Maintenance - MA1 MAINTENANCE GENERAL NOTES There are 2...

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Unformatted text preview: MA1 MAINTENANCE GENERAL NOTES: There are 2 separate maintenance schedules, namely A and B, which apply to different driving conditions. Find out how the vehicle is driven, select the appropriate schedule and service the vehicle accordingly. Every service item in the periodic maintenance list must be performed. Next to the columns of periods in the schedule, reference pages have been added for easy access to service data and procedures necessary for each operation. The service interval for scheduled maintenance is determined by the odometer reading or time interval, whichever comes first, shown in the schedule. Maintenance services after the last period should be performed at the same interval as before unless otherwise noted. Skipping even one item in the list can cause the engine to run poorly and increase exhaust emissions. MA2 MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE SCHEDULE A MA0320D CONDITIONS: S Towing a trailer, using a camper or car top carrier. S Repeated short trips of less than 8 km (5 miles) with outside temperature remaining below freezing. S Extensive idling and/or low speed driving for long distances, such as police, taxi or doorto door delivery use. S Operating on dusty, rough, muddy or salt spread roads. Maintenance operation: A = Check and adjust if necessary. R = Replace, change or lubricate. I = Inspect and correct or replace if necessary. MA6 (item 1) MA8 (item 12) MA6 (item 2) MA7 (item 6) MA7 (item 7) MA8 (item 11) MA6 (item 3,4) MA8 (item 10) MA8 (item 9) MA6 (item 5) MA7 (item 8) MA9 (item 15) MA9 (item 14) MA10 (item 16) MA8 (item 13) MA10 (item 17) MA11 (item 18) MA11 (item 20) MA11 (item 21,22) MA11 (item 19) MA13 (item 23) MA13 (item 24) MA13 (item 25) V05762 MA3 MAINTENANCE MAINTENANCE SCHEDULE (1) (2) (3) (4) (5) (6) (7) (8) H mark indicates maintenance which is part of the warranty conditions for the Emission Control Systems. The warranty period is in accordance with the owner's guide or the warranty booklet. (H: California, Massachusetts and New York specification vehicles only) Applicable to vehicles operated under conditions of extensive idling and/or low speed driving for long distances such as police, taxi or doortodoor delivery use. Applicable when operating mainly on dusty roads. Includes inspection of fuel tank band and vapor vent system. Nonmaintenance item except for California, Massachusets and New York. Also applicable to drum lining for parking brake. For other usage conditions, refer to SCHEDULE B. Check for leakage. Check for oil leaks from steering gear housing. Applicable only when operating mainly on rough, muddy roads. The applicable parts are listed below. For other usage conditions, refer to SCHEDULE B. S Front and rear suspension member to cross body. S Bolts for seat installation. MA4 MAINTENANCE MAINTENANCE SCHEDULE SCHEDULE B MA03304 CONDITIONS: Conditions others than those listed for SCHEDULE A. Maintenance operation: A = Check and adjust if necessary. R = Replace, change or lubricate. I = Inspect and correct or replace if necessary. MA8 MA6 MA7 MA7 MA8 MA6 MA8 MA6 MA7 MA9 MA9 (item 12) (item 2) (item 6) (item 7) (item 11) (item 4) (item 10) (item 5) (item 8) (item 15) (item 14) MA10 (item 16) MA8 (item 13) MA10 (item 17) MA11 (item 18) MA11 (item 20) MA11 (item 21) MA11 (item 19) MA13 (item 23) MA13 (item 24) MA13 (item 24) MA13 (item 25) V05763 (1) (2) (3) (4) (5) (6) H mark indicates maintenance which is part of the warranty conditions for the Emission Control Systems. The warranty period is in accordance with the owner's guide or the warranty booklet. (H: California, Massachusetts and New York specification vehicles only) Includes inspection of fuel tank band and vapor vent system. Nonmaintenance item except for California, Massachusetts and New York. Also applicable to drum lining for parking brake. Check for leakage. Check for oil leaks from steering gear housing. The applicable parts are listed below. S Front and rear suspension member to cross body. S Bolts for seat installation. LUBRICANT COOLANT Brake fluid Automatic transmission fluid (Drain and refill) Differential oil Item Engine oil (Drain and refill) w/ Oil filter change w/o Oil filter change Item Engine coolant (w/ Heater) Vernier calipers Torque wrench Thermometer Steel square Mirror Micrometer Dial indicator 1.35 liters (1.43 US qts, 1.19 lmp. qts) API GL5 Above 18 C (0 F) SAE 90 Below 18 C (0 F) SAE 80W90 or 80W 1.9 liters (2.0 US qts, 1.7 lmp. qts) Capacity 5.4 liters (5.7 US qts, 4.8 lmp. qts) 5.1 liters (5.4 US qts, 4.5 lmp. qts) MAINTENANCE EQUIPMENT Parking brake drum Brake hose Brake disc Brake disc MA00B0F MA00904 RECOMMENDED TOOLS PREPARATION Capacity 7.5 liters (7.9 US qts, 6.6 lmp. qts) PREPARATION Classification API grade SH, EnergyConserving II multigrade engine oil or ILSAC multigrade engine oil and recommended viscosity oil, with SAE 5W30 being preferred engine oil SAE J1703 or FMVSS No. 116 DOT3 ATF TYPE TII Classification Ethyleneglycol base MA5 MA00D0N EG0AZ0T MA6 MAINTENANCE MAINTENANCE OPERATIONS MAINTENANCE OPERATIONS ENGINE MA06R01 Cold Engine Operations 1. REPLACE TIMING BELT (See timing belt removal and installation in Engine Mechanical) INSPECT DRIVE BELT (See onvehicle inspection in Charging System) 2. 3. INSPECT AIR FILTER (a) Visually check that the air filter is not excessively dirty, damaged or oily. If necessary, replace the air filter. (b) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off from the outside of the air filter. 4. REPLACE AIR FILTER Replace the air filter with a new one. 5. REPLACE SPARK PLUGS (a) Disconnect the hightension cords. (See hightension cords and clamps removal in Ignition System) (b) Using a 16 mm plug wrench, remove the 6 spark plugs. (c) Check the electrode gap of new spark plugs. Correct electrode gap: 1.1 mm (0.043 in.) Recommended spark plug: ND PK16R11 NGK BKR5EP11 NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. (d) Using a 16 mm plug wrench, reinstall the 6 spark plugs. Torque: 18 Nm (180 kgfcm, 13 ftlbf) (e) Reconnect the hightension cords. (See hightension cords and clamps installation in Ignition System) MA7 MAINTENANCE MAINTENANCE OPERATIONS 6. REPLACE ENGINE OIL AND OIL FILTER (See oil and filter replacement in Lubrication System) Oil grade: API grade SH, EnergyConserving II multigrade engine oil or ILSAC multigrade engine oil. Recommended viscosity: SAE 5W30 Drain and refill capacity: w/ Oil filter change 5.4 liters (5.7 US qts, 4.8 lmp. qts) w/o Oil filter change 7. 5.1 liters (5.4 US qts, 4.5 lmp. qts) REPLACE ENGINE COOLANT (See coolant check and replacement in Cooling System) Coolant capacity (w/ Heater): 7.5 liters (7.9 US qts, 6.6 lmp. qts) HINT: Use a good brand of ethyleneglycol base coolant and mix it according to the manufacturer's directions. Using coolant which includes more than 50 % ethyleneglycol (but not more than 70 %) is recommended. NOTICE: Do not use a alcohol type coolant. The coolant should be mixed with demineralized water or distilled water. 8. INSPECT CHARCOAL CANISTER (a) Visually inspect the canister case. (b) Check for a crogged port and stuck check valve. Using low compressed air (4.71 kPa (48 gf/cm2, 0.68 psi)), blow into port A and check that air flows without resistance from the other ports. Blow low compressed air (4.71 kPa (48 gf/cm2, 0.68 psi)) into port B and check that air does not flow from the other ports. If operation is not as specified, replace the charcoal canister. MA8 MAINTENANCE MAINTENANCE OPERATIONS (c) Clean the filter in the canister. Clean the filter by blowing 294 kPa (3 kgf/cm2, 43 psi) of compressed air into port A while holding port B closed. NOTICE: Do not attempt to wash the canister. No activated carbon should come out. 9. REPLACE GASKET IN FUEL TANK CAP (a) Remove the old gasket from the tank cap. Do not damage the cap. (b) Install a new gasket by hand. (c) Check the cap for damage or cracks. (d) Install the cap and check the torque limiter. 10. INSPECT FUEL LINES AND CONNECTIONS Visually check the fuel lines for cracks, leakage, loose connections, deformation or tank band looseness. 11. INSPECT EXHAUST PIPES AND MOUNTINGS Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. 12. ADJUST VALVE CLEARANCE (See valve clearance inspection and adjustment in Engine Mechanical) Valve clearance (Cold): Intake .150.25 mm (0.0060.010 in.) Exhaust .250.35 mm (0.0100.014 in.) BRAKES MA06S01 13. INSPECT BRAKE LINE PIPES AND HOSES HINT: Check in a well lighted area. Check the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before checking the front brake. (a) Check all brake lines and hoses for: Damage Wear Deformation Cracks Corrosion Leaks Bends Twists MA9 MAINTENANCE MAINTENANCE OPERATIONS (b) Check all clamps for tightness and connections for leakage. (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines installed in grommets pass through the center of the grommets. 14. INSPECT BRAKE PADS AND DISCS FOR FRONT AND REAR (a) Check the thickness of the disc brake pads and check for irregular wear. Minimum pad thickness: 1.0 mm (0.039 in.) HINT: If a squealing or scraping noise comes from the brake during driving, check the pad wear indicator to see if it is contacting the disc rotor. If so, the disc pad should be replaced. (b) Check the disc for wear or runout. Minimum disc thickness: Front 30.0 mm (1.181 in.) Rear 15.0 mm (0.591 in.) Maximum disc runout: 0.05 mm (0.0020 in.) 15. INSPECT BRAKE LININGS AND DRUMS FOR PARKING BRAKE (a) Check the liningtodrum contact condition and lining wear. Minimum lining thickness: 1.0 mm (0.039 in.) MA10 MAINTENANCE MAINTENANCE OPERATIONS (b) Check the brake drums for scoring or wear. Maximum drum inside diameter: 191 mm (7.520 in.) (c) Clean the brake parts with a damp cloth. NOTICE: Do not use compressed air to clean the brake parts. (d) Settle the parking brake shoes and drum. When doing the road test in item 25, do the following: Depress the parking brake pedal with 147 N (15 kgf, 33 lbf) of force. Drive the vehicle at approx. 50 km/h (30 mph) on a safe, level and dry road. Drive the vehicle for approx. 400 meters (1/4 mile) in this condition. Repeat this procedure 2 or 3 times. Check parking pedal travel. If necessary, adjust the parking brake. 16. INSPECT AND CHANGE BRAKE FLUID (a) Visually inspect the master cylinder for leaks. (b) Change brake fluid. Fluid: SAE J1703 or FMVSS No.116 DOT3 CHASSIS MA06T01 17. INSPECT STEERING LINKAGE (a) Check the steering wheel freeplay. Maximum freeplay: 30 mm (1.18 in.) With the vehicle stopped and pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure. (b) Check the steering linkage for looseness or damage. Check that: Tie rod ends do not have excessive play. Dust seals and boots are not damaged. Boot clamps are not loose. MA11 MAINTENANCE MAINTENANCE OPERATIONS 18. INSPECT SRS AIRBAG Driver Airbag: Visually inspect the steering wheel pad (airbag and inflater). Use the diagnosis check to check if there are abnormalities. Check that there are no cuts, cracks or noticeable color changes on the surface of the steering wheel pad or in the center groove of the pad. Remove the steering wheel pad from the vehicle and check the wiring and steering wheel for damage and corrosion due to rusting, etc. If necessary, replace the steering wheel pad. Front Passenger Airbag: Visually inspect the front passenger airbag assembly (airbag and inflater). Use the diagnosis check to check if there are abnormalities. Check that there are no cuts, cracks or noticeable color changes in the front passenger airbag door. Remove the front passenger airbag assembly from the vehicle and check the wiring and front passenger airbag door for damage and corrosion due to rusting, etc. If necessary, replace the front passenger airbag assembly. CAUTION: For removal and replacement of the steering wheel pad or front passenger airbag assembly, see RS section and be sure to do the operation in the correct order. Before disposing of the steering wheel pad or front passenger airbag assembly must first be deployed by using SST (See RS section). 19. INSPECT STEERING GEAR HOUSING OIL Check the steering gear housing for oil leakage. 20. INSPECT DUST COVERS Visually check the dust covers for damage. 21. CHECK AUTOMATIC TRANSMISSION FLUID AND DIFFERENTIAL OIL Visually check the transmission for fluid (oil) and leakage. If leakage is found, check for the cause and repair. MA12 MAINTENANCE MAINTENANCE OPERATIONS 22. REPLACE AUTOMATIC TRANSMISSION FLUID AND DIFFERENTIAL OIL A. Replace automatic transmission fluid (oil) (a) Remove the drain plug, and drain the fluid (oil). (b) Clean the drain plug. (c) Reinstall the drain plug securely. (d) With the engine "OFF", add new fluid through the dipstick tube. Fluid type: ATF Type TII or equivalent Drain and refill capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts) (e) Start the engine and shift the selector into all positions from "P" through "L", and then shift into "P" position. (f) With the engine idling, check the fluid level. Add fluid up the "COOL" range on the dipstick. (g) Check that the fluid level is in the "HOT" range at the normal operating temperature (7080_ C) (158176_ F)) and add as necessary. NOTICE: Do not overfill. B. Replace differential oil (a) Remove the filler and drain plugs, and drain the oil. (b) Clean the drain plug. (c) Reinstall the drain plug securely. (d) Add new oil until it begins to run out of the filler hole. Differential oil: Oil grade API GL5 Viscosity Above18 C (0 F) SAE 90 Below18 C (0 F) SAE 80W90 or 80W Capacity: 1.35 liters (1.43 US qts, 1.19 lmp. qts) (e) Reinstall the filler plug securely. MA13 MAINTENANCE MAINTENANCE OPERATIONS 23. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the following parts: Front seattobody mounting bolts Torque: 37 Nm (375 kgfcm, 27 ftlbf) Front suspension membertobody mounting bolts Torque: 196 Nm (2,000 kgfcm, 145 ftlbf) Rear suspension membertobody mounting bolts Rear suspension member rear cushiontobody mounting bolts Torque: 196 Nm (2,000 kgfcm, 145 ftlbf) Torque: 43 Nm (440 kgfcm, 32 ftlbf) (a) Check the body exterior for dents, scratches and rust. 24. BODY INSPECTION (b) Check the underbody for rust and damage. If necessary, replace or repair. 25. ROAD TEST (a) Check the engine and chassis for abnormal noises. (b) Check that the vehicle does not wander or pull to one side. (c) Check that the brakes work properly and do not drag. (d) Set the parking brake shoes and drum. 26. FINAL INSPECTION (a) Check the operation of the body parts: Hood: Auxiliary catch operates properly Hood locks securely when closed Front and rear doors: Door locks operate properly Doors close properly Luggage compartment door: Door lock operates properly MA14 MAINTENANCE MAINTENANCE OPERATIONS Seats: Seat adjusts easily and locks securely in any position Front seat back locks securely in any position Folding down rear seat backs lock securely (b) Be sure to deliver a clean car and especially check: Steering wheel Shift lever knob All switch knobs Seats MA15 MAINTENANCE GENERAL MAINTENANCE GENERAL MAINTENANCE MA00M06 There are some maintenance and inspection items which are considered to be the owner's responsibility. They can be done by the owner or he can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows: OUTSIDE VEHICLE MA00P04 1. TIRES (a) Check the pressure with a gauge. Adjust if necessary. (b) Check for cuts, damage, uneven or excessive wear. 2. WHEEL NUTS When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them. 3. TIRE ROTATION It is recommended that tires be rotated every 12,000 km (7,500 miles). 4. WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not wipe clean. Replace if necessary. 5. FLUID LEAKS (a) Check underneath for leaking fuel, oil, water or other fluid. (b) If you smell gasoline fumes or notice any leak, have the cause found and corrected. 6. DOORS AND ENGINE HOOD (a) Check that all doors including the trunk lid operate smoothly, and that all latches lock securely. (b) Check that the engine hood secondary latch secures the hood from opening when the primary latch is released. INSIDE VEHICLE MA00R0B 7. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlight aiming. 8. WARNING LIGHT AND BUZZERS Check that all warning lights and buzzers function properly. 9. HORN Check that it is working. 10. WINDSHIELD GLASS Check for scratches, pits or abrasions. 11. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 12. WINDSHIELD DEFROSTER Check that the air comes out from the defroster outlet when operating the heater air conditioner at defroster mode. 13. REAR VIEW MIRROR Check that it is mounted securely. 14. SUN VISORS Check that they move freely and are mounted securely. 15. STEERING WHEEL Check that it has the specified freeplay. Be alert for changes in steering condition, such as excessive steering effort, excessive freeplay or strange noise. 16. SEATS (a) Check that all front seat controls such as seat adjusters, seatback recliner, etc. operate smoothly. (b) Check that all latches lock securely in any position. (c) Check that the locks hold securely in any latched position. (d) Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position. (e) For foldingdown rear seat backs, check that the latches lock securely. 17. SEAT BELTS (a) Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 18. ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. MA16 MAINTENANCE GENERAL MAINTENANCE 19. BRAKE PEDAL (a) Check that pedal for smooth operation. (b) Check that the pedal has the proper reserve distance and freeplay. (c) Check the brake booster function. 20. BRAKES At a safe place, check that the brakes do not pull to one side when applied. 21. PARKING BRAKE (a) Check that the pedal has the proper travel. (b) On a safe incline, check that the vehicle is held securely with only the parking brake applied. 22. AUTOMATIC TRANSMISSION PARK MECHANISM (a) Check the lock release button of the selector lever for proper and smooth operation. (b) On a safe incline, check that the vehicle is held securely with the selector lever in the "P" position and all brakes released. UNDER HOOD MA00T0G 23. WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank. 24. ENGINE COOLANT LEVEL Check that the coolant level is between the LEVEL lines on the seethrough reservoir at normal temperature (20 C (68 F)). 25. RADIATOR AND HOSES (a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs. (b) Check the hoses for cracks, kinks, rot or loose connections. 26. BATTERY ELECTROLYTE LEVEL Check the indicator. When the indicator color is blue, the condition is satisfactory. A red color indicates that distilled water must be added, and white indicates that charging is necessary. 27. BRAKE FLUID LEVEL Check that the brake fluid level is near the upper level line on the seethrough reservoir. 28. ENGINE DRIVE BELT Check drive belt for fraying, cracks, wear or oil contamination. 29. ENGINE OIL LEVEL Check that level on the dipstick with the engine turned off. 30. POWER STEERING FLUID LEVEL Check the level on the dipstick. The level should be in the "HOT" or "COLD" range depending on the fluid temperature. 31. AUTOMATIC TRANSMISSION FLUID LEVEL (a) Park the vehicle on a level surface. (b) With the engine idling and the parking and foot brake applied, shift the selector into all positions from "P" to "L", and then shift into "P" position. (c) Turn and pull out the dipstick and wipe off the fluid with a clean rag. Reinsert the dipstick fully and check that the fluid level is in the "HOT" range. (d) Do this check with the fluid at normal driving temperature (7080_ C (158176_ F)). If the level is at the low side, add fluid. NOTICE: Do not overfill. HINT: Wait about 30 minutes before checking the fluid level after extended driving at high speeds in hot weather, driving in heavy traffic or with a trailer. 32. EXHAUST SYSTEM Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected. Part tightened Spark plug X Cylinder head Front seat X Body Front suspension member X Body Rear suspension member X Body Rear suspension member rear cushion X Body Chassis Brake Engine SERVICE DATA TORQUE SPECIFICATIONS SERVICE SPECIFICATIONS Disc runout Parking brake Lining thickness Drum inside diameter Steering linkage Steering wheel freeplay Ball joint Vertical play Front and rear brakes Pad thickness Disc thickness Correct electrode gap Firing order Valve clearance Spark plug Recommended spark plug MAINTENANCE Minimum Minimum (Front) (Rear) Maximum SERVICE SPECIFICATIONS Maximum 0.3 mm (0.012 in.) Minimum 1.0 mm (0.039 in.) Maximum 191 mm (7.520 in.) Maximum 30 mm (1.18 in.) ND PK16R11 NGK BKR5EP11 1.1 mm (0.043 in.) 153624 Intake 0.150.25 mm (0.0060.010 in.) Exhaust 0.250.35 mm (0.0100.014 in.) Nm 18 37 196 196 43 1.0 mm (0.039 in.) 30 mm (1.181 in.) 15.0 mm (0.591 in.) 0.05 mm (0.0020 in.) kgfcm 180 375 2,000 2,000 440 ftlbf 13 27 145 145 32 MA17 MA0030E MA0020T MA18 MEMO ...
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This note was uploaded on 05/03/2010 for the course BUSINESS econ203 taught by Professor Shivaggo during the Spring '10 term at Columbia College.

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