GENERAL MAINTENANCE
MA-5
< SERVICE INFORMATION >
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UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically (e.g. each time you check the engine oil or refuel).
Seat belts
Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly and are installed securely. Check the
belt webbing for cuts, fraying, wear or damage.MA-27, "Checking Seat
Belts, Buckles, Retrac-
tors, Anchors and Adjust-
ers"
Accelerator pedalCheck the pedal for smooth operation and make sure the pedal does not catch
or require uneven effort. Keep the floor mats away from the pedal.—
Clutch pedalMake sure the pedal operates smoothly and check that it has the proper free play.MA-21
BrakesCheck that the brake does not pull the vehicle to one side when applied. —
Brake pedal and
boosterCheck the pedal for smooth operation and make sure it has the proper distance
under it when depressed fully. Check the brake booster function. Be sure to keep
floor mats away from the pedal.BR-5, "
Inspection and
Adjustment" and BR-18,
"On Board Inspection"
Parking brakeCheck that the lever has the proper travel and make sure that the vehicle is held
securely on a fairly steep hill when only the parking brake is applied.PB-4, "On-Vehicle Ser-
vice"
Automatic transaxle
“Park” mechanismCheck that the lock release button on the selector lever operates properly and
smoothly. On a fairly steep hill check that the vehicle is held securely with the se-
lector lever in the “P” position without applying any brakes.—
CVT P (Park) position
mechanismOn a fairly steep hill check that the vehicle is held securely with the selector lever
in the “P” position without applying any brakes.— ItemReference page
ItemReference page
Windshield wash-
er fluidCheck that there is adequate fluid in the tank. —
Engine coolant
levelCheck the coolant level when the engine is cold.CO-8, "
Inspection"
A/C condenser,
radiator and hos-
esCheck the front of the condenser and radiator and clean off any dirt, insects, leaves,
etc., that may have accumulated. Make sure the radiator hoses have no cracks, de-
formation, deterioration or loose connections.—
Brake and clutch
fluid levelsMake sure that the brake and clutch fluid levels are between the “MAX” and “MIN”
lines on the reservoirs.BR-8, "
On Board Inspec-
tion" and MA-21, "Checking
Clutch Fluid Level and
Leaks"
BatteryCheck the fluid level in each cell. It should be between the “MAX” and “MIN” lines.
Vehicles operated in high temperatures or under severe conditions require frequent
checks of the battery fluid level.—
Engine drive beltsMake sure that no belt is frayed, worn, cracked or oily.MA-12
Engine oil levelCheck the level on the dipstick after parking the vehicle on a level spot and turning
off the engine.LU-6, "Inspection"
Automatic tran-
saxle fluid levelCheck the level on the dipstick after putting the selector lever in “P” with the engine
idling.MA-19 and MA-22
Exhaust systemMake sure there are no loose supports, cracks or holes. If the sound of the exhaust
seems unusual or there is a smell of exhaust fumes, immediately locate the trouble
and correct it.MA-19
UnderbodyThe underbody is frequently exposed to corrosive substances such as those used
on icy roads or to control dust. It is very important to remove these substances, oth-
erwise rust will form on the floor pan, frame, fuel lines and around the exhaust sys-
tem. At the end of winter, the underbody should be thoroughly flushed with plain
water, being careful to clean those areas where mud and dirt can easily accumu-
late.—
Fluid leaksCheck under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has
been parked for a while. Water dripping from the air conditioner after use is normal.
If you should notice any leaks or gasoline fumes are evident, check for the cause
and correct it immediately.—
MA-16
< SERVICE INFORMATION >
ENGINE MAINTENANCE
1. Warm up engine, park vehicle on a level surface and check for engine oil leakage from engine compo-
nents. Refer to LU-6, "
Inspection" .
2. Stop engine and wait for 10 minutes.
3. Loosen oil filler cap (1) and then remove drain plug (2).
• Oil filter (3)
• Vehicle front
4. Drain engine oil.
5. Install drain plug (2) with new washer. Refer to EM-24
CAUTION:
Be sure to clean drain plug (2) and install with new washer.
6. Refill with new engine oil. Refer to MA-10
.
CAUTION:
• The refill capacity depends on the engine oil temperature
and drain time. Use these specifications for reference
only.
• Always use oil level gauge to determine the proper
amount of engine oil in the engine.
7. Warm up engine and check area around drain plug (2) and oil fil-
ter (3) for engine oil leakage.
8. Stop engine and wait for 10 minutes.
9. Check the engine oil level. Refer to LU-6, "
Inspection".
Engine Oil FilterINFOID:0000000001704736
REMOVAL
1. Remove oil filter using Tool (A).
•⇐ Front
CAUTION:
• Oil filter is provided with relief valve. Use Genuine NIS-
SAN Oil Filter or equivalent.
• Be careful not to get burned when engine and engine oil
may be hot.
• When removing, prepare a shop cloth to absorb any
engine oil leakage or spillage.
• Do not allow engine oil to adhere to drive belt.
• Completely wipe off any engine oil that adheres to engine and vehicle.
INSTALLATION
1. Remove foreign materials adhering to the oil filter installation surface.
2. Apply new engine oil to the oil seal contact surface of new oil fil-
ter.
PBIC3915E
Tool number : KV10115801 (J-38956)
PBIC3818E
SMA010
ENGINE MAINTENANCE
MA-17
< SERVICE INFORMATION >
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3. Screw oil filter manually until it touches the installation surface,
then tighten it by 2/3 turn. Or tighten to specification.
INSPECTION AFTER INSTALLATION
1. Check the engine oil level. Refer to LU-6, "Inspection" .
2. Start engine, and make sure there is no leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level and adjust engine oil. Refer to LU-6, "
Inspection" .
Changing Spark PlugsINFOID:0000000001704737
1. Remove intake manifold. Refer to EM-18 .
2. Remove ignition coil.
CAUTION:
• Handle ignition coil carefully and avoid impacts.
• Never disassemble.
3. Remove spark plug using suitable tool.
CAUTION:
Never drop or shock it.
INSPECTION AFTER REMOVAL
CAUTION:
• Never drop or shock spark plug.
• Checking and adjusting spark plug gap is not required
between change intervals.
• If spark plug tip is covered with carbon, a spark plug cleaner may be used. Oil filter: : 17.7 N·m (1.8 kg-m, 13 ft-lb)
SMA229B
PBIC3871E
SMA806CA
MA-18
< SERVICE INFORMATION >
ENGINE MAINTENANCE
• Never use wire brush for cleaning spark plug.
INSTALLATION
1. Install spark plug using suitable tool.
CAUTION:
Never drop or shock spark plug.
2. Install ignition coil.
CAUTION:
• Handle ignition coil carefully and avoid impacts.
• Never disassemble ignition coil.
3. Install intake manifold. Refer to EM-18
.
Checking EVAP Vapor LineINFOID:0000000001704738
1. Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections,
chafing and deterioration.
2. Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc.
Refer to "Checking EVAP Vapor Lines"Cleaner air pressure
: Less than 588 kPa (5.88 bar, 6 kg/cm
2, 85 psi)
Cleaning time : Less than 20 seconds
SMA773C
Plug type : Iridium tipped
Make : DENSO
Part number : FXE20HR11
Gap (nominal) : 1.1 mm (0.043 in)
PBIC3871E
CHASSIS AND BODY MAINTENANCE
MA-21
< SERVICE INFORMATION >
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NOTE:
About 30 to 50% extra fluid will be required for this procedure.
4. Check fluid level and condition. Refer to MA-19, "
Checking CVT Fluid" .
CAUTION:
Delete CVT fluid deterioration date with CONSULT-II after changing CVT fluid. Refer to CVT-47,
"CONSULT-III Function (TRANSMISSION)" .
Checking Clutch Fluid Level and LeaksINFOID:0000000001704743
If fluid level is extremely low, check clutch system for leaks.
Checking Clutch SystemINFOID:0000000001704744
Check fluid lines and operating cylinder for improper attachment, cracks, damage, loose connections, chafing
and deterioration.
Checking M/T OilINFOID:0000000001704745
OIL LEAKAGE AND OIL LEVEL
1. Make sure that oil is not leaking from transaxle or around it.
2. Remove filler plug (1) and check oil level at filler plug hole as
shown.
CAUTION:
Do not start engine while checking oil level
3. Install a new gasket onto filler plug (1) and install it into tran-
saxle. Tighten filler plug to specification. Refer to MT-17, "
Disas-
sembly and Assembly" .
CAUTION:
Do not reuse gasket.
Changing M/T OilINFOID:0000000001704746
DRAINING
1. Start engine and let it run to warm up transaxle.
2. Stop engine. Remove drain plug (1) and drain oil.
3. Install a new gasket onto drain plug (1) and install it into tran-
saxle. Tighten drain plug to specification. Refer to MT-17, "
Dis-
assembly and Assembly" .
CAUTION:
Do not reuse gasket.
FILLING
SCIA7623E
SCIA7622E
MA-22
< SERVICE INFORMATION >
CHASSIS AND BODY MAINTENANCE
1. Remove filler plug (1). Fill with new oil until oil level reaches the
specified limit at filler plug hole as shown.
2. After refilling oil, check oil level. Install a new gasket on filler plug
(1), then install it into transaxle. Tighten filler plug to specifica-
tion. Refer to MT-17, "
Disassembly and Assembly" .
CAUTION:
Do not reuse gasket.
Checking A/T FluidINFOID:0000000001704747
1. Warm up engine.
2. Check for A/T fluid leakage.
3. Before driving, A/T fluid level can be checked at A/T fluid tem-
peratures of 30 to 50°C (86 to 122°F) using the “COLD” range
on A/T fluid level gauge.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear posi-
tion. Leave selector lever in “P” position.
c. Check A/T fluid level with engine idling.
d. Remove A/T fluid level gauge and wipe clean with lint-free cloth.
CAUTION:
When wiping the A/T fluid level gauge, always use lint-free
cloth.
e. Re-insert A/T fluid level gauge into A/T fluid charging pipe as far
as it will go.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging
pipe using the stopper attached.
f. Remove A/T fluid level gauge and note reading. If reading is at
low side of range, add A/T fluid to the A/T fluid charging pipe.
CAUTION:
Do not overfill.
4. Drive vehicle for approximately 5 minutes.
5. Re-check A/T fluid level at A/T fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on A/T
fluid level gauge.
CAUTION:
• When wiping the A/T fluid level gauge, always use lint-free cloth.
• Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using the stopper attached.
6. Check A/T fluid condition and make any necessary repairs. Refer to AT-48, "
Inspections Before Trouble
Diagnosis" . If the A/T fluid contains frictional material (clutches, bands, etc.), or if the A/T is repaired,
overhauled, or replaced, inspect and clean the A/T fluid cooler mounted in the radiator. Refer to AT-16, "
A/
T Fluid Cooler Cleaning" .
7. Install the removed A/T fluid level gauge into the A/T fluid charging pipe.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using the stopper attached.
Changing A/T FluidINFOID:0000000001704748
1. Warm up A/T fluid.Oil grade and capacity
: Refer to MA-10, "
Fluids and Lubricants"
SCIA7623E
SCIA3451E
SMA051D
CHASSIS AND BODY MAINTENANCE
MA-25
< SERVICE INFORMATION >
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Check the brake pads for wear or damage. Refer to BR-32, "Disas-
sembly and Assembly of Wheel Cylinder" .
WHEEL CYLINDER
Check for leakage.
LINING
Check for lining thickness (A). Refer to BR-32, "Disassembly and
Assembly of Wheel Cylinder" .
Axle and Suspension PartsINFOID:0000000001704755
Check front and rear axle and suspension parts for excessive play,
cracks, wear or other damage.
• Shake each wheel to check for excessive play.
• Check wheel bearings for smooth operation.
• Check axle and suspension nuts and bolts for looseness.
• Check strut (shock absorber) for oil leakage or other damage.
• Check suspension ball joint for grease leakage and ball joint dust
cover for cracks or other damage.
BRA0010D
SFIA0657J
SBR021A
SMA525A
MT-1
TRANSMISSION/TRANSAXLE
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CONTENTS
MANUAL TRANSAXLE
SERVICE INFORMATION ............................2
PRECAUTIONS ...................................................2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
2
Precaution for Procedure without Cowl Top Cover ......2
Precaution .................................................................2
PREPARATION ...................................................3
Special Service Tool .................................................3
Commercial Service Tool ..........................................5
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .............................
7
NVH Troubleshooting Chart ......................................7
DESCRIPTION ....................................................8
Cross-Sectional View ................................................8
M/T OIL ...............................................................10
Changing M/T Oil ....................................................10
Checking M/T Oil .....................................................10
SIDE OIL SEAL ..................................................11
Removal and Installation .........................................11
POSITION SWITCH ............................................12
Checking .................................................................12
CONTROL LINKAGE ........................................13
Component of Control Device and Cable ................13
Removal and Installation .........................................13
AIR BREATHER HOSE ....................................15
Removal and Installation .........................................15
TRANSAXLE ASSEMBLY ................................16
Removal and Installation .........................................16
Disassembly and Assembly .....................................17
INPUT SHAFT AND GEARS ............................35
Disassembly and Assembly .....................................35
MAINSHAFT AND GEARS ...............................39
Disassembly and Assembly .....................................39
REVERSE IDLER SHAFT AND GEARS ..........44
Disassembly and Assembly .....................................44
FINAL DRIVE ....................................................46
Disassembly and Assembly .....................................46
SHIFT CONTROL ..............................................49
Inspection ................................................................49
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
50
General Specification ..............................................50