PERIODIC MAINTENANCE SERVICES 1 +5 Pay SUBARLJ. ‘SCHEDULE OF INSPECTION AND ha MAINTENANCE SERVICES. 1. DRIVE BELT(S) [EXCEPT CAMSHAFT] 1992 2. CAMSHAFT DRIVE BELT (TIMING BELT) 3. ENGINE OIL .. . ENGINE OIL FILTER . REPLACE ENGINE COt COOLING SYSTEM, HOSES AND CONNECTIONS SERVICE 6. REPLACE FUEL FILTER AND INSPECT FUEL SYSTEM, LINES AND CONNECTIONS MANUAL 2. AIR CLEANER ELEMENT 8. SPARK PLUGS 9, ENGINE IDLE SPEED (FOR CARBURETOR ENGINE ONLY) AND IDLE MIXTURE (NOT NECESSARY FOR CATALYTIC CONVERTER EQUIPPED VEHICLES) 10. TRANSMISSION/DIFFERENTIAL (FRONT AND REAR) GEAR OIL AND AUTOMATIC TRANSMISSION FLUID 11, BRAKE FLUID 12, DISC BRAKE PADS AND DISCS/FRONT AND REAR AXLE BOOTS AND AXLE SHAFT JOINT PORTIONS .... 18, BRAKE LININGS AND DRUMS 14, INSPECT BRAKE LINES AND CI OPERATION OF PARKING AND SERVICE BRAKE ‘SYSTEM 1. CLUTCH AND HILL-HOLDER SYSTEM 16. STEERING AND SUSPENSION SYSTEM 17. FRONT AND REAR WHEEL BEARING LUBRICANT .. 22 25 27 29 31 33 36 42CCortinue perlodic maintenance beyond 100,000 km {80, 000 miles) or 48 months by returning tothe frst col umn of the maintenance schedule and adding 100,000 km (80, 000 miles} of 48 monthe to the column headings. PERIODIC MAINTENANCE SERVICES. ‘Symbols used: Fi Ropia Inspect, end than adjust, correct o replace if necessary. : Perform () : Recommended service for safe vehicle operation ‘MAINTENANCE INTERVAL [Number of months or km (las), whichever occurs frst} MAINTENANCE ITEM Months 2 24 38 48 | REMARKS: fete} es a sie ee ee ete ee ; + mame re yon ee ate [aw noe 9 ; Sa ae se Aa hoe re myn a ee : ; a ie aaa nee : heres [77 [Air cteaner element 1 R 1 | See NOTE 2) tat See m : mmm] pp Sg i rales mito = ieee loco . lone cenraracnrerenemenes| [sf || 1 fen = ere as [eae eecanamnserameemmmnes] fv + |r |r [va Adjust pedal 16 |cuach and hited system ra 1 [feat = fart Stas 17 | Front and rear bearing lubricant ) @PERIODIC MAINTENANCE SERVICES {o000) 1-5 » NOTES: “Severe driving conditior d 1) When the vehicle is used under severe driving con- ditions mentioned below*, the engine oil and oi filter should be changed more frequently. 2) When the vehicle is used under severe driving con- ditions mentioned below*, the air filter elements should be replaced more frequently. 3) When the vehicle Is used under severe driving con- ditions mentioned below*, inspection should be performed at every 12,500 km (7,500 miles) or 6 months whichever occurs first. 4) When the automatic transmission vehicle Is fre- ‘quently opersted under severe conditions, such as pulling trailer or driving on sand, replacement of transmission fluid and front differential thould be performed more frequently. 5) When the vehicle is used under following areas, change fluid every 25,000 km (15,000 miles) or 12 months whichever occurs first. (1) High humidity areas {2) Mountainous reas (1) Operating in extremely cold weather (Items 3, 4 ‘and 16 only) (2) Pulling trailer (Items 3, 4, 12 and 13 only) (8) Repeated short trips (Items 3, 4, 12 and 13 only) (4) Driving on dusty roads (Items 7, 12, 13 and 16 only) (6) Driving on rough and/or muddy roads (Items 12, 13 and 16 only) (6) Driving in areas using road salt or other corrosive materials (Items 6, 12, 13, 14 and 16 only) (2) Living in coastal areas {Items 6, 12, 13, 14 and 16 only)rT eee 1-5 [01A0] PERIODIC MAINTENANCE SERVICES See Cee Cece ECC eee ee eee WAINTENANEE TERVAL y = [Number of months or km (miles) wh yer occurs first] 1. Drive Belt(s) aie 7 on 7 ig [Except Camshaft] mow Tye | as 7 ete einer moo | ys [ow | wo | « | © i 7 i 7 ‘a force 98 N (10 kg, 22 tb) midway between the ‘A: INSPECTION Re ee eS Tt pulleys. 1) Replace belts, if cracks, fraying or wear is found. 2) Check drive belt tension and adjust it if necessary by changing alternator installing position and/or idler pul- ley installing position. Tendion Pulley arrangement mm (in/98 N {10 kg, 22 tb) A * Now bot: 79-30 (0278 — 0354 ating belt: 20 n0 (ose 0439) (0384 — 0208 Fig. 1 1-204 &) : ¢ © Now bat 70-99 (0276 — 0354) esting bot 30110 (0.354 — 0499) Fig. 2 Aa | C/P: Crankshaft pulley UP; Idler pulley ALT: Alternator pulley *There is no belt [8] on models without an air condi- P/S: Power steering oil pump pulley tioner. AVC: Air conditioner compressor pulley (PERIODIC MAINTENANCE SERVICES. B: REPLACEMENT 1. REMOVE V-BELT COVER. » Fig. 3 2, FRONT SIDE BELT (Driving Power Steering Oi! Pump and Alterna- tor) 1) Loosen the lock bolt on the slider bolt. 2) Loosen the slider bolt, ‘Siider bor (0183) 1-5 2) Install @ new belt and tighten alternator mounting bolts so as to obtain the specified belt tension shown in the above table. 3) Wipe off any oil or water on belt and pulleys. 3. REAR SIDE BELT (Driving Air Conditioner) Before removing the rear side belt, remove the front side belt. 1) Loosen the lock bolt on the slider bolt. 2) Loosen the slider bolt. ZAe-S? oO iz (ioe ( Usktal roa » Fig. 4 ; 3) Remove the front side belt. 4) Install a new belt, and tighten the slider bolt so as to ‘obtain the specified belt tension shown in the above table. 5) Tighten the lock nut. Wipe off eny oil or water on the belt and pulley. (Driving Atternator only) 1) Loosen alternator mounting bolts and remove belt. B1-049) Fig. 6 3) Remove the rear side belt. 4) Install a new belt, and tighten the slider bolt so as to ‘obtain the specified belt tension shown in the above table. 5) Tighten the lock nut. Wipe off any oil or water on the belt end pulley.1-5 [02A0] 2. Camshaft Drive Belt (Timing Belt) A: REPLACEMENT 1) Disconnect ground cable (—} from battery. 2) Remove reserve tank. PERIODIC MAINTENANCE SERVICES TWANTENANGE WTERVAL [Number of months or km (miles) whichever occurs first) Werte a [m= |» | « xiao Tse | as | wo | om | 0 moet Pow | ow | we | 4) Remove radiator fan ASSY. {1) Remove the two bolts from the upper side of the shroud, (2) Loosen the two bolts at the lower side of the shroud, Biss] Fig. 7 3) Remove radiator fan motor connector and air condi- tioner fan motor connector. 81-053, Fig. 9 (3) Remove radiator fan ASSY. Remove air conditioner fan ASSY in same steps described in the removal of radiator ASSY. 5) Remove V-belt cover.PERIODIC MAINTENANCE SERVICES 6) Remove V-belts, {Refer to “Drive Bett(s)”.) 7) Remove air conditioner compressor drive belt ten- sioner. 8) Remove crankshaft pulley, 9) Remove front belt covers. 10) Loosen the 2 tensioner adjuster bolts. f Fig. 11 11) Remove the 2 belt idlors. 12) Remove camshaft drive bett (timing belt). Jo2ct)_1-6 Br08e Fig. 12 For removal of camshaft drive belt, refer to “2-3 ENGINE” [W2A2}. B: INSTALLATION To install, reverse order of removal procedures, For installation of tensioner adjuster and camshaft drive bolt, refer to “2-3 ENGINE” [W2C2} [W2C3]. C: INSPECTION 1. SOHC MODEL 1) Remove left and right timing belt covers @ and @. 81-485 Fig. 13 2) While cranking engine at least four rotations, check timing belt back surface for cracks or damage. Replace faulty timing belt as needed. 3) Measure timing belt width W. If it is less than 27 mm (1.06 in}, check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (square- ness). Replace worn timing belt. 4) Install left and right timing belt covers @ and @.1-5 [02c2] PERIODIC MAINTENANCE SERVICES 2. DOHC MODEL 3), Measure timing belt width W. If itis less then 30 mm. 41) Remove left and right timing belt covers @ and @. _(1.18in), check idlers, tensioner, water pump pulley and 2) While cranking engine at least four rotations, check cam. sprocket to determine idler alignment (square- timing belt beck surface for cracks or damage, if a fault ness). Replace worn timing belt. is found replace the bolt with a new one. 4) Install left and right timing belt covers © and @. Brst8 Fig. 14PERIODIC MAINTENANCE SERVICES 1030) 1-5 ‘MAINTENANCE INTERVAL [Numor of monthe or km (miles) whichever occurs first 3. Engine Oil ‘ctu: 2 Pyare ar a 1,000 too | ae | we | wo | 7 | 10 1,000 io | ys | ws | a | as | oo Change avery 12500 km (7,800 miles) or @ morthe, whichever occurs fst, A; REPLACEMENT 3) Tighten engine oil drain plug after draining engine 1) Drain oa oil by loosening engine oil drain plug. ed nen 4) Fill engine oil through filler pipe up to upper point on. level gauge. Make sure that vehicle is placed level when checking oil level. Use engine oil of proper quality and viscosity, selected in accordance with the table below. © Recommended oil API classification: SF or SG “GAE Viecoity No, and Applicable Temperature Fig. 15 ¢r)got4s 0 2990 00 2) Open engine oil filler cap for quick draining of the | (c) 24-26 -18 5 0 16 32 engine oil, 10w30, 10W40__|*t 10W-20, 10.40 +2 Fig. 17 1: For Carburetor engine 2: For SPFi, MPFl and TURBO engine 1.278 81.0871-5 [0380] PERIODIC MAINTENANCE SERVICES ‘The proper viscosity helps starting by reducing viscous friction and thus increasing anking speed. ‘2, Insert the oil level gauge into gauge hole in proper direction as figure. b, When replenishing oil, it does not matter ifthe oll to be added is a different brand from that in the engine, however, use oll having the API classification and SAE viscosity No. designated by SUBARU. ¢. SAE 5W-30 Is not recommended for sustained high speed driving. d. If vehicle is used in desert sreas or areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: “30, 40, 10W — 50, 20W — 40, 20W — 50”” 5) Close engine oil filler cap. 6) Recheck the oil level when the engine is cold. If necessary, add oil up to the upper pain on level gauge. INSPECTION 1) Park vehicle on a level surface. 2) Remove oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation, with the symbol on the top appearing as shown in the fi 4) Remove it again and note the reading. if the engine oil level is below the L” line, add oil to bring the level up to the “F” line, 10 1 get good cold and hot 5) After turning off the engine, wait a few minutes for the oil to drain back into ths oil pan before checking the level. 6) Just after driving or while the engine is warm, engine oil level may show in the range between the “F” line and the notch mark. This is caused by thermal expan- sion of the engine oi 7) To prevent over ing the engine oil, do not add oil above the “F” line when the engine is cold. Upperievel ‘About 1.0.8 (tUsq 2aimpq Lowortevel, toh mark ow-4140-4516) 4.5 € (4.8 US at, 4.0 imp at) Lower level 3.5 €(3.7 US qt, 3.1 Imp at)PERIODIC MAINTENANCE SERVICES [04A0}_ 1-5 ) CEE z [Nurnbt of mont or km re whichever occurs a 4. Engine Worth 2] |» | « x00 |e | ae | wo | wm | 100 moo | Ts | wm | ws | Chango every 12500 en (00 mln) or @ more, viichver oer et A: REPLACEMENT 1) Remove oll filter with an oil filter wrench. 2) Get a new oil fiter and apply a thin coat of engine oil to the seal rubber. D3) instal oil fter by turning it with hand, being careful not to damage seal rubber. 4) Tighten more approximately two thirds turn after the seal rubber contacts the oil pump case. Do not tighten excessively, or oil may leak, 5) After installing oll filter, run engine and make sure that no oil is leaking around seal rubber. ‘The filter element and filter case are permanently joined; therefore, interior cleaning is not necessary.5 _[05A1] PERIODIC MAINTENANCE SERVICES MAINTENANCE INTERVAL . {Numbor of month or km (ila), whichever occurs ft) 5. Replace Engine Coolant and | [,, Sar lrveilcae=| sam [oor] bom ae] ea Inspect Cooling System, 1,000 Hoses and Connections ba s 4a] 12 | 26] a6 | ae | 60 | 72 | 94 | 96 xiao | | 75 16 [228] 20 [ars] «8 |s25| oo 6) Securely tighten engine side drain plugs. A: REPLACEMENT 7) Tighten radiator drain plug securely after draining coolant. (Drain tube may face downward.) 1. REPLACEMENT OF COOLANT 8) Install reserve tank to original position. ‘¢ Non-TURBO model 9) Remove air vent plu 1) Fit end of vinyl tube into drain pipe, 10) Slowly pour prepared coolant from radiator filler Bort to neck of filer, then pour into reserve tank up to 4 “FULL” level. 11) Install air vent plug. 12) Securely install radiator cap. 13) Run engine for more than five minutes at 2,000 to 3,000 rpm. (Run engine until radiator becomes hot in order to purge air trapped in cooling system.) 14) Stop engine and wait until coolant temperature lowers. Then open radiator cap to check coolant level, and add coolant up to radiator filler neck, Next, add coolant into reserve tank up to “FULL” level. ‘The radiator is of the pressurized type. Do not attempt to open the radiator cop immedistaly after the engine Fig. 20 has been stopped. 2) Place a container under drain tube, and loosen drain 15) After adding coolant, securely install radistor and reserve tank caps. coolant. 4) Drain coolant from reserve tank, © TURBO model 5) Remove two drain plugs on engine side, and drain 1) 1 ,osen radiator drain plug after following the same coolant procedures 1) and 2) as described for the Non-TURBO engine. 2) Loosen coolant flow tank cap to drain coolant. 3) Remove the two drain plugs on engine side, and drain coolant. 4) Securely tighten engine side drain plugs after drain- ing coolant. 6) Tighten radiator drain plug securely. 6) Slowly pour prepared coolant from coolant flow tank filler port up to the brim of port, and install cap, then pour coolant into reserve tank up to “FULL” level. 7) Run engine for about 15 minutes, not exceeding 2,000 rpm. (Run engine until radiator becomes hot in order to purge air trapped in cooling system.) 8) Stop engine and wait until coolant temperature low- ‘ers, [below 50°C (12°F) or 80°C (140°F)] Open coolant flow tank cap and add coolant up to the brim of the port. 12PERIODIC MAINTENANCE SERVICES. {05A2] 9} Wait until coolant temperature lowers further [below 30°C (86°F], then pour into reserve tank up to the "ULL" level. 10) Run the vehicle until the coolant temperature rises to 80°C (176°F) and check the level in the coolant flow tank, add coolant up to the “FULL” level. ‘The radiator for the turbo engine does not hav vent plug. Cool ecity (fill up to “FULL” leve 1800 cc, 1600 oc Approx. 6:3 ¢ (6.7 US qt, 5.5 Imp at) 2000 ce Approx. 6.1 (6.4 US qt, 5.4 Imp qt) 2000 oc TURBO Approx. 7.2 (7.6 US at, 6.3 Imp gt} 2200 ec Approx, 5.9 € (6.2 US at, 5.2 Imp qt) air ‘The SUBARU Genuine Coolant containing anti-freeze and enti-rust agents is especially made for SUBARU engine, which has an eluminum crankcase. Always use SUBARU Genuine Coolant, since other coolant may couse corrosion. 2, RELATIONSHIP OF SUBARU COOLANT CON- CENTRATION AND FREEZING TEMPERATURE The concentration and safe operating temperature of the SUBARU coolant is shown in the following diagram. Measuring the temperature and specific gravity of the ; coolant will provide this information, 13 40-20 -20-10 0 10 20 30 4d 80 40) 2211-4 94) (32) (80) (08D (88) 104111221 Coolant. temperature *C (°F) 81-063} Fig, 22 [Example] H the coolant temperature is 25°C (77°F) and its specific gravity is 1.054, the concentration is 35%(point A), the safe operating temperature is —14°C (7°F} (point B), and the freezing temperature is —20°C (—4°F) (point C).PERIODIC MAINTE! [05A3} 3. PROCEDURE TO ADJUST THE CONCENTRA- TION OF THE COOLANT To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50). ‘The amount of coolant that should be replaced can be determined using the following diagram. 8 (63,5) \Nocestary concentration 8 (63,44) 4 42,38) 3 (92,26) 2 (24,1.8) 1 41.1,0.9) ° ‘Quantity of coolant to be drained 2 (US at, Imp at) 50, 10 2 «3040 Concentration of coolant inthe vahiela coating eystem % Concentration of egclant In vehlele and quentity tobe drained 1-064) Fig. 23 14 NANCE SERVICES [Example] ‘Assume that the coolant concentration must be increased from 30% to 40% . Find point A, where the 30 line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 3.0 liters (3.2 US, Qt, 2.6 Imp at). Drain 3.0 liters (3.2 US at, 2.6 Imp at) of coolant from the cooling system and add 3.0 liters (3.2, US at, 2.6 Imp qt) of the undiluted solution of SUBARU coolant. Ifa coolant concentration of 60% is needed, drain all the coolant and refil with the undiluted solution only.PERIODIC MAINTENANCE SERVICES. B: INSPECTION 1) Check the radistor reserve tank and hoses for dam- age or clogging. 2) Check the hose connections for leakage. 3) Check the vaive, spring and packing in the cap for dama 4) Check rubber seal on cap for tears, oration after cleaning it. Install the cap on a tester and if cap does not hold or does not release the specified pressure, replace cap. Brsi9! Cap relief pressure: 88 kPa (0.9 kg/em?, 13 psi) sree 8) if the coolant temperature exceeds 76.0 to 80.0°C (169 to 176°F) while radiator is not so hot, check ther. mostat. 7) If thermostat does not open at 76.0 to 80.0°C (169 to 176°), replace it with a new one. 8) If electric fan does not operate with coolant temper- ature above 90.0 to 94.0°C (194 to 201°F), check ther- moswitch or fan motor, (carburetor equipped model only) 1.065 Fig. 24 5) Check the radiator for leakage. Inspect radiator for leakage using a cap tester and applying a pressure of 157 kPa (1.6 kg/em?, 23 psi). detected, repair or replace the radiator. ‘Won-Turko model Fig. 25 1641-5 [061] PERIODIC MAINTENANCE SERVICES 1:5 1060 eee @ (MAINTENANCE INTERVAL 7 urbe of ms (rile) whichever occurs 6. Replace Fuel Filter and 4 a 7 = ot Inspect Fuel System, Lines %1,000 | 4g 8 50 | 100 7 im and Connections samo |, w | o | #% | o Lf te : 2) Installation A: REPLACEMENT (1) Connect the hose as shown in the figure below: ‘a. Before starting the job, be sure to carry out the Put hose on nipple a6 following. fermion ye ce “No fire” signs near the working area. connect ground cable from battery. Hose: careful not to spill fuel on the floor. 1, CARBURETOR 1) Removai (1) Remove the fuel filter from the holder. (2) Unfasten the clip which connects the fuel hose to the fuel filter, and disconnects the hose. Fuel filter can not be disassembled as ‘ip ‘ridge type. 21.200] Fig. 28 (2) Install the filter to the holder, 2. SPFI AND MPFI 1) Removal (1) Before removing the hose, filter, pump, etc., be re to release the fuel pressure, as follows: ® Disconnect the wiring connector of the fuel pump. ‘© Crank the engine for mote than five seconds. 6 aimee If the engine starts, let the engine run until it stops, After turning IG switch OFF, connect the wiring connector of the fuel pump. {2) Loosen the screw of the hose clamp and pull off ‘the hose from the filter. 16PERIODIC MAINTENANCE SERVICES fo6B1) 1-5 d {3) Remove the filter from the holder. (3) Tighten the hose clamp screw to the specified torque. Tightening torque: 4.0 — 1.5 Nem (0.1 — 0.18 kg-m, 0.7 — 1.4 felb) ‘8, IF the hose is damaged at the clamping portion, replace the hose with » new one. b, If the hose clamp is too deformed, replace with a new one, : © Correct the hose position by removing any twist s0 that it will not interfere with the filter body or washer tank, before tightening the screw of the hose clamp. 2) Installation B: INSPECTION (1) Install the filter to the holder, 9 _ (2) Connect the hose 2s ilustrated betow: 4. FUEL PIPING AND CONNECTIONS Check fuel piping and connections for leakage, Unit: mem tot ‘sctatches, swelling and corrosion. aL 1-4 008-016) When Fitting length Is species HL 1-4 1004-0.16) When fitting length ‘sot specified res] Fig. 30 71-5 _07A0} 7. Air Cleaner Element A: INSPECTION Inspect or change the elements at the specified inter- vals. Under extremely dusty conditions, inspect or change more often, B: REPLACEMENT Brsit Fig. 32 1800 ce and 1600 cc PERIODIC MAINTENANCE SERVICES. -——Wwanrenancenmen [Nurbor of mao mine) wtihover oes et orth 2 fs |» | « x00 1000 | te | a | wo | me | 0 xo | le | | we | of che ote ‘8, Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a spe- cial non-inflammeble slow-evaporating viscous liq- uid. It is resistant to cold weather and has a long service life, Dirt adhering to this filter paper forms porous laminations with the viscous liquid, which function os a filtration layer to reduce dust penetra tion into the filter paper. If this filter paper is cleaned, the fittration layer thus formed will be lost ‘long with the viscous liquid. b, Under extremely dusty conditions, replace it more frequently. 18PERIODIC MAINTENANCE SERVICES (MAINTENANCE INTERVAL [Number of months of tm (miles) whichever occurs fst 8. Spark Plugs Mont. 2 [™ | « | « 1,000 yoo | xe | 2 | so | 7 | 100 4,000 x00 | we | 9% | w& | o R R R For TURBO . ‘ ‘A: REPLACEMENT Spark plua gem 11800 ce, 1600 ce: ) Carburetor Recommended sperk plug NGK BKRGE NIPPONDENSO K20PR-U ‘Spark plug gap thresd 0.8 mm (0.031 in) Oia Size (047 to) SPFI Pitch =1.28 mm Recommended spark plug NGK BKRGE-11 Brot NIPPONDENSO = K20PR-U11 Fig. 33 ‘Spark plug gep ‘When installing spark plugs on cylinder head, tighten to, 4.0 — 1.1 mm (0.039 — 0.043 in) the specified tora 2000 ce (Turbo) Recommended spark plug NGK BKRGEVX ‘Spark plug gap 0.7 — 0.8 mm (0.028 — 0.031 in) 2200 e¢, 2000 oc (Non-Turbo) Without 0, sensor Recommended spark plug NGK BKRGE NIPPONDENSO K20PR-U ‘Spark plug gap 0.8 mm (0.031 in) With 0, sensor Recommended spark plug NGK BKR6E-11 NIPPONDENSO K20PR-U11 Spork plug gap 1.0 — 1.1 mm (0.039 — 0.043 in) 19 , Be sure to place the gasket between the cylinder heed and spark plug. b. If torque wrench is not available, tighten spark plug until gasket contacts cylinder head; then tighten fur- ther 1/4 to 1/2 turns.[oat 9. Engine Idle Speed (for carbu4 retor engine only) and Idle Mixture (not necessary for catalytic converter equipped vehicles) PERIODIC MAINTENANCE SERVICES. (MAINTENANCE INTERVAL [Number of months or km (miles) whichever occurs fist] Months 2 2 36 “8 me |e 5 50 % 100 6 30 6 0 1 1 t 1 A: INSPECTION AND ADJUSTMENT 1, ENGINE IDLE SPEED (for carburetor engine only) ‘a. Before measuring the engine idle speed, make sure that the ignition timing Is within specifications. (Refer to C.2-2 [0280}) b. Make sure thet vacuum hoses, blow-by hoses and other hoses which are connected to the intake system, ‘are tight and secure. ©. Clog the purge hose to carburetor after disconnect ing it. 1) Set the gear position at “Neutral” for MT, or “N” or “P for AT. 2) Warm up engine sufficiently until cooling fan starts to operate, 3) Measure the engine idle speed using the tachome- ter. At this time, make sure thot cooling fon, head light, air conditioner and heater are turned OFF. Engine idle speed: 1800 cc 800 + 50 rpm 1600 cc 900 + 50 rpm 4) ff out of specifications, adjust using the throttle ijusting screw on carburetor. Fig. 34 2. IDLE MIXTURE (not necessary for catalytic converter equipped vehicle} [Carburetor model] ‘a. Bofore measuring the idle mixture, make sure that, the ignition timing and the engine idle speed are within specifications. b, Make sure that vacuum hoses, blow-by hoses, and ‘other hoses which ore connected to the intake system, ‘re tight and secure. 41) Set the gear position at “Neutral” for MT, or “N” or “P" for AT. 2) Warm up engine sufficiently until cooling fan starts, 4) If out of specification, adjust using the idle mixture adjusting screw on carburetor.PERIODIC MAINTENANCE SERVICES {09A2] 1-5 ! 3) Measure the idle mixture with the CO meter. Engine idle spood 601%) 800 = 100 rm 10= 06 4) If out of specification, adjust using the idle mixture adjusting screw on air flow meter. Fig. 35 IMPFI model] Before measuring the idle mixture, mal ignition timing and the engine idle speed are within specifications, 1) Set the gear position at “Neutral” for MT, or “N” or “P" at AT. up engine sufficiently until cooling fan starts 211-5 [020811 PERIODIC MAINTENANCE SERVICES a im MAINTENANCE INTERVAL oe - 7 2 of mnths ork ils) whichever occurs fst 410. Transmission/Differential wm nas : a oe a (Front and Rear) Gear Oil x00 | 5 iz i aay and Automatic Transmission i ay Fluid aml fw | we | w bow R Rr A: REPLACEMENT 1, MANUAL TRANSMISSION 1} Drain oil by removing drain plug. Viper ‘a coer ‘oa over40-4489 Br311 Fig, 38 2. AUTOMATIC TRANSMISSION 1) Drain fluid by removing drain plug attr allowing the engine to cool for 3 to 4 hours. Fig. 37 2) Reinstall drain plug after draining oil and tighten it to the specified torque. Tightening torque: Nem (kg-m, ft-Ib) 41 — 47 (4.2 — 4.8, 30 — 36) eee eee 8. Be sure to place a gasket between the transmission case and drain plug. b. Replace the gasket with a new one. 3) Fill transmission gear oil through the oil level gauge hole up to upper point on level gauge. Oil capacity Unt: €(US at Imp ath 1800 08 sepece Fo 26127,23) 1800 ee ‘4W0 (Selective) 36, 20) 2200 ce FW seer 1800 ce 2000 ce 4W0 (Center citferonia | 3.6/2.7, 3.1) 2200 ce 22 2) Reinstall drain plug after draining fluid, and tighten it Tightening torque: 25 Nem (2.5 kg-m, 18 ft-lb) 3) Fill ATF through the fluid level gauge hote, ®PERIODIC MAINTENANCE SERVICES 4 [01044] 1-5 Fluid capacity: € (US qt, Imp qt) 4AT 8.0—8.6(85— 9.1, 7.0—7.6) Oil capacity: €(US gt, Imp qt) @AT 1.11.3 (12 — 1.4, 1.0—1.1) e514) Fig. 40 4AT 44) Run the vehicle until the ATF temperature rises to 60 to 80°C (140 to 176°F) and the check the ATF level. Recommended automatic transmission fluid: ATF Dexron I 3. FRONT DIFFERENTIAL (Automatic Transmission) 1) Drain oil by removing front differential drain plug. BASSE reeadpimnsas de | f Fig. 41 4aT 2) Reinstall drain plug after draining oil, then tighten it to the specified torque. Tightening torque: 25 Nem (2.5 kg-m, 18 fb) ‘8. Bo sure to place a gasket between the differential ‘geer case and the drain plug. 'b. Replace the gasket with a new one, 3) Fill differential gear oll through the oil level gauge ) hole up to upper point on the level gauge. Fig. 42 4AT 4. REAR DIFFERENTIAL {4WD Vehicle) 1) Drain oil by removing drain plug. 2) After installing drain plug onto rear differential gear case firmly, fill oil up fully to the mouth of filler hole. Oil capacity: 0.8 € (0.8 US qt, 0.7 Imp qt) 3) Install filler hole plug onto rear differential gear case firmly. Fig. 43 231-5 {01044} PERIODIC MAINTENANCE SERVICES Recommended oil oN. end une IPF1-30 9 390 60 9p frorse-e 6 te a2 #Trensmiion Sedattorenti 3 were aw as ew e4yv0 ree sitre EG, TONE b1.202 Fig. 44 a. Each oil manufacturer has its base oll and edditives. ‘Thus, do not mix two or more brands. b. *For differential gear oil (AT) © Apply fluid packing to drsin plug threads before installation. Fluid packing: ‘Three Bond 1105 or equivalent Drain plug tightening tora 44. Nem (4.8 kg-m, 33 ft-lb)PERIODIC MAINTENANCE SERVICES. 11. Brake Fi fo11ag] 1 ‘MAINTENANCE INTERVAL [Number of monthe or km (miles) whichever oecure fist ‘Menthe 2 2 % e 1,000 yore | 8 8 60 7% | 100 1,000 ee | -cH 15 30 48 cy R a A; REPLACEMENT #8. The FMVSS No. 116, fresh DOTS or 4 brake fluid must be used. b. Cover bleader with waste cloth, when loosening it, to prevent brake fluid from being splashed over sur- rounding parts. ©. Avoid mixing different brands of brake fluld to pre- vent degrading the quality of the fluid. . Be careful not to allow dirt or dust to got into the reservoir tank. @. During bleeding operation, keep the brake reserve tank filled with brake fluid to eliminate entry of alr. {. Brake pedal operating must be very slow. @ For convenience and safety, it is advisable to have ‘two man working. h. The amount of brake fluid required is approxl- mately 300 mé (10.1 US fl 02, 10.6 Imp fl oz) for total brake system, 41) Either jack up vehicle and place a safety stand under it, oF left up vehicle. 2) Remove both front and rear wheels. 3) Draw out the brake fluid from master cylinder with syring 4) Refill reservoir tank with recommended brake fluid. Recommended brake fluid FMVSS No. 116, fresh DOTS or 4 brake fluid 5) Install one end of a vinyl tube onto the air bleeder of, ‘and insert the other end of the tube into a container to collect the brake fluid. Replacing quence D—-@ —- © —@ Ol eo. C_)e Roerieh Fig. 46 6) Instruct your co-worker to depress the brake pedal slowly two of three times and then hold it depressed. 7) Loosen bleeder screw approximately 1/4 turn until 8 ‘small amount of brake fluid drains into container, and then quickly tighten screw. 8) Repeat steps 6) and 7) above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube, ‘Add brake fluid as necossary while performing the air bleed operation, in order to prevent the tank from run- ning short of brake fluid. 9) After completing the bleeding operation, hold brake pedal depressed and tighten screw and install bleeder cap. nq ® ight Rear 25{011A0} PERIODIC MAINTENANCE SERVICES htening torque (Bleeder screw): ™? wa Nem (0.7 — 0.9 kg-m, 6.1 — 6.5 ft-lb} Fig. 47 11) Depress brake pedal with a force of approximately 284 N (30 kg, 66 Ib} and hold it there for approximately 20 seconds. At this time check pedal to see if it shows any unusual movement. Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage. 12) Install wheels, and drive cer for a short distance between 2 to 3 km (1 to 2 miles) to make sure brakes are operating properly. 26PERIODIC MAINTENANCE SERVICES [012A1) ) ANTENANGE WTERAL 12. Disc Brake Pads and Discs ae ee en ee a /Front and Rear Axle Boots | [ico ae iz re a ‘0 and Axle Shaft Joint Por- bed pa i 16 30 45 Cy tions rls A: INSPECTION 1. DISC BRAKE PAD AND DISC (Front and Rear) 1) Jack up vehicle and support with rigid racks, Then remove wheels. 2) Visually check pad thickness through inspection hole of disc brake assembly. Replace pad if necessary. FRONT) — qi ad thicknose including back motel mm (i) \ | Front Rear es Seana T7087, 75089) y Wear ini 7510296) 65 (0.266) on hole: Wear limit Inspection hol prstr| [tocclude beck matay| 1510959) 1.8 (0.059) etn ‘2, When replacing @ pad, always replace the pads for both the left and right wheels at the same time, Also replace pad clips If they are twisted or worn. Lining b, The clip incorporated with pad is also used as warning device for worn pads. When we ‘the pad to such an extent that the cli contact with the rotor, (squeak) Is pro- duced. If such a noise is noticed, replace the pads. ' ‘Back metal “Thickness of pad Brsia) Fig. 49 271-5 [012A2] PERIODIC MAINTENANCE SERVICES 3) Dise rotor _ 2, FRONT AND REAR AXLE BOOTS 4 Check for wear and damage, and correct or replace if inspect front and rear axle boots for deformation, dam- abnormal. age or failure. If faulty, replace them with new ones. Brake dis thickness mm rd Front Rese For 1s” | Foria'é wheels | 18" whoole | SH | Ventloted Standard | 1010.71) | 24(004 | t0(oa% | 19 (0.79 Weer limit | re (o.ea | 221087) | 8.510.338) | 16 (063) Br-086) Fig. 53 eke of dae Bu 81-304 Fig. 61 Disc rotor runout: Limit: 0.10 mm (0.0039 in) Mesure the disc rotor runout at @ point less than 5 mm (0.20 in) from the outer periphery of the rotor. ig. 54 Bi-085, 28PERIODIC MAINTENANCE SERVICES [or9A21_ 1.5 _——_____________ PERIODIC MAINTENANCE SERVICES 01321_1-5 a [eta ENTERAL aw | ae {Munro monte of hm ile) wishover osu 13. Brake Linings and Drums onthe ee mao tae [ms | wo |» | 10 rs a 7 7 A: INSPECTION 1. REAR DRUM BRAKE 1) Remove brake drum, end check that there is no fluid leakage from wheel cylinder. (jl there is tuid leakage from wheel cylinder, replace it 2) Inspect brake shoes for damage or deformities and check brake linings for wear. Always replace both leading and trailing brake shoes for the left and right wheels at the same time, Measuring inside diameter Brake lining thickness excluding brake metal: mm (0.161 in) 1-308] Fig. 56 If deformation or wear on back plate, shoe etc. is notable, replace the effected parts. 2. PARKING BRAKE Inspect brake finings and drums of both sides of the tear brake at the same time by removing brake drums. ing 1) Inspect brake shoes for damage or deformities and check brake linings for wear. Alweys replace both primary and secondary bral shoes for the loft and right wheels at the same time. Brake lining thickness excluding beck motal: Standard:3.2 mm (0.128 in) Srrantetak Wear limit:1.5 mm (0.059 in) Lower shoe raturn spring 1.208) Fig, 65 3) Check brake drum for wear, dents or other damage. If the inside surface of brake drum is streaked, correct. the surface with emery cloth (#200 or more). If it Is ‘unevenly worn, tapered, or the outside surface of brake drum is damaged, correct or replace it. Broke drum diameter: Standard: 228.6 mm (9 in) = Wear limit: 230.8 mm (9.08 in) Brake shoe rime (Secondary) 1-207 Fig. 57 29PERIODIC MAINTE 1-5 [01381] 2) Check brake drum for wear, dents or other damage. If the inside surface of brake drum is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn, tapered, or the outside surface of brake drum is damaged, correct or replace it. Brake drum inside diameter: ‘Standard: 170 mm {6.69 in} Wear limit: 171 mm (6.73 in) Dine brake ASSY ‘Maasuring inside dlernatar 1-089) Fig. 58 3) If the deformation or wear of back plate, shoe, etc. are notable, replace them. 4) When the shoe return spring tension is excessively weakened, replace it, taking care to identify upper and lower springs. NANCE SERVICES. B: ADJUSTMENT 1, REAR DRUM BRAKE ‘The main brake is adjusted automatically, and so there is no need to adjust it. 2, PARKING BRAKE For rear dise brake, adjust parking brake after bleeding the air. 1) Remove rear cover (rubber) installed at back plate. 2) Turn adjuster toward allow mark (upward) until itis locked slightly, by using slot-type screwdriver as shown in illustration below. Fig. 59 3) Turn back (downward) adjuster 3 to 4 notches. 4) Install cover (rubber) at original position correctly. 30PERIODIC MAINTENANCE SERVICES 14. Inspect Brake Lines and Check Operation of Parking and Service Brake System [01481] MAINTENANCE INTERVAL [Number of month or km (miles) whichever occurs fire] ‘Morthe @ 4 3% 48 1,000 ie | 8 50 % 100 1,000 eo 1 6 0 48 Cy ? A: INSPECTION B: CHECKING 1. BRAKE LINE 1) Check scratches, swelling, corrosion and/or traces of fluid leakage on brake hoses or pipe joints. 1, SERVICE BRAKE 1) Check the free pley of brake pedal with a force of less than 10 N (1 kg, 2 Ib). Fig. 61 2) Check the possibility of adjacent parts interfering with brake pipes/hoses during driving, and loose connsctions/elamps. 3) Check any trace of fluid leakage, scratches, ete. on ler, wheel cylinder, pressure control valve and hill-holder. When the br than the specified limit, the brake fluid warning light on the instrument panel will come on. 31 Brake pedal free play: 1.0 — 3.0 mm (0.039 — 0.118 in) If the free play is out of specifications above, adjust the brake pedal as follows: (1) Be sure engine is off. (No vacuum is applied to brake booster.) (2) There should be play between brake booster cle- vis and pin at brake pedal installing portion. (Depress brake pedal pad with a force of less than 10 N (1 kg, 2 tb) to a stroke of 1.0 to 3.0 mm (0.038 to 0.118 in). 10~30mm (0.039 — 0.158 in) Fig. 62 {8) Depress the surface of brake pad by hand. (4) If there is no free play between clevis clevis, loosen lock nut for operating rod and adjust operating rod by turning in the direction that short- ens it. 2) Measure the distance between brake pedal and floor when the pedal is depressed with a force of approxi- mately 294 N (30 kg, 66 Ib),[01482] Brake pedal reserve distance: More than 67 mm (2.64 in)/294 N (30 kg, 66 Ib) (0039 —0.118 in) 2. Stroke 4 Reserve distance 5 6 Bi-004) Fig. 63 3) Check to see if airs in the hydraulic brake line by the {feel of pedal operation. If air appears to exist in the line, bleed it from the system. 4) Check for even operation of all brakes, using a brake tester or by driving the vehicle for a short distance on a straight road, 2, PARKING BRAKE SYSTEM 1) Remove front console cover. 2) Remove rear console cover. 3) Adjust parking brake lever by turning adjuster (dou- ble nut) until parking brake lever stroke is set at 7 to 8 notches with operating force of 196 N (20 kg, 44 Ib), ‘Adjuster {Double nut) yo 1-095} Fig. 64 PERIODIC MAINTENANCE SERVICES 3. BRAKE SERVO SYSTEM 1) With the engine off, depress the brake pedal several times applying the same pedal force: Make sure the travel distance should not chang 2) With the brake pedal depressed, start the engine: Make sure the pedal should move slightly toward the floor. 3) With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds: Make sure the pedal height should not change. 4) Check valve is built into vacuurn hose. Disconnect vacuuum hose to inspect function of check valve. Blow air into vacuum hose from its brake booster sice ‘end: Air must flow out of engine side end of hose. Next blow air into hose from engine side: Air should not flow ‘out of hose. Replace both check valve and vacuum hose if check valve is faulty. Engine side of vacuum hose is indicated by marking “ENGINE” as shown, as ee voor - SENG (mm a Fig. 65 5) Check vacuum hose for cracks or other dams When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections, 6) Check vacuum hose to make sure it is tight and secure. 32PERIODIC MAINTENANCE SERVICES [o15A1] 1. MAINTENANCE INTERVAL [Number of monthe or km (miles) whichover occurs first 15. Clutch and Hill-holder Sys- | [7,, w [aw [oe | « tem mo | as | as | co | os | 100 min. w | 0 | © | 0 7 7 i 7 A: INSPECTION AND ADJUSTMENT Fut woke: 1. MECHANICAL APPLICATION TYPE ta Toa 200m (012-016) 1) Inspect free play of clutch pedal by operating pedal by hand. | If itis out of the specified value, adjust it by turning adjusting nut on engine side of clutch cable at release fork. ‘Standerd free play: At clutch pedal 10 — 20 mm {0.39 — 0.79 in) At conter of cable on clutch release fork 3 — 4 mm (0.12 — 0.16 in) 1 Lock nut 2 Adjurting nut 3 Release fork Units mm (ind peste Fig. 67 Lock nut tightening torque ada ploy: 5.4 — 0.3 Nem (0.55 — 0.95 kg-m,4.0 — 6.9 ft-b) fOr20mm (020-0791 pr oa ie @. When replacing clutch cable with a new one and/or making clutch pedal free play adjustment, make ‘adjustment of hillholder system without fail as fol- lows, b. After replacing clutch cable and/or pressure hold valve {PHV) cable with @ new one, depress clutch pedal about thirty (30) times 2s @ running i Prior to this adjustment. 331-6 [01562] PERIODIC MAINTENANCE SERVICES B: INSPECTION AND ADJUSTMENT 2, HYDRAULIC APPLICATION TYPE 1) Inspect free play of clutch pedal by operating pedal by hand. Ifitis out of the specified value, loosen lock nut for push tod and adjust push rod by turning in the direction that 3.— 15 mm (0.12 — 0.59 in) Units me (ind look nut Ful atroke as 670) Bie Fig. 68 Tightening torque (Adjusting nut): 9 — 11 Nem (0.9 — 1.1 kg-m,6.5 — 8.0 ft-Ib) 2) Check the fluid level using the scale on the outside of, tho clutch master cylinder tank. If the level is below MIN”, add clutch fluid to bring it up to “MAX”. Recommended clutch fluid: FMVSS No. 116, fresh DOTS or DOT4 brake fluid a. Avoid mixing different brands of brake fluid to pre- vent degradation of the fluid. b. Be careful not to allow dirt or dust to get into the reservoir tank. ©. Use fresh DOTS or DOTS brake fluid when refilling fluid, 3. HILL-HOLDER 1) Confirm stopping and starting performance by acti- vating hil-holder on an uphill road of 3° or higher incli- nation. (1) If vehicle does not stop; Tighten adjusting nut of PHV cable, Fig. 69 (2) If vehicle does not start properly; ‘® Case A — When hill-holder is released later than engagement of clutch (engine tends to stal Loosen adjusting nut gradually until smooth starting is enabled. ‘© Case B— When hill Tighten adjusting nut so that hill-holder is released later than engagement of clutch (status in Case A). Then make adjustment the same as in Case A. 2, Whenever turning adjusting nut, hold inner cable with pliers to prevent it from turning. (PERIODIC MAINTENANCE SERVICES (01581) 1-5 b, Replace pressure hold valve (PHY), return spring o or PHY or PHV cable with new ones, if they and/or damaged. 2) Make sure that the automatic adjuster is operating. © Check if the cable is able to be pulled out as shown in the figure below. 355 [016A1] 16. Steering and Suspension System A: INSPECTION 1, STEERING WHEEL 1) Set steoring wheel in a straight-head position, and check wheel spokes to make sure they are correctly set in their specified positions. 2) Lightly turn steering wheel to the left and right to determine the point where front wheels start to move. Measure the distance of the movement of steering Wheel at the outer periphery of wh ‘Steering whee! free play: © — 17 mm (0 — 0.67 in) Free play: O= 17 mm (0-067 1») Br.sta| Fig. 72 3) Move st wheel vertically toward the shaft to ascertain if there is play in that direction. Maximum permissible play: 0.5 mm (0.020 in) 4) Drive vehicle and check the following items during operation. (1) Steering force «nm The effort required for steering should be smooth and even at all points, and should not vary. (2) Pull to one side Steering wheel should not be pulled to either side while driving on a level surface. PERIODIC MAINTENANCE SERVICES WANTENANGE WTERVAL |Numbr of mon orem wht ose Wen 2 fs |» |« xo ie | a | | m | 10 aoe] [we | » | « | o pa pa (3) Wheel runout... Steering wheel should not show any sign of runout. (4) Return factor wnsons Steering wheel should return to its original position after it has been tured and then released, 2. STEERING SHAFT JOINT 1) When steering wheel free play is excessive, discon- nect universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing irection). Also inspect for any damage to sealing or ‘worn serrations. Fig. 73 If the joint is loose, retighten the mounting bolts to the specified torque, Tightening torque: 21 — 26 Nem (21 — 7 kg-m, 15 — 20 ft-lb) 36PERIODIC MAINTENANCE SERVICES ) 3, GEARBOX 1) With wheels placed on a level surface, turn steering whee! 90° in both the left and right directions. While wheel is being rotated, reach under vehicle and check for looseness in gearbox, Tightening torque: 47 —71 Nem (4.8 —7.2 kg-m, 35 — 52 ft-lb) 1-109] Fig. 74 2) Check boot for damage, cracks or deterioration. ise ER iso brake ASSY Fig. 76 3) With vehicle on a level surface, quickly turn steering Wheel to the left and right. While steering wheel is being rotated, check the gear backlash, if any unusual noise is noticed, adjust the gear backlash in the following manner. (1) Tighten adjusting screw to 6 Nem (0.6 kg-m, 3.6 ft-lb) and then loosen. Repeat this operation twice. (2) Retightan adjusting screw to 5 Nem (0.5 kg-m, 3.6 ft-lb) and back off 30°, (3) Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread. 1-104] 01645] 1-5 ‘Apply liquid pecking to at laste 1/3 of entire pavimeter. 50] Fig. 76 (4) Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using SPANNER (926230000). Tightening torque (Lock nut}: 29 — 49 Nem (3.0 —5.0 kgom, 22 — 36 ft-lb) Hold the adjusting screw with wrench to prevent it from turning while tightening the lock nut. 4, THE-ROD 1) Check tie-rod and of other damage. 2) Check connections of knuckle ball joints for play, inspect for damage on dust seals, and check the free play of ball studs, 3) Make sure that the cotter pin is installed correctly in the castle nut of the tie-rod end. -rod ends for bends, scratches 1464] Fig. 77 5. POWER STEERING FLUID LEVEL 1) Place vehicle with engine “off” on the flat and level surface. 2) Check the fluid level by removing filler cap of oil pump. 371-5 [016A5) (1) Check at temperature 21°C (70°F) of fluid temper- ature. Fig. 78 (2) Check at temperature 60°C (140*F) of fluid tem- perature. 1.108 Fig. 79 3) Fluid level should be maintained in the each speci- fied range on the indicator of filer cap. fluid level is at lower point or below, add fluid to keep the level in the specified range of indicator. If fluid level is at upper point or above, drain fluid to keep the level in the specified range of indicator by using a syringe or the like, Recommended fluid Manufacturer BP. CALTEX ATF CASTROL Dexron it MOBIL ‘SHELL TEXACO Fluid capacity: 0.7 € (0.7 US qt, 0.6 Imp at) PERIODIC MAINTENANCE SERVICES. 6. POWER STEERING FLUID FOR LEAKS Inspect the underside of oll pump and gearbox for power steering system, hoses, piping and their cou- pings for fiuid leaks. If fluid leaks are found, correct them by retightening their fitting bolts (or nuts) and/or replacing their parts. ‘& Wipe the leakage fluid off after correcting fluld Yeaks, or a wrong diagnosis is taken later. b. Also pay attention to clearances between hoses (or pipings) and other parts when inspecting fluid leaks, 7. HOSES OF OIL PUMP FOR DAMAGES: 0 ke} 1.465 Fig. 80 Check pressure hose and return hose of oil pump for crack, swell or damage. Replace the hoses with new ‘ones if necessary. Prevent hoses from revolving and/or turning when installing hoses. ‘8, POWER STEERING PIPES FOR DAMAGE Check power steering pipes for corrosion and damage. Replace pipes with new ones if necessary.PERIODIC MAINTENANCE SERVICES [016A11]_ 1-5 Do. ceanzox BOOTS Inspect both sides of gearbox boots as follows, and correct the defects if necessary. Ss PWY Ly eovansens {| ee averse ator instaling 1.309] Fig. 81 4 1) © and © position of gearbox boot are fitted corre- spondingly in @ and © grooves of gearbox and the rod, 2) Clips are fitted outside of @ and © positions of ‘ boot 8 8) Boot does not have crack, hole, ae Rotate © position of gearbox boot against twist of it Brit produced by adjustment of toe-in, etc. Fig. 82 10. FITTING BOLTS AND NUTS. Tightening torque: Nem (kg-m, felb) Inspect fitting bolts and nuts of oil pump and bracketfor —-T1: 18 — 28 (1.8 2.3, 13—17) looseness, and retighten them if necessary. Ta: 42— 62 (43 —63,31—46) 73: 20—24(20—24,14—17) Inspect and/or retighten them when engine is cold, 11. SUSPENSION SYSTEM Care should be taken not to apply paint, undercoating agent, anti-corrosive wax, etc. to the following parts of alr-suspension equipped models while refinishing the ’ undercerriage. (1) Diaphragm and rolling surfacos (2) Air suspension compressor and dryer assembly 1) Play of front ball joint .... Inspect every 25,000 km (15,000 miles) or 12 months, whichever occurs first. (1) Jack up vehicle until front wheels are off ground. (2) Next, grasp bottom of tire and move it in and out. If relative movement is observed between brake disc cover and end of transverse link, ball joint may be excessively worn. 391-5 [016A11] Housing “Traneverte tok Dise cover Ball joint Relotive movement 81-467, Fig. 63 (3) Next, grasp end of transverse link and move it up ‘and down. Relative movement between housing and transverse link boss indicates bell joint may be exces- sively worn. Relative movement nsverva lnk Bail joint Bi-468| Fig. 84 (4) If relative movement is observed in tests (2) and (8) above, remove and inspect ball joint according to chapter 4-1. If looseness exceeds standard, replace ball joint, 2) Damage of dust seal .... Inspect every 26,000 km (15,000 miles) or 12 months, whichever occurs first. Visually inspect ball joint dust seal. If it is damaged, remove ball joint as instructed in chapter 4-1 and mea- sure looseness of ball joint. (1) When looseness exceeds standard value, replace ball joint. PERIODIC MAINTENANCE SERVICES (2) When looseness is less than standard value, wipe off old grease, apply the proper amount [about 3 g (0.11 o2)] of designated grease {SUNLIGHT 2, P/N (003602010), and install a new dust seal. ‘When transverse link ball joint has been removed or replaced, check toe-in (or side slip) of front wheel. If front wheel toe-in (or side alip) is net at specified value, adjust according to chapter 4-1 so that toe-in conforms to service standard. 3) Transverse link’s liquid-flled bushing Check oil leaks at or around liquid-filled bushing. If oll leaks, replace bushing. 4) Wheel alignment and ground clearance ... Inspect every 50,000 km (30,000 miles) or 24 months, which- ever occurs first, {1) Unload cargoes and set vehicle in cur weight {empty) condition. (2) Then, check ground clearance of front and rear ‘Suspensions to ensure that thay are within specified values. {Adjusting procedure) — Ground clearance ‘When ground clearance is out of standard, visually inspect following components and replace deformed parts. ® Suspensions components [Front: strut assembly, ‘crossmember, transverse link, etc. Rear: shock absorber, lateral links, trailing link, etc] ‘* Body parts to which suspensions are installed. When no components are deformed, adjust ground clearance by replecing coll spring in the suspension ‘whose ground clearance is out of standard. (3) Check alignment of front suspension to ensure that following items conform to standard values pro- vided in chapters 4-1 and 4-3. © Toe-in (or side slip) ‘© Camber angle © Caster angle © Turing angle of (Adjusting procedure) — Front suspension alignment (a) Camber and caster angles are not adjustable. When camber or caster angle does not conform to standard value, visually inspect following compo- nents and replace deformed parts. ® Suspension components [Strut crossmember, transverse link, etc.] © Body parts to which suspensions are installed. (b) When toe-in (or side slip) is out of standard value, adjust by the method described in chapter 4-1 so that it conforms to service standard. (c) When right-and-left turning angles of tire are out of standard, adjust to standard value by method described in chapter 4-3. (4) Check alignment of rear suspension to ensure that following items are within standard values. assembly,PERIODIC MAINTENANCE SERVICES ‘© Toe.in (or side slip) © Camber angle (Adj procedure) — Rear suspension alignment. When toe (or side slip) or camber angle does not conform to standard value, visually inspect parts listed below. If deformation is observed, replace damaged parts, # Suspension components [Shock absorber, lateral links, trailing link, crossmember, etc.] © Body parts to which suspensions are installed. When no components are deformed, adjust align- ment by the method described in chapter 4-1 so that it conforms to service standard. 5) Oil leakage of shock absorber .... Inspect every 50,000 km (30,000 miles) or 24 months, whichever occurs first. Remove tire and visually inspect shock absorber for oil leakage as instructed in chapter 4-1. Replace shock absorber if cil leaks excessively. 6) Tightness of bolts and nuts... Inspect every 50,000 km (30,000 miles) or 24 months, whichever occurs first. Check bolts shown below for looseness, Retighten, bolts to specified torque. Further, check that cotter pin, in place a8 shown below. If not, install new cotter pin. B18, 4 [o16A11} 4 Fig. 87 Tightening torque: Nem (kg-m, ft-Ib) ‘T1: 83 — 113 (8.5 — 11.5, 61 — 83) 2: 196 — 294 (20 — 30, 145 — 217) 73: 118 — 157 (12 — 16, 87 — 116) ‘T4: 98 — 127 (10 — 13, 72 — 94) 7) Dirt on and damage to rolling diaphragm of air sus- pension ..... Inspect every 25,000 km (16,000 miles) or 12 months, whichever occurs first. (1) After loosening wheel nuts, jack up vehicle until all four wheels are off ground according to instruc- tions in “Pre-Delivery Inspection.” Remove tires. (2) Visually inspect rolling diaphragm. if dirty, remove dirt from diaphragm. Be careful not to da ly inspect rolling diaphragm. Replace sir ASSY if damaged. However, replace- not required if only fine scratches on dia- phragm surface caused by sand. These do not present a problem. (4) Visually inspect rolling diaphragm for rust. if rusty, remove rust and touch up. When touching up diaphragm, be coreful paint do not adhere to diaphragm. (Lower jack after touch-up paint has dried completely.) 8) Damage to suspension parts Check the following parts and the fastening portion of the car body for deformity or excessive rusting which impairs the suspension. Replace faulty parts. If minor tust formation, pitting, etc. are noted, remove rust and apply remedial anti-corrosion measures. (1)_Front suspension © Transverse link © Crossmember © Strut {including air suspension) (2) Rear suspension © Crossmember © Lateral inks © Trailing link © Strut (including air suspension)1-5 {017A1) 17. Front and Rear Wheel Bearing Lubricant A: INSPECTION Inspect the condi grease as follows: n of front and rear wheel bearing 1, FRONT WHEEL BEARING 1) Jack up the front of vehicle. 2) While holding front wheel by hand, swing it in and ‘out to check beating free plat 3) Loosen wheel nuts and remove front wheel. 4) If bearing free play exists in step 2) above, attach a dial gauge to hub and measure axial displacement in axial direction. ‘Service lim Straight-ahead position within 0.05 mm (0.0020 in) Br-119] Fig. 88 5) Remove bolts and self-locking nuts, and extract transverse link from front crossmember. 8) lightly hammering spring pi D.0.J. to transmission spindl 7) Extract D.O.J. from transmi: 5 8) While supporting front drive shaft horizontally with ‘one hand, turn hub with the other to check for noise or binding. if hub Is noisy or binds, disassemble front axle and check condition of oil seals, bearing, etc. PERIODIC MAINTENANCE SERVICES MAINTENANCE INTERVAL [Number of months or km (miles) whichever occurs fret} Werth zfs fas | @ mom Tre | a | wo | m | wo cr) soy | w | w | w | 0 oy 2. REAR WHEEL BEARING 1) Jack up the rear of vehicle, 2) While holding rear whee! by hand, swing it in and out to check bearing free play. 3) Loosen wheel nuts and remove rear wheel. 4) If beating free play exists in step 2) above, attach a dial gauge to hub and measure axial displacement in axial direction, Service limit: ‘Straight-shead position within 0.05 msn (0.0020 in) 1-120] Fig. 89 4WD Hub nit Fig. 90 FWD 5) Turn hub by hand to check for noise or bi If hub is noisy or binds, disassemble front a check condition of oil seals, bearings, etc. 42PERIODIC MAINTENANCE SERVICES 017A2} When the vel self-locking nuts, crossmember. Lightly hammer spring pin which secures 0.0. to rear differential spindle, to remove it. Extract D.O.J. from rear differential spindle. While sup- porting rear drive shaft horizontally with one hand, turn hub with the other hand to check for noise or binding, Hfhub is noisy o binds, disassemble rear axle and check condition of oil seals, bearing, etc. is a 4WD model, remove bolts and ind remove front lateral link from 43