Page 140 of 190

7-3
INSPECTION AND MAINTENANCE
53MH0-74E
*Interval: This interval should be judged by
odometer reading or months, whichever comes
first.km (x 1,000)
monthsFREE INSPECTIONS PERIODIC MAINTENANCE SERVICE AT COST
1 5 10 20 30 40 50 60 70 80
1 6 12 24 36 48 60 72 84 96
ENGINE
1.Water pump drive belt (Tension, Wear) AIIIIIIRAI
2. Engine Coolant (Level, Leakage) I I I R I R I R I R
3.Engine oil and Oil filter R I RRRRRRRR
4. Cooling system hoses and connections (Leakage, Damage) I I IIIIIIII
5. Engine bolts (All cylinder head and manifold fixings) – – T – T – T – T –
6. Engine mounting (Loose, Damage) – – T – T – T – T –
7. Valve Clearance – A – A – A – A – A
8. Camshaft timing belt (Damage, Wear)–––I–I–I–I
Replace Every 1,00,000 km
9. Exhaust system (Noise, Leakage etc.) – I – I – I – I – I
10. Positive crankcase ventilation System (Hoses, Connections and Valve) – I – I – I – I – I
IGNITION
1. Ignition wiring (Damage, Deterioration) – – – I – I – I – I
2. Spark plugs (Clean and Adjust the gap) – – I R I R I R I R
FUEL
1. Air cleanerPaved-road Clean every 5,000 km. Replace after every 40,000 km.
Dusty condition Clean every 2,500 km or as required. Replace after every 40,000 km.
More frequent replacement if dust condition is severe.
2. Fuel tank cap, fuel lines and connections (Leakage, Damage) – I – – – I – – – I
3. Fuel filter (Leakage) I I I I I R I I I R
CLUTCH AND TRANMISSION
1. Clutch pedal (Play) I I IIIIIIII
2. Clutch slipping (Dragging or Excessive damage) I I IIIIIIII
3. Manual Transmission Oil (Level, Leakage)IIIIIIIIII
Replace every 1,60,000 kms or 10 years, which ever comes earlier
DRIVE SHAFTS
1. Drive shafts boot (Boot cut / Damage) – I IIIIIIII
2.Drive Shaft Noise IIIIIIIIII
Page 141 of 190

7-4
INSPECTION AND MAINTENANCE
53MH0-74E
*Interval: This interval should be judged by
odometer reading or months, whichever comes
first.km (x 1,000)
monthsFREE INSPECTIONS PERIODIC MAINTENANCE SERVICE AT COST
1 5 10 20 30 40 50 60 70 80
1 6 12 24 36 48 60 72 84 96
BRAKE
1. Brake fluid (Level, Leakage) I I I R I R I R I R
2.Brake pedal (Pedal-to-wall clearance) IIIIIIIIII
3.Parking brake lever and cable (Play, Damage) IIIIIIIIII
4.a. Brake discs and pads (Wear) – I IIIIIIII
b. Brake drums & shoes (Wear) – – IIIIIIII
5.Master cylinder, wheel cylinder, caliper piston (Fluid leakage, Boot/Seal
Damage)IIIIIIIIII
6.Brake hoses and pipes (Fluid leakage, Damage)
IIIIIIIIII
WHEEL
1. Tyres (Air pressure, Abnormal wear, Crack, Rotation) I
I&OI&O I&OI&OI&OI&OI&OI&O I&O
2. Wheels (Damage) I
I I I I I I I I I
3. Front/Rear wheel bearings (Loose, Damage) –
I I I I I I I I I
FRONT AND REAR SUSPENSION
1. Suspension strut (Oil leakage, Damage) I
I I I I I I I I I
2. Suspension arms/knuckle support (Loose, Damage) –
IIIIII I I I
3. Rear spring (Damage) –
I I I I I I I I I
4. Shock absorbers (Oil leakage, Damage) I
I I I I I I I I I
5. All bolts and nuts (Loose)–
T T T T T T T T T
6. Suspension arms and Tension rods –
I I I I I I I I I
STEERING
1. Steering wheel (Play, Loose) I
I I I I I I I I I
2. All rods and arms (Loose, Damage, Wear) I
I I I I I I I I I
ELECTRICAL
1. Battery electrolyte (Level, leakage) I
I I I I I I I I I
2. Wiring harness connection (Loose, Damage) –
I I I I I I I I I
3. Lighting system (Operation, Stains, Damage) I
I I I I I I I I I
4. Horn (Operation) I
I I I I I I I I I
5. System voltage I
I I I I I I I I I
BODY
1. All chassis bolts and nuts (Tighten)
–II T
T T T T T T
2. All latches, hinges and locks (Function)
II&LI&L I&L
I&L I&L I&L I&L I&L I&L
Page 144 of 190

7-7
INSPECTION AND MAINTENANCE
53MH0-74E
*Interval: This interval should be judged by
odometer reading or months, whichever comes
first.km (x 1,000)
monthsFREE INSPECTIONS PERIODIC MAINTENANCE SERVICE AT COST
1 5 10 20 30 40 50 60 70 80
1 6 12 24 36 48 60 72 84 96
ENGINE
1.Water pump drive belt (Tension, Wear) ––––– I ––– I
2. Engine Coolant (Level, Leakage) I I I R I R I R I R
3. Engine oil and Oil filter – – RRRRRRRR
4. Cooling system hoses and connections (Leakage, Damage)IIIIIIIIII
5. Engine bolts (All cylinder head and manifold fixings) – – T – T – T – T –
6. Engine Mounting (Loose, Damage) – – T – T – T – T –
7.Valve Clearance –––– I –– I ––
8. Exhaust System (Noise, Leakage etc.) – I – I – I – I – I
9. Positive crankcase ventilation System (Hoses, Connections and Valve) – I – I – I – I – I
IGNITION
1. Ignition wiring (Damage, Deterioration) – – – I – I – I – I
2.Spark plugs –––––R–––R
FUEL
1. Air cleanerPaved-road Clean every 5,000 km. Replace after every 40,000 km.
Dusty condition Clean every 2,500 km or as required. Replace after every 40,000 km.
More frequent replacement if dust condition is severe.
2. Fuel tank cap, fuel lines and connections (Leakage, Damage) – I – – – I – – – I
3. Fuel filter (Leakage) – I I I I R I I I R
CLUTCH AND TRANMISSION
1.Clutch pedal (Play) IIIIIIIIII
2.Clutch slipping (Dragging or Excessive damage) IIIIIIIIII
3. Manual Transmission Oil (Level, Leakage)IIIIIIIIII
Replace every 1,60,000 kms or 10 years whichever comes first
DRIVE SHAFTS
1. Drive shaft boots (Boot cut / Damage)IIIIIIIIII
2.Drive Shaft Noise IIIIIIIIII
BRAKE
1. Brake fluid (Level, Leakage) I I I R I R I R I R
2. Brake pedal (Pedal-to-wall clearance)IIIIIIIIII
Page 145 of 190

7-8
INSPECTION AND MAINTENANCE
53MH0-74E
*Interval: This interval should be judged by
odometer reading or months, whichever comes
first.km (x 1,000)
monthsFREE INSPECTIONS PERIODIC MAINTENANCE SERVICE AT COST
1 5 10 20 30 40 50 60 70 80
1 6 12 24 36 48 60 72 84 96
3. Parking brake level and cable (Play, Damage)IIIIIIIIII
4.a. Brake discs and pads (Wear) – I I IIIIIII
b. Brake drums & shoes (Wear) ––IIIIIIII
5.Master cylinder, wheel cylinder, caliper piston (Fluid leakage, Boot/Seal
Damage)IIIIIIIIII
6.Brake hoses and pipes (Fluid leakage, Damage)
IIIIIIIIII
WHEEL
1. Tyres (Air pressure, Abnormal wear, Crack and Rotation) I
I&OI&O I&OI&OI&OI&OI&OI&O I&O
2. Wheels (Damage) I
I I I I I I I I I
3. Front/Rear wheel bearing (Loose, Damage) –
I I I I I I I I I
FRONT AND REAR SUSPENSION
1. Suspension strut (Oil leakage, Damage) I
I I I I I I I I I
2. Suspension arms/knuckle support (Loose, Damage) –
IIIIII I I I
3. Rear spring (Damage) –
I I I I I I I I I
4. Shock absorbers (Oil leakage, Damage) I
I I I I I I I I I
5. All bolts and nuts (Loose)–
T T T T T T T T T
6. Suspension arms and Tension rods –
I I I I I I I I I
STEERING
1. Steering wheel (Play, Loose) I
I I I I I I I I I
2. All rods and arms (Loose, Damage, Wear) I
I I I I I I I I I
ELECTRICAL
1. Battery electrolyte (Level, Leakage) I
I I I I I I I I I
2. Wiring harness connection (Loose, Damage) –
I I I I I I I I I
3. Lighting system (Operation, Stains, Damage) I
I I I I I I I I I
4. Horn (Operation) I
I I I I I I I I I
5. System voltage I
I I I I I I I I I
BODY
1. All chassis bolts and nuts (Tighten)
–ITT
T T T T T T
2. All latches, hinges and locks (Function)
II&LI&L I&L
I&L I&L I&L I&L I&L I&L
ROAD TEST
1. Operation of Brakes, Gear shifting and speedometer
II I I
I I I I I I
2.Body and Chassis noise
II I I
I I I I I I