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 speci®cations.
UNDER HOOD Ð engine off
hRadiator coolant level and coolant hose connec-
tions for leaks
hBattery ¯uid level, speci®c gravity and condi-
tions of battery terminals
hDrive belts tension
hFuel ®lter for water or dusts, and fuel lines and
connections for leaks
hEngine oil level and oil leaks
hClutch and brake reservoir ¯uid level and ¯uid
lines for leaks
hWindshield and rear window washer and head-
lamp cleaner reservoir ¯uid level
hPower steering reservoir ¯uid level and hose
connections for leaks
ON INSIDE AND OUTSIDE
hXRemove front spring/strut spacer (If applicable)
hOperation of all instruments, gauges, lights and
accessories
hOperation of horn(s), wiper and washer
hSteering lock for operation
hCheck air conditioner for gas leaks
hFront and rear seats, and seat belts for opera-
tion
hAll moldings, trims and ®ttings for ®t and align-
ment
hAll windows for operation and alignment
hHood, trunk lid, door panels for ®t and alignment
hLatches, keys and locks for operation
hWeatherstrips for adhesion and ®t
hHeadlamp aiming
hTighten wheel nuts (Inc. inner nuts if applicable)
hTire pressure (Inc. spare tire)
hCheck front wheels for toe-in
hInstall clock/voltmeter/room lamp fuse (If appli-
cable)
h
XInstall deodorizing ®lter to air puri®er (If appli-
cable)
h
XRemove wiper blade protectors (If applicable)
UNDER BODY
hManual transmission/transaxle gear oil, transfer
¯uid and differential gear oil level
hBrake and fuel lines and oil/¯uid reservoirs for
leaks
hTighten bolts and nuts of steering linkage and
gear box, suspension, propeller shafts and drive
shafts
h
XTighten rear body bolts and nuts (Models with
wooden bed only)
ROAD TEST
hClutch operation
hParking brake operation
hService brake operation
hAutomatic transmission/transaxle shift timing
and kickdown
hSteering control and returnability
hEngine performance
hSqueaks and rattles
ENGINE OPERATING AND HOT
hAdjust idle mixture and speed (and ignition tim-
ing*1)
hAutomatic transmission/transaxle ¯uid level
hEngine idling and stop knob operation (Diesel
only)
FINAL INSPECTION
hInstall necessary parts (outside mirror, wheel
covers, seat belts, mat, carpet or mud ¯aps)
hInspect for interior and exterior metal and paint
damage
hCheck for spare tire, jack, tools (wheel chock),
and literature
hWash, clean interior and exterior
*1: Not required on models with a direct ignition system
h
X: Not applicable to this model.
PRE-DELIVERY INSPECTION ITEMS
MA-2
Chassis and Body Services
Annual driving distance below 30,000 km (18,000 miles)
Abbreviations: R = Replace, I = Inspect, and correct or replace as necessary, L = Lubricate,T=Tighten.
[ ]: At the speci®ed mileage only
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform either at number of kilometers (miles) or months,
whichever comes ®rst.km x 1,000 10 20 30 40 50 60 70 80 90
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)
Months 6 12 18 24 30 36 42 48 54
CHASSIS AND BODY Underhood and under vehicle
Brake & clutch ¯uid (For level & leaks).I I I I MA-23, 20
Brake ¯uid.R R MA-24
Brake booster vacuum hoses, connections & check valve I I MA-24
Power steering ¯uid & lines (For level & leaks) I I I I MA-26
Brake & clutch systemsI I I I MA-24, 20
Manual transmission oil (For leaks) I I I I MA-20
Manual transmission oil[R] MA-20
Transfer ¯uidI I R I MA-21
Limited slip differential (LSD) gear oil (For level & leaks).*1 I I R I MA-22
Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system.I I I I MA-26, 20 *2
Greasing points of propeller shaftLLLLMA-21
Drive shafts & steering damper.IIII *3
Body mounting bolts & nutsTTTT *4
Outside and Inside
Wheel alignment (If necessary, rotate & balance wheels) I I I I MA-25, *5
Brake pads, discs & other brake components.I I I I MA-24
Front wheel bearing grease I R I R MA-22
Axle joint in knuckle ¯angeL L MA-23
Free running hub greaseI I I I MA-23
Headlamp aimingIIII *6
Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I *7
Ventilation air ®lterRRR*8
Body corrosionAnnually MA-28
Air bag systemSee NOTE (1) *9
NOTE: (1) Inspect after 10 years, then every 2 years.
(2) Maintenance items with ``.'' should be performed more frequently according to ``Maintenance Under Severe Driv-
ing Conditions''.
*1: Including differential gear with differential lock
*2: ``Front Axle and Front Suspension Parts'' in FA section, ``Rear Axle and Rear Suspension Parts'' in RA section
*3: ``FRONT AXLE Ð Drive Shaft'' in FA section
*4: ``CAB BODY'' in BT section
*5: ``Front Wheel Alignment'' in FA section
*6: ``Aiming Adjustment'' in EL section
*7: ``Brake Pedal and Bracket'' in BR section, ``Adjusting Clutch Pedal'' in CL section
*8: ``Ventilation air ®lter'' in HA section
*9: ``Maintenance Items'' in RS section
PERIODIC MAINTENANCE
MA-6
Annual driving distance over 30,000 km (18,000 miles)
Abbreviations: R = Replace. I = Inspect, and correct or replace as necessary, L = Lubricate,T=Tighten.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page km x 1,000 10 20 30 40 50 60 70 80 90
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54)
CHASSIS AND BODY Underhood and under vehicle
Brake & clutch ¯uid (For level & leaks).I I I MA-23, 20
Brake ¯uid.R MA-24
Brake booster vacuum hoses, connections & check valve I MA-24
Power steering ¯uid & lines (For level & leaks) I I I MA-26
Brake & clutch systemsI I I MA-24, 20
Manual transmission oil (For leaks) I I I MA-20
Manual transmission oilR MA-20
Transfer ¯uidI R I MA-21
Limited slip differential (LSD) gear oil (For level & leaks).*1 I R I MA-22
Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system.I I I MA-26, 20 *2
Geasing points of propeller shaft L L L MA-21
Drive shafts & steering damper.III*3
Body mounting bolts & nutsTTT*4
Outside and Inside
Wheel alignment (If necessary, rotate & balance wheels) I I I MA-25, *5
Brake pads, discs & other brake components.I I I MA-24
Front wheel bearing greaseI R I MA-22
Axle joint in knuckle ¯angeL MA-23
Free running hub greaseI I I MA-23
Headlamp aimingIII*6
Foot brake, parking brake & clutch (For free play, stroke & operation) I I I *7
Ventilation air ®lterRRR*8
Body corrosionAnnually MA-28
Air bag systemSee NOTE (1) *9
NOTE: (1) Inspect after 10 years, then every 2 years.
(2) Maintenance items with ``.'' should be performed more frequently according to ``Maintenance Under Severe Driv-
ing Conditions''.
*1: Including differential gear with differential lock
*2: ``Front Axle and Front Suspension Parts'' in FA section, ``Rear Axle and Rear Suspension Parts'' in RA section
*3: ``FRONT AXLE Ð Drive Shaft'' in FA section
*4: ``CAB BODY'' in BT section
*5: ``Front Wheel Alignment'' in FA section
*6: ``Aiming Adjustment'' in EL section
*7: ``Brake Pedal and Bracket'' in BR section, ``Adjusting Clutch Pedal'' in CL section
*8: ``Ventilation air ®lter'' in HA section
*9: ``Maintenance Items'' in RS section
PERIODIC MAINTENANCE
Chassis and Body Services (Cont'd)
MA-7
Maintenance Under Severe Driving Conditions
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A Ð Driving under dusty conditions
B Ð Driving repeatedly short distances
C Ð Towing a trailer or caravan
D Ð Extensive idling
E Ð Driving in extremely adverse weather condi-
tions or in areas where ambient temperatures
are either extremely low or extremely high
F Ð Driving in high humidity areas or in mountain-
ous areasG Ð Driving in areas using salt or other corrosive
materials
H Ð Driving on rough and/or muddy roads or in
the desert
I Ð Driving with frequent use of braking or in
mountainous areas
J Ð Frequent driving in water
Maintenance operation: Check = Check and correct or replace as necessary.
Driving
conditionMaintenance
itemMaintenance
operationMaintenance
interval
Reference
page Annual driving distance
below 30,000 km
(18,000 miles)over 30,000 km
(18,000 miles)
ABCD......Engine oil & oil ®lter
ReplaceEvery 3 months or
5,000 km (3,000
miles)Every 5,000 km
(3,000 miles)MA-13, 14
A.........Aircleaner ®lter Viscous paper type
ReplaceEvery 30,000 km
(18,000 miles) or
18 monthsEvery 30,000 km
(18,000 miles)MA-18
A...E.....Fuel ®lter
ReplaceEvery 20,000 km
(12,000 miles) or
12 monthsEvery 30,000 km
(18,000 miles)MA-16
.....F....Brake ¯uid
ReplaceMA-24
..C....H..Limited slip differential (LSD) gear oil*3
ReplaceEvery 30,000 km
(18,000 miles) or
18 monthsEvery 30,000 km
(18,000 miles)MA-22
......GH..Steering gear & linkage, axle & suspension parts &
propeller shaft & exhaust systemCheck
Every 10,000 km
(6,000 miles) or 6
monthsEvery 15,000 km
(9,000 miles)MA-26, 21,
23 *1
......GH.JGreasing points of propeller shafts Lubricate MA-21
..C....H..Drive shafts & steering damper Check *1
A.C...GHI.Brake pads, discs & other brake components Check MA-24
.........JFront wheel bearing grease & free-running hub grease Check *2, MA-23
*1: ``Front Axle and Front Suspension Parts'' in FA section, ``Rear Axle and Rear Suspension'' in RA section
*2: ``Front Wheel Alignment'' in FA section
*3: Including differential gear with differential lock
Maintenance for off-road driving
Whenever you drive off-road through sand, mud or water as deep as the wheel hub, more frequent mainte-
nance may be required of the following items:
mBrake pads and discs
mBrake lining and drums
mBrake lines and hoses
mWheel bearing grease and free-running hub grease
mDifferential, transmission and transfer oil
mSteering linkage
mPropeller shafts and front drive shafts
mAir cleaner ®lter
mClutch housing (Check water entry. Refer to MA-21.)
PERIODIC MAINTENANCE
MA-8
Precautions
+When installing rubber parts, ®nal tightening must be car-
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
+Use ¯are nut wrench when removing and installing brake
tubes.
+After installing removed suspension parts, check wheel
alignment and adjust if necessary.
+Always torque brake lines when installing.
Special Service Tools
Tool number
Tool nameDescription
KV40101000
Axle stand
NT159
Removing rear axle shaft
ST36230000
Sliding hammer
NT126
Removing rear axle shaft
ST38080001
Bearing lock nut wrench
NT507
Removing wheel bearing lock nut
a: 58 mm (2.28 in)
KV40106500
Wheel bearing puller
NT724
Removing wheel bearing
GG94310000
Flare nut torque
wrench
NT406
Removing and installing brake piping
a: 10 mm (0.39 in)
SBR820BA
PRECAUTIONS AND PREPARATION
RA-1
Maintenance Items
CAUTION:
Do not use a circuit tester to check SRS circuit.
1. Check operation of ``AIR BAG'' warning lamp.
After turning ignition key to ``ON'' position, both warning lamps
illuminate. The ``AIR BAG'' warning lamp will go off after about
7 seconds if no malfunction is detected.
If any of the following warning lamp conditions occur, immedi-
ately check the air bag or seat belt pre-tensioner system. Refer
to RS-30 for details.
+The ``AIR BAG'' warning lamp does not illuminate when the
ignition switch is turned ``ON''.
+The ``AIR BAG'' warning lamp does not go off about 7 seconds
after the ignition switch is turned ``ON''.
+The ``AIR BAG'' warning lamp blinks about 7 seconds after the
ignition switch is turned ``ON''.
2. Visually check SRS components.
(1) Diagnosis sensor unit
+Check diagnosis sensor unit and bracket for dents, cracks or
deformities.
+Check connectors for damage, and terminals for deformities.
(2) Air bag module and steering wheel
+Remove air bag module from steering wheel or instrument
panel. Check harness cover and connectors for damage, ter-
minals for deformities, and harness for binding.
+Install driver air bag module to steering wheel to check ®t or
alignment with the wheel.
+Check steering wheel for excessive free play.
+For dual air bag system, install passenger air bag module to
instrument panel to check ®t or alignment with the instrument
panel.
(3) Spiral cable
+Check spiral cable for dents, cracks, or deformities.
+Check connectors and protective tape for damage.
+Check steering wheel for noise, binding or heavy operation.
(4) Harness related to SRS
+Check connectors for poor connections, damage, and terminals
for deformities.
+Check harnesses for binding, cha®ng or cut.
(5) Seat belt pre-tensioner
+Check harness cover and connectors for damage, terminals for
deformities, and harness for binding.
+Check belts for damage and anchors for loose mounting.
+Check retractor for smooth operation.
+Perform self-diagnosis for seat belt pre-tensioner using
bulb or CONSULT. Refer to ``SRS Operation Check'' for details.
(RS-30)
CAUTION:
Replace previously used special bolts, ground bolt and anchor
bolt with new ones.
SRS451
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
RS-11
To repair the SRS for a frontal collision, perform the following steps.
When SRS (except the side air bag) is activated in a collision:
V1Replace the diagnosis sensor unit.
V2Remove the air bag modules.
V3Check the SRS components using the table shown below:
+Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
V4Install new air bag modules.
V5Conduct self-diagnosis using CONSULT and ``AIR BAG'' warning lamp. Refer to ``SRS Operation Check''
for details (RS-30). Ensure entire SRS operates properly.
When SRS is not activated in a collision:
V1Check the SRS components using the table shown below:
+Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
V2Conduct self-diagnosis using CONSULT and ``AIR BAG'' warning lamp. Refer to ``SRS Operation Check''
for details (RS-30). Ensure entire SRS operates properly.
SRS inspection
Part SRS (except the
side air bag) is acti-
vatedSRS is NOT activated
Air bag module
(driver and passen-
ger side)REPLACE
Install air bag mod-
ule with new bolts
coated with bonding
agent.1. Remove air bag module. Check harness cover and connectors for damage, ter-
minals for deformities, and harness for binding.
2-1. Install driver air bag module into the steering wheel to check ®t and alignment
with the wheel.
2-2. Install passenger air bag module into the instrument panel to check ®t with the
instrument panel.
3. No damage found, reinstall with new bolts coated with bonding agent.
4. If damagedÐREPLACE. Air bag must be deployed before discarding.
Diagnosis sensor
unitREPLACE
Install diagnosis sen-
sor unit with new
bolts coated with
bonding agent.1. Check case and bracket for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall with new bolts coated with bonding agent.
4. If damagedÐREPLACE. Install diagnosis sensor unit with new bolts coated with
bonding agent.
Seat belt pre-ten-
sioner assemblyREPLACE
Install seat belt pre-
tensioner with new
bolts coated with
bonding agent.1. Remove seat belt pre-tensioners.
Check harness cover and connectors for damage, terminals for deformities, and
harness for binding.
2. Check belts for damage and anchors for loose mounting.
3. Check retractor for smooth operation.
4. If no damage is found, reinstall with new bolts coated with bonding agent.
5. If damagedÐREPLACE. Install the seat belt pre-tensioners with new bolts coated
with bonding agent. Seat belt pre-tensioners must be deployed before discarding.
Steering wheel 1. Visually check steering wheel for deformities.
2. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities.
3. Install air bag module to check ®t or alignment with steering wheel.
4. Check steering wheel for excessive free play.
5. If no damage is found, reinstall the steering wheel.
6. If damagedÐREPLACE.
Spiral cable 1. Visually check spiral cable and combination switch for damage.
2. Check connectors, ¯at cable and protective tape for damage.
3. Check steering wheel for noise, binding or heavy operation.
4. If no damage is found, reinstall the spiral cable.
5. If damagedÐREPLACE.
Harness and Con-
nectors1. Check connectors for poor connection, damage, and terminals for deformities.
2. Check harness for binding, cha®ng, cuts, or deformities.
3. If no damage is found, reinstall harness and connectors.
4. DamagedÐREPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS
harness.
Instrument panel Refer to the table on the next page.
COLLISION DIAGNOSIS
RS-45
Checking Steering Wheel Play
+With wheels in a straight-ahead position, check steering wheel
play.
Steering wheel play:
35 mm (1.38 in) or less
+If it is not within speci®cation, check the following for loose and
worn components.
Steering gear assembly
Steering linkage
Steering column
Front suspension and axle
Checking Neutral Position on Steering Wheel
Pre-checking
+Make sure that wheel alignment is correct.
Wheel alignment:
Refer to SDS in FA section.
+Verify that the steering gear is centered before removing the
steering wheel.
Checking
1. Check that the steering wheel is in the neutral position when
driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel and
reinstall it correctly.
3. If the neutral position is between two teeth, loosen drag link lock
nuts. Adjust neutral position by turning drag link adjuster.
Front Wheel Turning Angle
1. Rotate steering wheel all the way right and left; measure turn-
ing angle.
Turning angle of full turns:
Refer to SDS in FA section.
2. If not within speci®cation, adjust using stopper bolt.
SST489B
SST490BA
SST756C
SMA127
SST773C
ON-VEHICLE SERVICE
ST-4