switch and engine. b. pply liquid gasket and tighten oil pressure switch to specification. Use enuine Silicone RTV Sealant or equivalent. Refer to -42, "Recommended hemical roduct and Sealant". il pressure switch c. heck engine oil level. d. fter warming up engine, make sure there are no leaks of engine oil with running engine. L : hanging ngine il : 14.7 m (1.5 kg-m, 11 ft-lb) : WR: e careful not to burn yourself, as engine oil may be hot. rolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used engine oil. f skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. -23

24 T (R20) < SRV RT > 1. ark vehicle on a level surface and check for engine oil leakage from engine components. Refer to - 22, " L : nspection". 2. Warm up the engine. 3. Stop engine and wait for 10 minutes. 4. Remove oil filler cap (1) and then remove oil pan drain plug (2). il filter (3) : ngine front 5. rain the engine oil. 6. nstall the oil pan drain plug (2) with a new washer. il pan drain plug : 34.3 m (3.5 kg-m, 25 ft-lb) e sure to clean drain plug (2) and install with new washer. 7. Refill with new engine oil. Refer to -14, "R20". 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 the engine. 8. Warm up engine and check area around drain plug (2) and oil filter (3) for engine oil leakage. 9. Stop engine and wait for 10 minutes. 10. heck the engine oil level. Refer to -22, " L : nspection". o not overfill the engine with oil. L LTR L LTR : Removal and nstallation 3915 : RVL 1. Remove oil filter using Tool (). Tool number : V (-38956) : ront WR: e careful not to get burned, engine and engine oil may be hot. When removing, prepare a shop cloth to absorb any engine oil leakage or spillage. o not allow engine oil to adhere to drive belt. ompletely wipe off any engine oil that adheres to the engine and the vehicle

25 T (R20) The oil filter has a built in pressure relief valve. Use enuine SS oil filter or equivalent. STLLT 1. Remove foreign materials adhering to the oil filter installation surface. 2. pply new engine oil to the oil seal contact surface of the new oil filter. L Screw the new oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. r tighten to specification. il filter: : 17.7 m (1.8 kg-m, 13 ft-lb) S010 ST TR STLLT 1. heck the engine oil level. Refer to Start engine, and make sure there are no leaks of engine oil. 3. Stop engine and wait for 10 minutes. 4. heck the engine oil level and adjust as necessary. Refer to -22. SR LU S229-25

26 T (R20) < SRV RT > SR LU : omponent : V hose 2. Rocker cover 3. Spark plug 4. gnition coil 5. V hose 6. V valve 7. -ring 8. asket. To air duct. Refer to To intake manifold SR LU : Removal and nstallation : RVL 1. Remove intake manifold. Refer to Remove ignition coil. andle it carefully and avoid impacts. ever disassemble. 3. Remove spark plug using suitable tool. ever drop or shock it

27 4. Remove rocker cover. Loosen bolts in reverse order as shown. ngine front T (R20) ST TR RVL ever drop or shock spark plug. hecking and adjusting spark plug gap is not required between change intervals S806 f spark plug tip is covered with carbon, a spark plug cleaner may be used. leaner air pressure : Less than 588 ka (5.88 bar, 6 kg/cm 2, 85 psi) leaning time : Less than 20 seconds ever use wire brush for cleaning spark plug. STLLT 1. nstall rocker cover gasket to rocker cover. 2. nstall rocker cover. Tighten bolts in two steps separately in numerical order as shown. 1st step 2nd step : 1.96 m (0.20 kg-m, 17 in-lb) : 8.33 m (0.85 kg-m, 73 in-lb) ngine front heck if rocker cover gasket is not dropped from the installation groove of rocker cover. S

28 T (R20) < SRV RT > 3. nstall spark plug using suitable tool. pplication xcept for alifornia or alifornia ake : : enso art number : LZR6-11 : X20R-11 ap (nominal) : 1.1 mm (0.043 in) : 1.1 mm (0.043 in) ever drop or shock it nstall ignition coil. andle it carefully and avoid impacts. ever disassemble. 5. nstall intake manifold. Refer to -18. V VR LS V VR LS : hecking V Vapor Line : Visually inspect V 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

29 T (QR25 ) T (QR25 ) RV LT RV LT : hecking rive elts : W0275ZZ 1. enerator pulley 2. Water pump pulley 3. rive belt auto tensioner 4. dler pulley 5. rankshaft pulley 6. / compressor pulley. llowable use range (new belt). View. llowable use range. ndicator (notch). Temporary retaining boss WR: nspect the drive belt only when the engine is stopped. ake sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range. T: heck the drive belt auto-tensioner indicator (notch) when the engine is cold. When the new drive belt is installed, the range of possible use should be as shown. Visually check entire belt for wear, damage or cracks. f the indicator is out of allowable use range or belt is damaged, replace the drive belt. RV LT : Tension djustment elt tension is not manually adjustable, it is automatically adjusted by the drive belt auto-tensioner. LT LT : nspection : : WR: ever remove the radiator cap when the engine is hot. Serious burns could occur from high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap. Slowly push down and turn it a quarter turn to allow built-up pressure to escape. arefully remove the cap by pushing down and turning it all the way. L SYST SS heck hoses for the following: mproper attachment Leaks racks amage -29

30 T (QR25 ) < SRV RT > Loose connections hafing eterioration RSRVR LVL heck if the reservoir tank engine coolant level is within to X when the engine is cool. djust the engine coolant level as necessary. S412 L SYST R LS To check for leakage, apply pressure to the cooling system using Tool. Tool number : ( ) Testing pressure : 157 ka (1.6 kg/cm 2, 23 psi) WR: ever remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. igher pressure than specified may cause radiator damage. W0568 RTR 1. nspect the radiator cap. Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket. Replace the cap if deposits of waxy residue or other foreign material are on the black rubber gasket or the metal retainer. T: Thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material. 2. ull the negative-pressure valve to open it and check that it closes completely when released. heck that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. heck that there are no abnormalities in the opening and closing conditions of the negative-pressure valve. S967-30

31 T (QR25 ) 3. heck radiator cap relief pressure using Tool. Tool number : ( ) Standard: ka ( kg/cm 2, psi) Limit: 59 ka (0.6 kg/cm 2, 9 psi) When connecting the radiator cap to the tester, apply water or coolant to the cap seal surface. Replace the radiator cap if there is an abnormality in the negative-pressure valve, or if the open-valve pressure is outside of W0570 the standard values. RTR heck radiator for mud or clogging. f necessary, clean radiator as follows. e careful not to bend or damage the radiator fins. When radiator is cleaned without removal, remove all surrounding parts such as cooling fan shroud and horns. Then tape the harness and electrical connectors to prevent water from entering. 1. pply water by hose to the back side of the radiator core, with the hose pointed 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 the radiator. 4. low air into the back side of radiator core, with the air hose pointed vertically downward. Use compressed air lower than 490 ka (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. 6. heck for leaks. LT : hanging ngine oolant : WR: To avoid being scalded, do not change the engine coolant when the engine is hot. Wrap a thick cloth around radiator cap and carefully remove the cap. irst, turn the cap a quarter of a turn to release built-up pressure. Then push down and turn the cap all the way to remove. e careful no to allow engine coolant to contact drive belt. R LT 1. Remove the engine undercover using power tool. 2. pen the radiator drain plug (1) at the bottom of the radiator, and remove the radiator filler cap. This is the only step required when partially draining the cooling system (radiator only). ront erform this step when engine is cold. o not spill engine coolant on drive belt ollow this step for heater core removal/replacement only. isconnect the upper heater hose at the engine side and apply moderate air pressure [ ka (15 psi, kg/cm 2 ) maximum air pressure] into the hose for 30 seconds to blow the excess coolant out of the heater core. 4. When draining all of the coolant in the system, remove the reservoir tank and drain the coolant, then clean the reservoir tank before installation. -31

32 T (QR25 ) < SRV RT > 5. When draining all of the coolant in the system for engine removal or repair, open the drain plug on the cylinder block heck the drained engine coolant for contaminants such as rust, corrosion or discoloration. f the coolant is contaminated, flush the engine cooling system. ollow the "LUS L SYS- T" procedure. RLL LT 1. nstall the radiator drain plug. nstall the reservoir tank and cylinder block drain plug, if removed for a total system drain or for engine removal or repair. The radiator must be completely empty of coolant and water. pply sealant to the threads of the cylinder block drain plugs. Use enuine igh erformance Thread Sealant or equivalent. Refer to -42, "Recommended hemical roduct and Sealant". Radiator drain plug ylinder block drain plug 2. f disconnected, reattach the upper radiator hose at the engine side. 3. Set the vehicle heater controls to the full T and heater position. Turn the vehicle ignition with the engine as necessary to activate the heater mode. 4. nstall the Tool by installing the radiator cap adapter onto the radiator neck opening. Then attach the gauge body assembly with the refill tube and the venturi assembly to the radiator cap adapter. Tool number : Refer to -43, "Removal and nstallation". : Refer to : V (-45695) 5. nsert the refill hose into the coolant mixture container that is placed at floor level. ake sure the ball valve is in the closed position. Use enuine SS Long Life nti-freeze coolant or equivalent, mixed 50/50 with distilled water or demineralized water. Refer to -16, "nti-freeze oolant ixture Ratio". ngine coolant capacity (with reservoir tank) : Refer to nstall an air hose to the venturi assembly, the air pressure must be within specification. ompressed air supply pressure : ka ( kg/cm 2, psi) LL0058 The compressed air supply must be equipped with an air dryer. 7. The vacuum gauge will begin to rise and there will be an audible hissing noise. uring this process open the ball valve on the refill hose slightly. oolant will be visible rising in the refill hose. nce the refill hose is full of coolant, close the ball valve. This will purge any air trapped in the refill hose. -32