Page 1497 of 1701

PERIODICMAINTENANCE (ForEurope)
Engine andEmission ControlService
Abbreviations: I
=
Inspect andcorrect orreplace asnecessary,
R
MAINTENANCE OPERATION
MAINTENANCEINTERVAL
60 90
(36) (54)
Perform
eitheratnumber ofkilometers (miles)
or months, whichever comesfirst. km
x1,000
(Miles x1,000)
Months
Replace,
30
(18)
12 24
36120
(72) 48
Reference
page
•
Underhood andunder vehicle
GA
CD
Engine anti-freeze cootant(Ethylene glycolbase)(LLC)
SeeNOTE (1)
RMA-19
MA-38
Cooling system
I
I
I
I
MA-21 MA-40
Fuel lines
I
I
MA-22
MA-40
Air cleaner filter(Viscous papertype)*
RRMA-23 MA-41
Intake
&
exhaust valveclearance
SeeNOTE (2) EM-41
-
w
Drive
belts
SeeNOTE (3) I
I
I
MA-17,18
-
z
Ci
Fuel
filter* RMA-22
-
z
w
Spark plugs
SeeNOTE (4)
RR
RRMA-25
-
w
z
Ignition wires'
IMA-26
:::;
-
0
(fJ
PCVfilter* RRMA-26
-
<{
Cl
Vapor lines(Hoses, connections, etc.)
SeeNOTE (5) IIMA-26
-
(Heated) oxygensensor'
I
IMA-27
-
Fuel filter
RR
-
MA-41
--,w
wz
Nozzles SeeNOTE (6)
-
MA-43
(fJ-
wCl
-z
EM-120,
Ow
Timing beltsforcamshalt andinjection pump Replaceevery90,000 km(54,000 miles)
-
124
'. Except forSwedish models
NOTE: (1)Replace atthe first 90,000 km(54,000 miles)or60 months, thenevery 60,000 km(36,000 miles)or24 months, which-
ever comes first.
(2)
If
valve noise Increases, checkvalveclearance.
(3) After 60,000 km(36,000 miles)or24 months, inspectevery30,000 km(18,000 miles)or12 months, whichever comes
first.
(4) For Swedish models,performalmileage intervalonly.
(5) For Swedish models,inspectalthe first 90,000 km(54,000 miles),andthen every 60,000 km(36,000 miles)or24
months, whichever comesfirst.
(6)
If
engine powerdecreases, blacksmoke isemitted orengine noiseincreases, checkand,ifnecessary, adjustthe
fuel injection nozzle'sstartingpressure andthefuel spray pattern.
*
Maintenance itemswith
"*"
should beperformed morefrequently accordingto"Maintenance UnderSevere Driv-
ing Conditions".
MA-11
Page 1499 of 1701

PERIODICMAINTENANCE (ForEurope)
Maintenance UnderSevere Driving Conditions
The maintenance intervalsshownonthe preceding pagesarefornormal operating conditions. Ifthe
vehicle ismainly operated undersevere drivingconditions asshown below,morefrequent maintenance •
must beperformed onthe following itemsasshown inthe table. •
SEVERE DRIVING CONDITIONS
A -Driving underdustyconditions
B -Driving repeatedly shortdistances
C -Towing atrailer
D -Extensive idling
E -Driving inextremely adverseweather con-
ditions orinareas where ambient temper-
atures areeither extremely lowor
extremely high F
-Driving inhigh humidity areasorinmoun-
tainous areas
G -Driving inareas usingsaltorother corro-
sive materials
H -Driving onrough and/or muddy roadsorin
the desert
- Driving withfrequent useofbraking orin
mountainous areas
Driving
MaintenanceMaintenance
MaintenanceReference
condition itemoperationintervalpage
A B
C D Engine
oil
&
oil filter
Gasoline engine ReplaceEvery
7.500km(4,500 miles) MA-24
or 6months
Diesel engine ReplaceEvery5.000km(3,000 miles) or MA-41
3 months
A Aircleaner IiIter
&
PCV filter Replace MA-23,
41
A E Fuel
filter ReplaceMA-22,41
Every 30,000 km(18,000 miles)
F Brakefluid Replaceor
12months MA-47
G H
Steering gear
&
linkage, axle
&
suspension parts
&
exhaust Check MA-50,45
system FA-5
RA-4
C H
Automatic
&
manual transaxle oil Replace
Every60,000 km(36,000 miles) MA-46,45
or 24 months
A C GH
I
Brake pads,discs
&
other brake components Check MA-48
Every 15,000 km(9,000 miles)
A C GH
I
Brake
lining,drums
&
other brake components Check
or6months MA-49
C H
Driveshaft CheckFA-7
Maintenance operation:Check
=
Check. Correct orreplace
if
necessary.
MA-13
Page 1503 of 1701

ENGINEMAINTENANCE
EXCEPT FORGA14DE ENGINE Checking
DriveBelts
•
~ 16-21
(1.6 •2.1, 12•15)
Alternator
SMA786CA
Without
airconditioner
Crankshaft
pUlley
~
25.5 -32.4 (2.60 -3.30, 18.8-23.9)
Compressor
Power steering
pump (or Idler pulley)
With
airconditioner
Idler
pulley
Crankshaft
pulley
Power
steering pump
(or Idler pulley)
~.
~6.3 -8.3 (0.64 -0.85, 55.6-73.8)
~ :Checking point
A :
N.m (kg-m, ft-lb)
III :
N.m (kg-m, in-Ib)
1.Inspect forcracks, fraying, wearoroil adhesion. If
necessary, replacewithanew one.
2. Inspect drivebeltdeflections bypushing onthe belt midway
between pulleys.
Adjust ifbelt deflections exceedthelimit.
Belt deflection:
Unit:mm(in)
Used beltdeflection
Deflectionofnew
Limit Deflection
after
belt
.
adjustment
Alternator With aircondi-
10(0.39) 6-7 (0.24 -0.28) 5.5
-6.5
lioner compressor
(0.217-0.256)
Without aircondi-
11(0.43) 7-9 (0.28 -0.35) 6-8 (0.24 -0.31)
lioner compressor
Power steering oil
7.5(0.295) 4
-6 (0.16 -0.24) 3-5 (0.12 -0.20)
pump
Applied pushing force
98
N
(10
kg,
22
Ib)
Inspect drivebeltdeflections whenengine iscold.
MA-17
Page 1504 of 1701
ENGINEMAINTENANCE
Checking DriveBelts(Cont'd)
FOR GA14DE ENGINE
L
Idler pulley
Crankshaft
pulley
Withoutpowersteering
Idler
pulley locknut __
~ 25•32 (2.6 •3.3, 19-24)
)~'\c, ~ Crankshaft
'~~UlleY
~ ~\ Idlerpulley
Loosen
/
~
.
~~- - Withpower steering
SMA357CB
1. Inspect forcracks, fraying, wearoroil adhesion. If
necessary, replacewithanew one.
2. Inspect drivebeltdeflections bypushing onthe belt midway
between pulleys.
Adjust ifbelt deflections exceedthelimit.
Belt deflection:
Unit:mm(in)
Used beltdeflection
Deflectionofnew
Limit Deflection
alter
belt
adjustment
Alternator
With power steer-
11(0.43)
ing 7-9
6-8
Without power (0.28
-0.35)
(0.24-0.31)
steering 10
(0.39)
Air conditioner com-
9.5(0.374) 6
-8
5-7
pressor (0.24-0.31)
(0.20-0.28)
Power steering oil
7.5(0.295) 4-6
3-5
pump (0.16-0.24)
(0.12-0.20)
Applied pushing force
98N(10 kg, 22Ib)
Inspect drivebeltdeflections whenengine iscold.
MA-18
Page 1507 of 1701

SLC053B
Water
inlet
Wateroutlet ENGINE
MAINTENANCE
@KJ
Changing EngineCoolant (Cont'd)
16. Stop engine andcool itdown.
• Cool down usingafan toreduce thetime.
17. Remove theradiator fillercapand check coolant level.
• If
necessary, refillradiator uptofiller neckwithcoolant. •
18. Refill reservoir tanktoMax linewith coolant. •
19. Repeat step14through step18two ormore times.
20. Warm upengine, andcheck forsound ofcoolant flowwhile
running enginefromidleupto4,000 rpmwith heater tem-
perature controlsetatseveral positions betweenCOOLand
HOT.
• Sound maybenoticeable atheater watercock.
21. Ifsound isheard, bleedairfrom cooling systembyrepeat-
ing steps 14through 18until coolant levelnolonger drops.
• Clean excess coolant fromengine.
CAUTION:
When heater unitisremoved orreplaced, refillengine coolant
as shown, removing heaterhoseatfeeding connector on
engine.
Checking CoolingSystem
CHECKING HOSES
Check hosesforimproper attachment andforleaks, cracks,
damage, looseconnections, chafinganddeterioration.
CHECKING RADIATORCAP
Apply pressure toradiator capwith captester tosee if
it
is sat-
isfactory.
Radiator caprelief pressure:
Standard 78 -98 kPa
(0.78 •0.98 bar,0.8-1.0 kg/cm
2,
11.14 psi)
Limit
59 -98 kPa
(0.59 -0.98 bar,0.6-1.0 kg/cm
2,
9-14 psi)
SLC613-A
MA-21
Page 1508 of 1701

ENGINEMAINTENANCE ~
Checking CoolingSystem(Cont'd)
Pull thenegative-pressure valvetoopen it.Check thatitcloses
completely whenreleased.
SMA871B CHECKING COOLINGSYSTEMFORLEAKS
Apply pressure tothe cooling systemwithcaptester tocheck
for. leakage.
Testing pressure:
157 kPa (1.57 bar,1.6kg/cm
2,
23psi)
CAUTION: Higher pressure thanthespecified valuemaycause damage to
radiator.
Checking Fuellines
Inspect fuellines andtank forimproper attachment andfor
leaks, cracks, damage, looseconnections, chafinganddeteri-
oration. If necessary, repairorreplace faultyparts.
SMA803A
3 (0.12) Unit:mm(in)
-- --- ----,;~-r--1
"
,
-,-,-,
~-
_______ .J",_~__
28 (1.10)
~ Fuel hose clamps
1.0 -1.5 N.m
(0.10 -0.15 kg-m,
8.7 -13.0 in-Ib)
MMA104ACAUTION:
Tighten high-pressure rubberhoseclamp sothat clamp endis
3 mm (0.12 in)from hose end.
Tightening torquespecifications arethesame forallrubber
hose clamps.
Ensure thatscrew doesnotcontact adjacent parts.
Changing FuelFilter
WARNING: Before removing fuelfilter, release fuelpressure fromfuelline
to eliminate danger.
MA-22
Page 1509 of 1701
ENGINEMAINTENANCE @KJ
Changing FuelFilter (Cont'd)
1. Remove fuseforfuel pump.
2. Start engine.
3. After engine stalls,crankengine twoorthree times tomake
sure thatfuel pressure isreleased. •
4. Turn ignition switchoffand install fuseforfuel pump.
i
AECBBO
5.Loosen fuelhose clamps.
6. Replace fuelfilter.
• Becareful nottospill fuelover engine compartment. Place
a shop towel toabsorb fuel.
• Use ahigh-pressure typefuelfilter. Donot use asynthetic
resinous fuelfilter.
• When tightening fuelhose clamps, refertoChecking Fuel
Lines.
Cleaning andChanging AirCleaner Filter
VISCOUS PAPERTYPE
The viscous papertypefilter does notneed cleaning between
renewals.
DRY PAPER TYPE
Clean orreplace element moreoftenunder dustydriving con-
ditions.
SMA384C MA-23
Page 1510 of 1701

ENGINEMAINTENANCE
Changing EngineOil
WARNING:
• Becareful nottoburn yourself, asthe engine oilishot.
• Prolonged andrepeated contactwithused engine oilmay
cause skincancer; trytoavoid direct skincontact withused
oil.
If
skin contact ismade, washthoroughly withsoap or
hand cleaner assoon aspossible.
1. Warm upengine, andcheck foroilleakage fromengine
components.
2. Remove drainplugandoilfiller cap.
3. Drain oiland refill withnewengine oil.
Refill oilcapacity (Approximate):
Unit:
f
(Imp qt)
.With oilfilter change
Without oilfilter change
3.2
(2-7/8)
2.8 (2-1/2)
Regarding theAnti-freeze CoolantMixtureRatio,referto"REC-
OMMENDED FLUIDSANDLUBRICANTS".
CAUTION:
• Besure toclean drainplugandinstall withnew washer.
Drain plug:
~: 29-39 N'm (3.0-4.0 kg-m, 22-29 ft-Ib)
• Use recommended engineoil"API SE,SF,SGorSH" with
suitable viscosity.
• Refill oilcapacity changesdepending onthe oiltemperature
and drain time.Usethese values asareference andbe
certain tocheck withthedipstick whenchanging theoil.
4. Check oillevel.
5. Start engine andcheck areaaround drainplugandoilfilter
for oilleakage.
6. Run engine forafew minutes, thenturnitoff. After several
minutes, checkoillevel.
Refill oiltothis
"H" level.
Do not overfill.
SMA822C
Changing OilFilter
1. Remove oilfilter withTool.
WARNING:
Be careful nottoburn yourself, asthe engine andtheengine
oil are hot.
MA-24