MAINTENANCE
SECTION
MA
CONTENTS
PRECAUTIONS AND PREPARATION..................... 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models).............................................. 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models).............................................. 1
Special Service Tools ............................................ 2
Commercial Service Tools ..................................... 2
PRE-DELIVERY INSPECTION ITEMS...................... 3
GENERAL MAINTENANCE...................................... 4
PERIODIC MAINTENANCE...................................... 5
Basic Schedule for Gasoline Engine Models ........ 5
Basic Schedule for Diesel Engine Models ............ 8
Maintenance Under Severe Driving Conditions .. 10
RECOMMENDED FLUIDS AND LUBRICANTS..... 12
Fluids and Lubricants........................................... 12
SAE Viscosity Number......................................... 13
Anti-freeze Coolant Mixture Ratio........................ 14
KA
ENGINE MAINTENANCE........................................ 15
Checking Drive Belts ........................................... 15
Changing Engine Coolant .................................... 16
Checking Cooling System.................................... 17
Checking Fuel Lines ............................................ 18
Changing Fuel Filter ............................................ 18
Changing Air Cleaner Filter (Viscous paper
type) ..................................................................... 19
Changing Engine Oil ............................................ 19
Changing Oil Filter ............................................... 20
Checking and Changing Spark Plugs.................. 20
Checking Ignition Wires ....................................... 21Checking Positive Crankcase Ventilation
(PCV) System ...................................................... 21
Changing Positive Crankcase Ventilation
(PCV) Filter .......................................................... 21
Checking Vacuum Hoses and Connections ........ 22
Checking Vapor Lines.......................................... 22
Checking Heated Oxygen Sensor ....................... 22
TD
ENGINE MAINTENANCE........................................ 23
Checking Manifold Tightening Torque ................. 23
Adjusting Intake and Exhaust Valve Clearance .. 23
Checking Drive Belt ............................................. 23
Changing Engine Oil ............................................ 24
Changing Engine Oil Filter................................... 24
Changing Engine Coolant .................................... 25
Checking Cooling System.................................... 26
Checking and Replacing Fuel Filter and
Draining Water ..................................................... 27
Checking Fuel Lines ............................................ 28
Cleaning and Replacing Air Cleaner Filter .......... 29
Checking Injection Nozzle ................................... 29
Checking Idle Speed............................................ 30
CHASSIS AND BODY MAINTENANCE................. 32
Checking Exhaust System ................................... 32
Checking Clutch Fluid Level and Leaks .............. 32
Checking Clutch System...................................... 32
Checking M/T Oil ................................................. 32
Changing M/T Oil ................................................. 32
Checking Water Entry - For 4WD models ........... 33
MA
Depending on annual driving distance and engine types, different basic schedules are introduced here.
Please follow the appropriate schedule for the vehicle. Furthermore, according to the weather and atmo-
spheric conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more
frequent maintenance may be required, as shown in ``Maintenance Under Severe Driving Conditions''.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.
Basic Schedule for Gasoline Engine Models
Engine maintenance for vehicles which drive less than 30,000 km/year (18,000 miles/year)
Abbreviations: R= Replace, I = Inspect and correct or replace as necessary.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform at kilometer (mile) interval or month interval, whichever comes
first.km x 1,000 15 30 45 60 75 90
(Miles x 1,000) (9) (18) (27) (36) (45) (54)
Months 12 24 36 48 60 72
Engine oil (Use API SG or SH oil)*RRRRRRMA-19
Engine oil filter*RRRRRRMA-20
Drive beltsIIIIIIMA-15
Engine anti-freeze coolant (Ethylene glycol base) See NOTE (1) MA-16
Cooling systemIIIIIIMA-17
Air cleaner filter (Viscous paper type)*R MA-19
Fuel linesI I I MA-18
Fuel filter*R MA-18
Vapor linesI I I MA-22
Spark plugs (Conventional type)R R R MA-20
Ignition wiresI I MA-21
Heated oxygen sensor (Exhaust gas sensor)I I I MA-22
PCV filter*R R R MA-21
NOTE: (1) Replace at the first 90,000 km (54,000 miles) or 60 months, then every 60,000 km (36,000 miles) or 48 months,
whichever comes first.
* Maintenance item with ``*'' should be performed more frequently according to ``Maintenance Under Severe Driving Condi-
tions''.
PERIODIC MAINTENANCE
MA-5
Chassis and body maintenance for vehicles which drive less than 30,000 km/year (18,000 miles/year)
Abbreviations: R= Replace, I = Inspect and correct or replace as necessary, L = Lubricate, T = Tighten. [ ] = At the specified distance only.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform at kilometer (mile) interval or month interval, whichever comes
first.km x 1,000 15 30 45 60 75 90
(Miles x 1,000) (9) (18) (27) (36) (45) (54)
Months 12 24 36 48 60 72
Headlamp aimingIIIIIINOTE (3)
Wheel alignment (If necessary, rotate & balance wheels)IIIIIIMA-35, NOTE (4)
Brake pads, discs & other brake components*IIIIIIMA-36
Brake linings, drums & other brake components*IIIIIIMA-36
Foot brake, parking brake & clutch (For free play, stroke & operation)IIIIIINOTE (5)
Brake booster vacuum hoses, connections & check valve I I I MA-36
Brake & clutch systemsIIIIIIMA-32, 35
Brake & clutch fluid (For level & leaks)IIIIIIMA-32, 35
Brake fluid*R R R MA-35
Power steering fluid & lines (For level & leaks)IIIIIIMA-37
Manual steering gear oil (For level & leaks)IIIIIIMA-38
Air bag system See NOTE (1) NOTE (6)
Manual transmission oil (Inspect for leaks or replace)IIIII[R]MA-32
Transfer fluid and standard differential gear oil (For leaks)* I I I R I I MA-33, 34
Limited-slip differential (LSD) gear oil (For level and leaks)* I I I R I I MA-34
Steering gear, linkage, axle, suspension parts & propeller shaft*IIIIIIMA-37, 33
Greasing point of steering linkage, propeller shaft & suspension* See NOTE (2)LLLLLLMA-33
Exhaust system*IIIIIIMA-32
Drive shaft*IIIIIINOTE (7)
Front wheel bearing grease (2WD models)I I I NOTE (8)
Front wheel bearing grease (4WD models)* I R I R I R NOTE (8)
Free-running hub grease (4WD models)*IIIIIINOTE (9)
Body mountingsTTTTTTNOTE (10)
Body corrosionAnnually MA-41
NOTE: (1) Inspect at the first 10 years, and then every 2 years.
(2) The propeller shaft should be re-greased daily if it is immersed in water.
(3) ``Aiming Adjustment'' in EL section
(4) ``Front Wheel Alignment'' in FA section
(5) ``Brake Pedal and Bracket'' in BR section, ``Adjusting Clutch Pedal'' in CL section
(6) ``Maintenance Items'' in RS section
(7) ``FRONT AXLE Ð Drive Shaft'' in FA section
(8) ``Front Wheel Bearing'' in FA section
(9) ``Manual-lock Free-running Hub Ð 4WD'' and ``Auto-lock Free-running Hub Ð 4WD'' in FA section
(10) ``CAB AND REAR BODY'' in BT section
* Maintenance item with ``*'' should be performed more frequently according to ``Maintenance Under Severe Driving Condi-
tions''.
PERIODIC MAINTENANCE
Basic Schedule for Gasoline Engine Models
(Cont'd)
MA-6
Engine maintenance for vehicles which drive more than 30,000 km/year (18,000 miles/year)
Abbreviations: R= Replace, I = Inspect and correct or replace as necessary.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at kilometer (mile) interval.km x 1,000 15 30 45 60 75 90 105 120
(Miles x 1,000) (9) (18) (27) (36) (45) (54) (63) (72)
Engine oil (Use API SG or SH oil)*RRRRRRRRMA-19
Engine oil filter*RRRRRRRRMA-20
Drive beltsIIIIIIIIMA-15
Engine anti-freeze coolant (Ethylene glycol base) See NOTE (1) R MA-16
Cooling systemIIIIMA-17
Air cleaner filter (Viscous paper type)*R R MA-19
Fuel linesI I MA-18
Fuel filter*R MA-18
Vapor linesI I MA-22
Spark plugs (Conventional type)RRRRMA-20
Ignition wiresI MA-21
Heated oxygen sensor (Exhaust gas sensor)I I MA-22
PCV filter*R R MA-21
NOTE: (1) Replace at the first 90,000 km (54,000 miles), then every 60,000 km (36,000 miles).
* Maintenance item with ``*'' should be performed more frequently according to ``Maintenance Under Severe Driving Condi-
tions''.
Chassis and body maintenance for vehicles which drive more than 30,000 km/year (18,000 miles/year)
Abbreviations: R= Replace, I = Inspect and correct or replace as necessary, L = Lubricate, T = Tighten.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at kilometer (mile) interval.km x 1,000 15 30 45 60 75 90 105 120
(Miles x 1,000) (9) (18) (27) (36) (45) (54) (63) (72)
Headlamp aimingIIIINOTE (3)
Wheel alignment (If necessary, rotate & balance wheels)IIIIMA-35, NOTE (4)
Brake pads, discs & other brake components*IIIIMA-36
Brake linings, drums & other brake components*IIIIMA-36
Foot brake, parking brake & clutch (For free play, stroke & operation)IIIINOTE (5)
Brake booster vacuum hoses, connections & check valve I I MA-36
Brake & clutch systemsIIIIMA-32, 35
Brake & clutch fluid (For level & leaks)IIIIMA-32, 35
Brake fluid*R R MA-35
Power steering fluid & lines (For level & leaks)IIIIMA-37
Manual steering gear oil (For level & leaks)IIIIMA-38
Air bag system See NOTE (1)NOTE (6)
Manual transmission oil (Inspect for leaks or replace) I I R I MA-32
Transfer fluid and standard differential gear oil (For leaks)* I R I R MA-33, 34
Limited-slip differential (LSD) gear oil (For level and leaks)* I R I R MA-34
Steering gear, linkage, axle, suspension parts & propeller shaft*IIIIMA-37, 33
Greasing point of steering linkage, propeller shaft & sus-
pension*See NOTE (2)LLLLMA-33
Exhaust system*IIIIMA-32
Drive shaft*IIIINOTE (7)
Front wheel bearing grease (2WD models)I I NOTE (8)
Front wheel bearing grease (4WD models)* I R I R NOTE (8)
Free-running hub grease (4WD models)*IIIINOTE (9)
Body mountingsTTTTNOTE (10)
Body corrosionAnnually MA-41
NOTE: (1) Inspect at the first 10 years, and then every 2 years.
(2) The propeller shaft should be re-greased daily if it is immersed in water.
(3) ``Aiming Adjustment'' in EL section
(4) ``Front Wheel Alignment'' in FA section
(5) ``Brake Pedal and Bracket'' in BR section, ``Adjusting Clutch Pedal'' in CL section
(6) ``Maintenance Items'' in RS section
(7) ``FRONT AXLE Ð Drive Shaft'' in FA section
(8) ``Front Wheel Bearing'' in FA section
(9) ``Manual-lock Free-running Hub Ð 4WD'' and ``Auto-lock Free-running Hub Ð 4WD'' in FA section
(10) ``CAB AND REAR BODY'' in BT section
* Maintenance item with ``*'' should be performed more frequently according to ``Maintenance Under Severe Driving Condi-
tions''.
PERIODIC MAINTENANCE
Basic Schedule for Gasoline Engine Models
(Cont'd)
MA-7
Basic Schedule for Diesel Engine Models
Engine maintenance for vehicles which drive less than 30,000 km/year (18,000 miles/year)
Abbreviations: R= Replace, I = Inspect and correct or replace as necessary. [ ] = At the specified distance only.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform at kilometer (mile)
interval or month interval,
whichever comes first.km x 1,000 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90
(Miles x 1,000) (4.5) (9) (13.5) (18) (22.5) (27) (31.5) (36) (40.5) (45) (49.5) (54)
Months 6 12 18 24 30 36 42 48 54 60 66 72
Engine oil (Use recommended
oil)*RRRRRRRRRRRRMA-24
Engine oil filter*RRRRRRRRRRRRMA-24
Drive beltsIIIIIIMA-23
Engine anti-freeze coolant
(Ethylene glycol base)See NOTE (1)R MA-25
Cooling systemIIIIIIMA-26
Air cleaner filter (Viscous paper type)* R R MA-29
Intake & exhaust valve clearance I I I MA-23
Fuel linesI I I MA-28
Fuel filter*R R R MA-27
Injection nozzles See NOTE (2)MA-29
NOTE: (1) Replace at the first 75,000 km (45,000 miles) or 60 months, then every 45,000 km (27,000 miles) or 36 months,
whichever comes first.
(2) If engine power decreases, black exhaust is emitted or engine noise increases, inspect and if necessary, adjust
the fuel injection nozzles starting pressure and the spray pattern.
* Maintenance item with ``*'' should be performed more frequently according to ``Maintenance Under Severe Driving Condi-
tions''.
Chassis and body maintenance for vehicles which drive less than 30,000 km/year (18,000 miles/year)
Abbreviations: R= Replace, I = Inspect and correct or replace as necessary, L = Lubricate, T = Tighten. [ ] = At the specified distance only.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform at kilometer (mile) interval or
month interval, whichever comes first.km x 1,000 15 30 45 60 75 90
(Miles x 1,000) (9) (18) (27) (36) (45) (54)
Months 12 24 36 48 60 72
Headlamp aimingIIIIIINOTE (3)
Wheel alignment (if necessary, rotate & balance wheels)IIIIIIMA-35, NOTE (4)
Brake pads, discs & other brake components*IIIIIIMA-36
Brake linings, drums & other brake components*IIIIIIMA-36
Foot brake, parking brake & clutch (For free play, stroke & operation)IIIIIINOTE (5)
Brake booster vacuum hoses, connections & check valve I I I MA-36
Brake & clutch systemsIIIIIIMA-32, 35
Brake & clutch fluid (For level & leaks)IIIIIIMA-32, 35
Brake fluid*R R R MA-35
Power steering fluid & lines (For level & leaks)IIIIIIMA-37
Manual steering gear oil (For level & leaks)IIIIIIMA-38
Air bag system See NOTE (1)NOTE (6)
Manual transmission oil (Inspect for leaks or replace)IIIII[R]MA-32
Transfer fluid and standard differential gear oil (for leaks)* I I I R I I MA-33, 34
Limited-slip differential (LSD) gear oil (For level and leaks)* I I I R I I MA-34
Steering gear, linkage, axle, suspension parts & propeller shaft*IIIIIIMA-37, 33
Greasing point of steering linkage, propeller
shaft & suspension*See NOTE (2)LLLLLLMA-33
Exhaust system*IIIIIIMA-32
Drive shaft*IIIIIINOTE (7)
Front wheel bearing grease (2WD models) I I I NOTE (8)
Front wheel bearing grease (4WD models)* I R I R I R NOTE (8)
Free-running hub grease (4WD models)*IIIIIINOTE (9)
Body mountingsTTTTTTNOTE (10)
Body corrosionAnnually MA-41
NOTE: (1) Inspect at the first 10 years, and then every 2 years.
(2) The propeller shaft should be re-greased daily if it is immersed in water.
(3) ``Aiming Adjustment'' in EL section
(4) ``Front Wheel Alignment'' in FA section
(5) ``Brake Pedal and Bracket'' in BR section, ``Adjusting Clutch Pedal'' in CL section
(6) ``Maintenance Items'' in RS section
(7) ``FRONT AXLE Ð Drive Shaft'' in FA section
(8) ``Front Wheel Bearing'' in FA section
(9) ``Manual-lock Free-running Hub Ð 4WD'' and ``Auto-lock Free-running Hub Ð 4WD'' in FA section
(10) ``CAB AND REAR BODY'' in BT section
* Maintenance item with ``*'' should be performed more frequently according to ``Maintenance Under Severe Driving Conditions''.
PERIODIC MAINTENANCE
MA-8
Engine maintenance for vehicles which drive more than 30,000 km/year (18,000 miles/year)
Abbreviations: R= Replace, I = Inspect and correct or replace as necessary.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at kilometer (mile) interval.km x 1,000 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90
(Miles x 1,000) (4.5) (9) (13.5) (18) (22.5) (27) (31.5) (36) (40.5) (45) (49.5) (54)
Engine oil (Use recommended oil)*RRRRRRRRRRRRMA-24
Engine oil filter*RRRRRRRRRRRRMA-24
Drive beltsIIIIIIMA-23
Engine anti-freeze coolant (Ethylene glycol base) See NOTE (1)R MA-25
Cooling systemI I I MA-26
Air cleaner filter (Viscous paper type)*R MA-29
Intake & exhaust valve clearance I I I MA-23
Fuel linesI MA-28
Fuel filter*R MA-27
Injection nozzles See NOTE (2)MA-29
NOTE: (1) Replace at the first 90,000 km (54,000 miles), then every 60,000 km (36,000 miles).
(2) If engine power decreases, black exhaust is emitted or engine noise increases, inspect and if necessary, adjust
the fuel injection nozzles starting pressure and the spray pattern.
* Maintenance item with ``*'' should be performed more frequently according to ``Maintenance Under Severe Driving Condi-
tions''.
Chassis and body maintenance for vehicles which drive more than 30,000 km/year (18,000 miles/year)
Abbreviations: R= Replace, I = Inspect and correct or replace as necessary, L = Lubricate, T = Tighten.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at kilometer (mile) interval.km x 1,000 30 60 90 120
(Miles x 1,000) (18) (36) (54) (72)
Headlamp aimingI I I I NOTE (3)
Wheel alignment (if necessary, rotate & balance wheels) I I I IMA-35,
NOTE (4)
Brake pads, discs & other brake components* I I I I MA-36
Brake linings, drums & other brake components* I I I I MA-36
Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I NOTE (5)
Brake booster vacuum hoses, connections & check valve I I MA-36
Brake & clutch systems I I I I MA-32, 35
Brake & clutch fluid (For level & leaks) I I I I MA-32, 35
Brake fluid*R R MA-35
Power steering fluid & lines (For level & leaks) I I I I MA-37
Manual steering gear oil (For level & leaks) I I I I MA-38
Air bag system See NOTE (1)NOTE (6)
Manual transmission oil (Inspect for leaks or replace) I I R I MA-32
Transfer fluid and standard differential gear oil (for leaks)* I R I R MA-33, 34
Limited-slip differential (LSD) gear oil (For level and leaks)* I R I R MA-34
Steering gear, linkage, axle, suspension parts & propeller shaft* I I I I MA-37, 33
Greasing point of steering linkage, propeller
shaft & suspension*See NOTE (2) L L L L MA-33
Exhaust system*I I I I MA-32
Drive shaft*I I I I NOTE (7)
Front wheel bearing grease (2WD models) I I NOTE (8)
Front wheel bearing grease (4WD models)* I R I R NOTE (8)
Free-running hub grease (4WD models)* I I I I NOTE (9)
Body mountingsT T T T NOTE (10)
Body corrosionAnnually MA-41
NOTE: (1) Inspect at the first 10 years, and then every 2 years.
(2) The propeller shaft should be re-greased daily if it is immersed in water.
(3) ``Aiming Adjustment'' in EL section
(4) ``Front Wheel Alignment'' in FA section
(5) ``Brake Pedal and Bracket'' in BR section, ``Adjusting Clutch Pedal'' in CL section
(6) ``Maintenance Items'' in RS section
(7) ``FRONT AXLE Ð Drive Shaft'' in FA section
(8) ``Front Wheel Bearing'' in FA section
(9) ``Manual-lock Free-running Hub Ð 4WD'' and ``Auto-lock Free-running Hub Ð 4WD'' in FA section
(10) ``CAB AND REAR BODY'' in BT section
* Maintenance item with ``*'' should be performed more frequently according to ``Maintenance Under Severe Driving Condi-
tions''.
PERIODIC MAINTENANCE
Basic Schedule for Diesel Engine Models
(Cont'd)
MA-9