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STANDARDIZED RELAY
PG-73
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D
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L
MA
B
PG
SEL188W
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PG-74
FUSE BLOCK - JUNCTION BOX (J/B)
FUSE BLOCK - JUNCTION BOX (J/B)
PFP:24350
Terminal ArrangementEKS0032F
CKWA0094E
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FUSE AND FUSIBLE LINK BOX
PG-75
C
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MA
B
PG
FUSE AND FUSIBLE LINK BOXPFP:24381
Terminal ArrangementEKS0032G
CKWA0095E
SMA for models with roof mounted driving lamp
Page 3780 of 3833
PG-76
FUSE AND FUSIBLE LINK BOX
Page 3781 of 3833

MA-1
MAINTENANCE
L MAINTENANCE
CONTENTS
C
D
E
F
G
H
I
J
K
M
SECTION
A
B
MA
MAINTENANCE
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
DESCRIPTION ............................................................ 4
Pre-delivery Inspection Items ................................... 4
GENERAL MAINTENANCE ....................................... 6
General Maintenance ............................................... 6
PERIODIC MAINTENANCE ....................................... 7
Periodic Maintenance ............................................... 7
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (QR20DE AND QR25DE PETROL
ENGINE) ............................................................... 7
CHASSIS AND BODY MAINTENANCE
(QR20DE AND QR25DE PETROL ENGINE) ....... 7
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD22DDTI DIESEL ENGINE) ................ 8
CHASSIS AND BODY MAINTENANCE
(YD22DDTI DIESEL ENGINE) .............................. 9
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 10
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (QR20DE AND QR25DE PETROL
ENGINE) .............................................................. 11
CHASSIS AND BODY MAINTENANCE
(QR20DE AND QR25DE PETROL ENGINE) ..... 12
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD22DDTI DIESEL ENGINE) .............. 13
CHASSIS AND BODY MAINTENANCE
(YD22DDTI DIESEL ENGINE) ............................ 14
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 14
RECOMMENDED FLUIDS AND LUBRICANTS ...... 16
Fluids and Lubricants ............................................. 16
SAE Viscosity Number ........................................... 17
GASOLINE ENGINE ........................................... 17
DIESEL ENGINE ................................................. 17
Engine Coolant Mixture Ratio ................................ 18
ENGINE MAINTENANCE (QR20DE·QR25DE) ........ 19
Checking Drive Belts .............................................. 19
Tension Adjustment ................................................ 19Changing Engine Coolant ....................................... 19
DRAINING ENGINE COOLANT .......................... 19
REFILLING ENGINE COOLANT ......................... 20
FLUSHING COOLING SYSTEM ......................... 21
Checking Cooling System ...................................... 21
CHECKING COOLING SYSTEM HOSES ........... 21
CHECKING RADIATOR ...................................... 21
CHECKING RADIATOR CAP .............................. 21
CHECKING RADIATOR SYSTEM FOR LEAKS ... 22
Checking Fuel Lines ............................................ ... 22
Changing Air Cleaner Filter .................................... 22
VISCOUS PAPER TYPE ..................................... 22
DRY PAPER TYPE .............................................. 22
Changing Engine Oil ............................................ ... 23
Changing Oil Filter .................................................. 23
Checking and Changing Spark Plugs ..................... 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 25
Checking EVAP Vapor Lines .................................. 25
ENGINE MAINTENANCE (YD22DDTI) .................... 26
Checking Drive Belts .............................................. 26
Tension Adjustment ............................................. ... 26
AIR CONDITIONER COMPRESSOR BELT ........ 27
ALTERNATOR AND WATER PUMP BELT .......... 27
Changing Engine Coolant ....................................... 27
DRAINING ENGINE COOLANT .......................... 27
REFILLING ENGINE COOLANT ......................... 28
FLUSHING COOLING SYSTEM ......................... 29
Checking Cooling System ...................................... 29
CHECKING COOLING SYSTEM HOSES ........... 29
CHECKING RADIATOR ...................................... 29
CHECKING RADIATOR CAP .............................. 30
CHECKING RADIATOR SYSTEM FOR LEAKS ... 30
Checking Fuel Lines ............................................ ... 30
Changing Fuel Filter ............................................... 31
REMOVAL ........................................................... 31
INSTALLATION ................................................... 31
Changing Air Cleaner Filter .................................... 32
VISCOUS PAPER TYPE ..................................... 32
Page 3782 of 3833

MA-2
Changing Engine Oil ............................................ ... 32
Changing Oil Filter .................................................. 33
REMOVAL ........................................................... 33
INSTALLATION .................................................... 34
Draining Water ........................................................ 34
CHASSIS AND BODY MAINTENANCE ................... 35
Checking Exhaust System ...................................... 35
Checking Clutch Fluid Level and Leaks ................. 35
Checking Clutch System ........................................ 35
Checking M/T Oil .................................................... 35
Changing M/T Oil .................................................... 35
Checking A/T Fluid ................................................. 36
Changing A/T Fluid ................................................. 36
Checking Transfer Oil ............................................. 37
Changing Transfer Oil .......................................... ... 37
Checking Propeller Shaft ........................................ 37
Checking Differential Gear Oil ................................ 38
Changing Differential Gear Oil ................................ 38
Balancing Wheels ................................................... 38
Rotation .................................................................. 38
Checking Brake Fluid Level and Leaks .................. 39
Checking Brake Lines and Cables ......................... 39
Changing Brake Fluid ............................................. 39
Checking Disc Brake .............................................. 39
ROTOR ................................................................ 39
CALIPER ............................................................. 40PAD ...................................................................... 40
Checking Steering Gear and Linkage ..................... 40
STEERING GEAR ............................................... 40
STEERING LINKAGE .......................................... 40
Checking Power Steering Fluid and Lines .............. 40
Axle and Suspension Parts ..................................... 41
Drive Shaft .............................................................. 41
Lubricating Locks, Hinges and Hood Latches ......... 41
Checking Seat Belts, Buckles, Retractors, Anchors
and Adjusters .......................................................... 42
Checking Body Corrosion ....................................... 42
HEMMED PANELS .............................................. 42
PANEL JOINT ...................................................... 42
PANEL EDGE ...................................................... 42
PARTS CONTACT ............................................... 42
PROTECTORS .................................................... 42
ANTI-CORROSION MATERIALS ........................ 42
DRAIN HOLES ..................................................... 42
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 43
Standard and Limit .................................................. 43
BELT DEFLECTION AND TENSION ................... 43
RADIATOR ........................................................... 43
ENGINE COOLANT CAPACITY .......................... 43
ENGINE OIL CAPACITY ...................................... 43
SPARK PLUG ...................................................... 43
Page 3783 of 3833
PREPARATION
MA-3
C
D
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F
G
H
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K
MA
B
MA
PREPARATIONPFP:00002
Special Service ToolsELS000B6
Commercial Service ToolsELS000K9
Tool number
To o l n a m eDescription
KV10115801
Oil filter wrenchRemoving and installing oil filter
(QR20DE and QR25DE engine models)
a: 64.3 mm (2.531 in)
EG17650301
Radiator cap tester adapterAdapting radiator cap tester to radiator filler
neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT375
S-NT564
To o l n a m eDescription
Spark plug wrench Removing and installing spark plug
(QR20DE and QR25DE engine models)
Fuel filter wrench Removing fuel filter
(YD22DDTi engine model)
S-NT047
PBIC0519E
Page 3784 of 3833

MA-4
DESCRIPTION
DESCRIPTION
PFP:00000
Pre-delivery Inspection ItemsELS000AK
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD — engine off
Radiator coolant level and coolant hose connections for leaks
Battery fluid level, specific gravity and conditions of battery terminals
Drive belts tension
Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks
Engine oil level and oil leaks
Clutch and brake reservoir fluid level and fluid lines for leaks
Windshield and rear window washer and headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
Remove front spring/strut spacer (If applicable)
Operation of all instruments, gauges, lights and accessories
Operation of horn(s), wiper and washer
Steering lock for operation
Check air conditioner for gas leaks
Front and rear seats, and seat belts for operation
All moldings, trims and fittings for fit and alignment
All windows for operation and alignment
Hood, trunk lid, door panels for fit and alignment
Latches, keys and locks for operation
Weatherstrips for adhesion and fit
Headlamp aiming
Tighten wheel nuts (Inc. inner nuts if applicable)
Tire pressure (Inc. spare tire)
Check front wheels for toe-in
Install clock/voltmeter/room lamp fuse (If applicable)
Install deodorizing filter to air conditioner (If applicable)
Remove wiper blade protectors (If applicable)
UNDER BODY
Manual transmission/transaxle, transfer and differential gear oil level
Brake and fuel lines and oil/fluid reservoirs for leaks
Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing and kickdown
Steering control and returnability
Engine performance