SECTION 1

PERIODIC MAINTENANCE SERVICE

CONTENTS

1-1. MAINTENANCE SCHEDULE ................................. 1-2

1-2. ENGINE .................................................. 1-4

'-3. IGNITION SYSTEM ........................................ '-8

1-4. FUEL SYSTEM ........................................... '-10

'-5. EMISSION CONTROL SYSTEM .............................. '-12

'-6. ELECTRiCAL ............................................ 1-13

1-7. CHASSIS AND BODY ...................................... 1-13

1- 1
 ,.,. MAINTENANCE SCHEDULE

This table includes services as scheduled up to 80,000 km (48,000 miles)

mileage. Beyond 80,000 km (48,000 miles), carry out the same services at
Interval: the same intervals respectively.
This interval should be judged
by odometer reading or months, km (x 1,000) 1 10 20 30 40 50 60 70 80
whichever comes first.
miles (x 1,000) 1 6 12 18 24 30 36 42 48
months 1 6 12 18 24 30 36 42 48
ENGINE

1. Water pump drive belt (tension, damage) I - I - R - I - R

2. Valve lash (clearance) I - I - I - I - I

3. Engine bolts (All cylinder head and manifold fixingsj - - - - T - - - T

4. Engine oil filter - R R R R R R R R

API Grade SO, SE or SF R Replace every 10,000 km (6,000 miles)
5. Engine oil
API Grade SC R Replace every 5,000 km (3,000 miles)

6. Engine coolant - - - - R - - - R
7. Cooling system hoses and connections - - I - I - I - I
8. Exhaust pipes and mountings (leakage, damage, tightness) - - I - I - I - I
IGNITION
9. Ignition wiring (high tension cords) - - I - I - I - I
f--
10. Distributor cap and rotor (crack, wear) - - I - I - I - I
11. Spark plugs and distributor breaker point - R R R R R R R R

12. Ignition timing I I I I I I I I I

13. Distributor advance - - I - I - I - I

FUEL SYSTEM
Paved-road Clean every 10,000 km (6,000 miles)
Dusty condition Clean every 2,500 km (1,500 miles) or as required
14. Air cleaner filter element
Replace every 40,000 km (24,000 miles)
More frequent replacement if under
dusty driving conditions.
15. Carburetor choke system and accelerator shaft - I&L I&L I&L I&L I&L I&L I&L I&L

16. Fuel tank cap, gas lines and connections (~:~:~:') I - - - I - - - I

17. Fuel filter - - - - R - - - R

18. Idle speed and idle mixture I - I - I - I - I

1'2
 This table includes services as scheduled up to 80,000 km (48,000 miles)
mileage. Beyond 80,000 km (48,000 miles), carry out the same services at
Interval. the same intervals respectively.
This interval should be judged
by odometer reading or months, km (x 1,000) 1 10 20 30 40 50 60 70 80
whichever comes first. miles (x 1,000) 1 6 12 18 24 30 36 42 48

months 1 6 12 18 24 30 36 42 48

EMISSION CONTROL SYSTEM

19. Crankcase ventilation hoses and connections - - I - I - I - I

*20. PCV valve - - - - I - - - I

21. Fuel vapor storage system, hoses and connections - - I - I - I - I

ELECTRICAL

22. Wiring harness connections and headlights - - I - I - I - I

CHASSIS AND BODY

*23. Clutch release arm free travel I I I I I I I I I

24. Brake discs and pads (wear, damage)
- I I I I I I I I
24-1. Brake drums and shoes (wear, damage)

25. Brake hoses and pipes (leakage, damage, clamp) -

.
I I I I I I I I
26. Brake fluid (level, leakage) I I I I R I I I R
27. Brake pedal (pedal-to-wall clearance) I I I I I I I I I
-
28. Brake lever and cable (stroke, damage) I I I I I I I I I
29. Tires (abnormal wear and pressure) - I I I I I I I I
30. Wheels, wheel nuts (damage, tightness) I I I I I I I I I
31. Shock absorbers (oil leakage, damage) I I I I I I I I I
32. Drive shafts (damage) - - I - I - I - I
*33. Transmission and differential oil (leakage, level) R I I I R I I I R
34. Suspension (Tightness, damage, rattle) T - T - T - T - T
-- --_.
35. Steering condition (Tightness, damage, breakage, rattle) I I I I I I I I I
36. Door hinges, gear shift control lever and shaft - L L L L L L L L
37. Test drive Test drive on completion of each service

* Item 20 is applicable to the car equipped with a PCV valve on the intake manifold.
* Items 23 and 33 are applicable to the car equipped with a manual transmission.
NOTICE:
"R" Replace or Change
"I" Inspect and correct or rep/ace if necessary
"T" Tighten to the specified torque
"L" Lubricate

1-3
'-2. ENGINE [Replacement and adjustment)
1) Disconnect negative battery lead at battery.
1. WATER PUMP BELT INSPECTION 2) Loosen alternator adjusting bolt and pivot
[ Inspection) bolts and move alternator inward.
1) Disconnect negative battery lead at battery.
2) Inspect belt for cracks, cuts, deformation,
wear and cleanliness. Check belt for tension.
The belt is in proper tension if it deflects 6
to 9 mm (0.24 - 0.35 in.) under thumb
pressure (about 10 kg or 22 lb.).

Belt tension 6 - 9 mm (0.24 - 0.35 in.)

specification as defle'ction

3) Replace belt.
4) Move alternator outward and adjust belt to
specified tension.
5) Tighten alternator adjusting bolt and pivot
bolts.
6) Connect negative battery lead to battery.

WARNING:
All adjustments noted above are to be
performed with ENGINE NOT RUNNING.
3) If the belt is too tight or too loose, adjust it
to specification by adjusting alternator
position. 2. VALVE LASH INSPECTION
1) Remove cylinder head cover.
2) Inspect intake and exhaust valve lash and
adjust as necessary.

Valve When cold When hot

lash
(gap A) Intake
specifi· 0.13·0,18 mm 0,23 ·0,28 mm
cation (0,005·0,007 in.) (0,009 ·0.011 in,)
Exhaust

Screw lock nut 15 - 20 N'm

(1.5 - 2.0 kg·m, 11,0 - 14,0 Ib·ft)

4) Tighten alternator adjusting bolt and pivot

bolt.
5) Connect negative battery lead to battery,

WARNING:
All adjustments noted above are to be
performed with ENGINE NOT RUNNING.

"4
3) Refer to SECTION 3 for valve lash inspection Tightening torque
and adjustment procedures.
Exhaust manifold N·m kg-m Ib-ft
4) Install cylinder head cover and tighten bolts
to specification. (Refer to item 3) nut 18 - 23 1.8 - 2.3 13.5 - 16.5
I ntake man ifold nut 18 - 23 1.8 - 2.3 13.5-16.5

3. ENGINE BOLTS (ALL CYLINDER HEAD

AND MANIFOLD FIXINGS)
1) To check cylinder head bolts, head cover
must be removed. The tightening torque for
the cyl i nder head bolts is as follows.
Tightening torque N·m kg-m Ib-ft
for cylinder head
bolts 55 - 60 5.5 - 6.0 40.0 - 43.0

2) When securing cylinder head or when

retightening these bolts, torque each bolt in
such a way as to equalize the pressure through-
out gasketed surface. The tightening sequence 4. ENGINE OIL FILTER CHANGE
is as shown below. 1) Loosen oil filter by using oil filter wrench
"A" (special tool 09915-47310).

"1" Camshaft pulley side

"2" Distributor side

3) Cylinder-head cover bolt should be tightened NOTICE:

to the following torque: Before fitting new oil filter, be sure to oil its
"0" ring. Use engine oil for this purpose.
Tightening torque N·m kg-m Ib-ft
for cylinder head 2) Screw on the new filter by hand until the
4-5 0.4 - 0.5 3.0 - 3.5 filter "O"ring contacts the mounting surface.
cover bolts

CAUTION:
4) Check the intake and exhaust manifold nuts To tighten the oil'filter properly, it is
for tightness and retighten them as necessary. important to accurately identify the.
position at which the filter "0" ring first
contacts the mounting surface.

1-s
3) Tighten the filter 2/3 turn from the point of
contact with the mounting surface using an
oil filter wrench.

CAUTION:
To prevent oil leakage, make sure that the
oil filter is tight, but do not overtighten it.
Low level mark
(hole)
4) After installing oil filter, start engine and
check oil filter for oil leakage. /~:....--- Full level mark (hole)

5. ENGINE OIL CHANGE

Before draining engine oil, check engine for oil NOTICE:
leakage. If any evidence of leakage is found, Steps 1) - 3) outlined above must be performed
make sure to correct defective part before with ENG INE NOT RUNNING. For step 4),
proceeding to the following work. be sure to have adequate ventilation while
1) Drain engine oil by removing drain plug. engine is running.

It is recommended to use engine oil of SD, SE

or SF class.

Proper Engine Oil Viscosity Chart

>
>
20W-50

l5W-40.l5W-50

10W-40. lOW-50 >

10W-30
Oil drain plug

'c
'F
<
-30
I
-22
-20
I
-4
-10
I
14
5W-30
0
I
32
10
I
50
20
I
68
30
I
86
40
I
104
2) After draining oil, wipe drain plug clean.
Reinstall drain plug, and tighten it securely. Temperature

Tightening torque N·m kg-m Ib-ft

for oil drain plug 30-40 3.0-4.0 22.0-36.0 Engine oil capacity

2.5 liters
3) Replenish oil until oil level is brought to Oil pan capacity
(5.3/4.4 US/Imp pt.)
FULL level mark on dipstick. (about 2.5
liters or 5.3/4.4 US/Imp pt.). The filler 0.2 liters
Oil filter capacity
inlet is atop the cylinder head cover. (0.4/0.3 US/Imp pt.)
4) Start engine and run it for three minutes. 0.3 liters
Others
Stop engi ne and wait another three minutes (0.6/0.5 US/Imp pt.)
before checking oil level. Add oil, as necessary, 3.0 liters
to bring oil level to FU LL level mark on dip Total
(6.3/5.3 US/Imp pt.)
stick.

1-6
6. ENGINE COOLANT CHANGE 5) Fill radiator with specified amount of coolant,
and run engine for 2 or 3 minutes at idle.
IMPORTANT: This drives out any air which may still be
To help avoid danger of being burned, do trapped within cooling system. STOP
not remove radiator cap while engine and ENGINE. Add coolant as necessary until
radiator are still hot. Scalding fluid and coolant level reaches the filler throat of
steam can be blown out under pressure if radiator. Reinstall radiator cap.
the cap is taken off too soon. 6) Add coolant to reservoir tank so that the level
aligns with Full mark.

1) Remove radiator cap when engine is cool: COOLANT CAPACITY

~
2) Disconnect water hose CD (radiator outlet) Manual Automatic
from water pipe ®. Item transm ission transm iss ion
Engine, radiator
2.4 liters 2.9 liters
and heater
Reservoir tank 0.6 liters 0.6 liters
Total 3.0 liters 3.5 liters

CAUTION:
When changing engine coolant, use mixture
of 50% water and 50% GOLDEN CRUISER
1200 for the market where ambient tempe-
rature falls lower than _16° C (3° F) in
winter and mixture of 70% water and
30% GOLDEN CRUISER 1200 for the
market where ambient temperature d,oesn't
fall lower than -16°C (3°F).
Even in a market where no freezing tempe-
3) Remove reservoir tank @, and drain. rature is anticipated, mixture of 70% water
4) Connect water hose CD to water pipe ® and and 30% GOLDEN CRUISER 1200 should
tighten clamp. Also reinstall reservoir. be used for the purpose of corrosion
protection and lu brication.

7. COOLING SYSTEM HOSES INSPECTION

1) Visually inspect cooling system hoses for any
evidence of leakage and cracks. Examine them
for damage, and check connection clamps
for tightness.

1- 7
2) Replace all hoses which show evidence of 1-3. IGNITION SYSTEM
leakage, cracks or other damage. Replace all
clamps which cannot maintain proper tight- 9. IGNITION WIRING (High Tension Cords)
ness. INSPECTION
1) Inspect high-tension cords for cracks and
check that their connections are secure.
8. EXHAUST PIPES AND MOUNTINGS 2) Measure resistance of high-tension cords by
INSPECTION using a circuit tester (special tool 09900-
25002).
IMPORTANT:
To avoid danger of being burned, do not
touch exhaust system when system is hot.
Any service on exhaust system should be
performed when system is cool.

When carrying out periodic maintenance, or the

car is raised for other service, check exhaust
system as follows:
• Check rubber mountings for damage, deterio-
ration, and out of position.
411 Check exhaust system for leakage, loose
connections, dents, and damages.
If bolts or nuts are loose, tighten them.
• Check nearby body areas for damaged, miss-
ing, or mispositioned parts, open seams, 3) Replace high-tension cords that show evidence
holes, loose connections or other defects of deterioration.
which could permit exhaust fumes to seep
into the car. NOTICE:
• Make sure that exhaust system components Check to make sure that each of the high
have enough clearance from the underbody to tension cord terminals and connections is
avoid overheating and possible damage to the secure and fully inserted into its mating compo-
floor carpet. nent. Any burnt fitting must be replaced.
• Any defects should be fixed at once.
HIGH-TENSION CORD RESISTANCE
Standard 16 kn/3.3 ft (1 m)
Service limit 20 kn/pc.

1-0
10. DISTRIBUTOR CAP AND ROTOR 2) Using a spark plug wrench, loosen and remove
INSPECTION plugs.
1) Inspect distributor cap and rubber caps for
cracks.
0,7 - 0,8 mm
2) Inspect center electrode and terminals for (0,027 - 0,031 in,)
wear.

NOTICE:
When replacing plugs, make sure to use new
plugs of specified heat range and size.

PLUG SPECIFICATION

Heat range
3) Inspect rotor for cracks, and its electrode Maker
Standard type
for wear.
4) Repair or replace as necessary any compo- NGK BP5ES (BPR5ES)
nent which is found to be in malcondition as Nippon Denso W16EX-U (W16EXR-U)
described above.

NOTICE: As can be seen in the above table, there are two

Dust and stains found within distributor can be types of spark plugs for this car, one without R
cleaned by using a dry, soft cloth. included in its code and the other with R as
in parenthesis. Which one is used depends on
11. SPARK PLUGS AND DISTRIBUTOR countries. Look at the label attached to the
BREAKER POINT REPLACEMENT car. If originally equipped plug was with R
[Spark plugs] included in its code, replacement plug should
have R in its code, too.
1) Disconnect high-tension cords from spark
plugs. Make sure to pull only on spark plug 3) Install new spark plugs. Tighten plugs to
caps. specification.
4) Connect high tension cords to spark plugs.
DO NOT push cords for connection. Push
boots.

20 - 30 N·m
Spark plug
2.0 - 3.0 kg-m
tightening torque
14.5 - 21.5 Ib-ft

1-9
 [Distributor breaker point] 1-4. FUEL SYSTEM
1) Remove the distributor cap.
2) Replace the point and apply a small amount 14. AIR CLEANER ELEMENT CLEANING
of grease to breaker arm heel. AND REPLACEMENT
3) Adjust the breaker point gap @ to specifica-
tions. Replacement
1) Remove air cleaner cap.
NOTICE: 2) Take cleaner element CD out of air cleaner
., Never loose the distributor housing clamp case.
bolt @ when replacing the breaker point. 3) Install new cleaner element CD into cleaner
Ell After adjust the breaker point gap to specifi-
case.
cations, check the ignition timing.

0.4 - 0.5 mm
Point gap @
(0.016 - 0.019 in.)

CD
4) When installing air cleaner cap, align two
arrow marks ® on the cap and the snorkel.

CDSlit ®Screws

12. IGNITION TIMING INSPECTION

Check to make sure that ignition timing is set
properly. If out of specification, adjust it.
Refer to SECTION 8 for ignition timing inspec- Inspection and cleaning
tion and adjustment procedure. After driving in a dusty area, check element
for dust. If found dusty, clean it as follows.
1) Blow off dust with compressed air from
13. DISTRIBUTOR ADVANCE INSPECTION inside of element.
Check advance for proper operation. Refer to
SECTION 8 for advance checking procedure.

2) Install cleaner element into air cleaner case .

. ' ..
1·10

_____ ~ __ '-'----~ ~ ____ ~-1...:...:..:

15. CARBURETOR CHOKE SYSTEM
AND ACCELERATOR SHAFT
LUBRICATION AND INSPECTION
1) Remove air cleaner case and lubricate rotating
parts.
2) Check if choke valve operates smoothly to
open and close fully when choke knob is
pulled and pushed back respectively. Correct
if it doesn't operate as described above.

16. FUEL TANK CAP, GAS LINES AND

CONNECTIONS INSPECTION
1) Visually inspect fuel lines and connections for
evidence of fuel leakage, hose cracking, and 18. ENGINE IDLE SPEED AND IDLE
damage. Make sure all clamps are secure. MIXTURE INSPECTION
Repair leaky joints, if any.
NOTICE:
Replace hoses that are suspected of being
• Requires external tachometer.
cracked.
2) Visually inspect packing of fuel tank cap. 1) As preliminary steps, check to be sure that:
CD Coolant temperature should be within the
If it is damaged or deteriorated, replace it
with new one. below indicated range. (Engine is normal
operating temperature.)

17. FUEL FILTER CHANGE

The entire filter unit is replaced at regular
schedu led i nte rva Is. The method of replacement
is as follows:
1) Fuel filter is located at the front part of
fuel tank. The filter is removed from the car
by disconnecting inlet and outlet hoses from
the filter.
2) Position the new filter in place, and connect • Choke valve is in full-open position.
inlet and outlet hoses to it. • All accessories (wipers; heater, lights, etc.) are
out of service.
NOTICE:
CD Ignition timing is within specification.
The top connection is for the outlet hose, the
CD Air cleaner has been properly installed and is
lower one for the inlet hose.
in good condition.
• Engine valve clearance is within specification.
WARNING:
The above procedure must be performed in [Idle speed and idle mixture adjustment]
a well ventilated area and away from any Adjust idle speed and idle mixture according to
open flames (such as gas hot water heaters). the following procedure.
1) Adjust idle speed to 950 r/min (rpm) by
repositioning (turning) idle speed adjusting
screw CD.
2) With engine idling at 950 r/min (rpm), turn""
idle mixture adjusting screw ® to the right or\\;,
left and set it where the highest engine speed:,~ ,
is obtained. (This is the best idle position).

,- 11
 3) Perform above 1) and 2) once again, and then 1-5. EMISSION CONTROL SYSTEM
readjust idle speed to 950 r/min (rpm) with
idle speed adjusting screw CD. 19. CRANKCASE VENTILATION HOSES
4) Upon completion of the work so far, readjust AND CONNECTIONS INSPECTION
engine idle speed to the below specification Check crankcase ventilation hose for leaks and
by turning idle mixture adjusting screw ® cracks, if any of these is defective, repair or
slowly to the right (close). replace.

All cars of this model now manufactured are

delivered with their CO% factory adjusted as 20. PCV (Positive Crankcase Ventilation)
follows. VALVE INSPECTION
This item is not applicable in this model.
Engine idle mixture CO% 1.5 ± 0.5
Engine idle speed r/min (rpm) 900 21. FUEL VAPOR STORAGE SYSTEM,
HOSES AND CONNECTIONS
In the country with the statutory requirements INSPECTION
for the exhaust gas (CO%), be sure to adjust the 1) Visually inspect hoses for cracks, damage, or
idle mixture adjusting screw so that the CO% excessive bends. Inspect all clamps for damage
indicated on the exhaust gas tester will meet the and proper position.
above specificati on. 2) If any of these is defective, repair or replace.

Special tool ® is necessary to turn the idle

Charcoal Canister
mixture adjusting screw ®.
[Applicable to the car equipped with canister in
engine compartment]
Check Canister.
For checking procedure, refer to canister check
of SECTION 5.

1. Idle speed adjusting screw

2. Idle mixture adjusting screw
®: Special tool (Carburetor
adjuster 09913-17310)

1-12
'·6. ELECTRICAL '-7. CHASSIS AND BODY

22. WIRING HARNESS CONNECTIONS AND 23. CLUTCH RELEASE ARM INSPECTION
HEADLIGHTS INSPECTION 1) Check clutch pedal height. It should be the
[Wiring harness and connections] same as brake pedal height.
1) Visually inspect all wires located in engine 2) Check clutch release arm free travel.
compa rtment for evi dence of breakage.
Inspect the condition of the insulation Clutch release arm 2-4mm
(cracks). All clips and clamps should have play (A) (0.08 - 0.16 in.)
solid connections to wires.
2) Replace any wires in a deteriorated or other-
wise defective condition.

[Headl ights]
1) Check vertical beam alignment.
2) Check horizontal beam alignment.
Refer headlight of SECTION 19 for above 1)
and 2) checking procedures.
24. BRAKE DISCS, PADS, BRAKE DRUMS
NOTICE: AND SHOES INSPECTION
In the countries where statutory regulations Brake Discs and Pads
define headlight alignments, adjust in conformity 1) Remove wheel and caliper but don't discon-
with such regulations. nect brake hose from cal iper.
2) Check front disc brake pads and discs for
excessive wear, damage and deflection.
Replace parts as necessary. For the details,
refer to p. 17-11 and 17-12 of SECTION 17.

Pad thickness Standard Limit

(lining + pad 15.5 mm 6.5 mm
rim) (0.610 in.) (0.256 in.)

Standard Limit
Disc thickness 11 mm 9.5mm
(0.433 in.) (0.374 in.)

Limit on disc deflection 0.15 mm (0.006 in.)

Be sure to torque caliper bolts to specifica-

tion for reinstallation.

Brake Drums and Shoes

1) Remove wheel and brake drum.
2) Check brake drums ~nd brake linings for
excessive wear and damage, while wheels and
drums are removed. Also check wheel cylin-
ders for leaks, at the same time. Replace
these parts as necessary.

1-13
 Item Standard Service Limit 3) Change brake fluid every 2 years. As fluid
Brake 180 mm 182 mm change procedure, drain existing fluid from
drum I.D. (7.09 in.) (7.16 in.) brake system completely, fill the system with
above recommended flu id and carry out air
Brake Service purge operation.
Standard For description of air purge, refer to p. 17-24
lining Limit
and 17-250f SECTION 17.
Thickness
7.0 mm 3.0mm
(lining +
(0.28 in.) (0.12 in.) 27. BRAKE PEDAL INSPECTION
shoe rim)
Check brake pedal travel.
For the details, refer to p. 17-12 and p.17- For checking procedure, refer to PEDAL TRA-
13 of SECTION 17. VEL CHECK (p. 17-21) of SECTION 17.

28. BRAKE LEVER AND CABLE

25. BRAKE HOSES AND PIPES INSPECTION INSPECTION
Check brake hoses and pipes for proper hook- 1) Check tooth tip of each notch for damage or
up, leaks, cracks, chafing and other damage. wear. If any damage or wear is found, replace
Replace any of these parts as necessary. parking lever.
2) Pull up parking lever all the way with one
hand to apply brake futly, and see how many
CAUTION: notches of ratchet lever has traversed. If the
After replacing any brake pipe or hose, be number of traversed notches is more than
sure to carry out air purge operation. 5 (five), adjust the parking brake cable.

Parking brake stroke;

Within
When lever is pulled up
2 - 5 notches
26. BRAKE FLUID INSPECTION AND at 20 kg (44 Ib)
CHANGE
1) Check around master cylinder and reservoir For stroke measurement and parking brake
for fluid leakage. adjustment, refer to MAINTENANCE SER-
If found leaky, correct. VICE (p. 17-22) of SECTION 17.
2) Check fluid level
If fluid level is lower than the minimum level 3) Parking brake cable
of reservoir, refilling is necessary. Fill reservoir Inspect brake cable for damage and smooth
with either one of brake fluids listed below: movement. Replace cable if it is in deteriorat-
ed condition.
Specifications
Brake fluid
\
DOT 3, or SAE J1703

For the details, refer to MAINTENANCE

SERVICE (p. 17-20) of SECTION 17.

CAUTION:
Since the brake system of this car is factory-
filled with glycol-base brake fluid, do not
use or mix different type of fluid when
refilling the system; otherwise serious
damage will occur. Do not use old or used
brake fluid, or one taken from unsealed
container.

'-14
29. TIRE INSPECTION AND ROTATION When measurement exceed limit, replace
1) Check tires for uneven or excessive wear, or bearing.
damage. If defective, replace. By rotating wheel actually, check wheel
bearing for noise and smooth rotation. If
Less than 1.6 mm defective, replace bearing.
Tire wear limit (0.063 in.) depth of
tread at two places

2) Check inflating pressure of each ti re and

adjust pressure to specification as necessary.
NOTICE:
• Tire inflation pressure should be checked
when tires are cool.
• Specified tire inflation pressure should be
found on tire placard or in owners' manual
which came with the car.
3) Rotate tires.

FRONT FRONT
2) Check rear wheel bearing for wear, damage or
rattles. When measuring thrust play, apply a
dial gauge to the drum center after removing
wheel center cap from wheel disc.

0.3 mm
Thrust play Limit Rear
(0.012 in)

·0 When the measurement exceeds limit, replace

bearing.
d By rotating wheel actually, check wheel
bearing for noise and smooth rotation. If it is
5 WHEEL ROTATION 5 WHEEL ROTATION defective, replace bearing.
[Radial Tires] [Bias Tires)

Wheel Nuts
Check wheel nuts for tightness and, retighten
them to specificat ion as necessary.
30. WHEELS AND WHEEL NUTS
40 -70 N·m
INSPECTION Tightening torque
4.0 - 7.0 kg-m
for wheel nuts
(29.0 - 50.5 Ib-ft)
Wheel Disc
Inspect each wheel disc for dents, distortion and
cracks. A disc in badly damaged condition must
be replaced.

Wheel Bearings
1) Check front wheel bearing for wear, damage
or rattles. When measuring thrust play, apply
a dial gauge to wheel hub center after remov-
ing wheel center cap from wheel disc.

Thrust play Limit 0.4 mm (0.016 in)

1- 15
31. SHOCK ABSORBERS INSPECTION 2) Inspect the boots for breakage and replace if
1) Inspect absorbers for evidence of oil leakage, broken.
dents or any other damage on sleeves; and
inspect anchor ends for deterioration.
2) Depending on the results of the above inspec-
tion, replace absorbers.

33. TRANSMISSION OIL INSPECTION AND

CHANGE (For manual transmission)

32. DRIVE SHAFTS INSPECTION [ Inspection 1

1) Jack up the car body and confirm that the 1) Inspect transmission case for evidence of oil
drive shaft is free from play in the rotatio- leakage. Repair leaky point if any.
nal direction and rotates smoothly. 2) Make sure that the car is placed level for oil
level check.
3) Take out the oil level gauge from the trans-
mission case and wipe off the oil.
4) Bring face ® of the oil level gauge to con-
tact face @ of the transmission case and
check the oil level indicated by the oil on the
gauge.
The oil level must be somewhere between
FULL level line and LOW level line on the
gauge.

Transmission
case

'-16
[Change] 34. SUSPENSION INSPECTION AND
Oil change procedure is as follows. TIGHTENING
1) Place the car level. 1) Check leaf spring for wear, crack and damage.
2) Drain oil by removing drain plug. If excessive wear of cracking is noted, replace
3) Apply SUZUKI BOND No. 1215 (99000- the spring with a new one.
31110) to the screw part of the drain plug. 2) Check bolts and nuts for tightness and retigh-
4) Tighten drain plug to specified torque. ten them as necessary.
5) Pour specified amount of specified oil as in Repair or replace defective parts, if any.
the below table. NOTICE:
For the details of check points, refer to the
NOTICE: table of RECOMMENDED TORQUE SPECIFI-
For the car used in such areas where ambient CATIONS (p. 15-5, 15-10 and 15-11) of SEC·
temperature becomes lower than -15°C (5°F) TION 15.
during the coldest season, it is recommended
that oil be changed with SAE80W or 75W/80 -
85 oils on such occasion of service as periodic 35. STEERING CONDITION
maintenance. 1) Check steering wheel for play and rattle,
holding car in straight forward condition on
Transmission oil change the ground.
2.0 liters
Oil capacity 0- 30 mm
(4.2/3.5 US/Imp pt.) Steering wheel play
(0 -1.2 in.)
Gear oil, SAE # 90,
Type of oil SAE 75W/SO - S5 or 2) Check steering shaft joint of steering shaft for
SAE SOW rattle and damage. If rattle or damage is
found, replace defective part with a new one.
3) Check bolts and nuts for tightness and retigh-
ten them as necessary. Repair or replace
defective parts, if anv.
Refer to p. 16-12 for particular check points.
4) Check the steering ra.ck boot for deteriora-
tion, cracks and other damage and replace if
defective.
5) Check boots of tie rod ends for damage. If
damage is found, replace it with a new one.
6) Check wheel alignment.

Alignment service data

CD 25 - 30 N·m (2.5 - 3.0 kg-m, 18.5 - 21.5Ib-ft) Side slip OUT 3 - IN 3 m/km
O~ 3mm
Toe-in
6) After pouring specified amount of oil, per- (0~0.12in.)
form step 4) of transmission oil inspection. Camber 1° 20' ± 1°
7) Tighten oil level gauge. 0
Kingpin inclination 12° 50' ± 0.8
Caster 3° 15' ± 10

NOTICE:
For the details of wheel alignment, refer to
WHEEL ALIGNMENT (p. 16-10) of SECTION
16.

1·17
7) Drive the car on road to be sure that: 4) Brake
a) Steeri ng wheel does not show abnormal [Foot brake]
resistance. Check the following when depressing brake
b) Steering wheel does not wobble. pedal while driving;
• that brake works properly,
• that it is free from noise,
36. DOOR HINGES, GEAR SHIFT CONTROL • and that braking force applies equally on
LEVER AND SHAFT LUBRICATION all wheels.
[Door hinge]
[Parking brakf;l]
Wipe off dirt and apply a thin coat of engine oil.
Check to ensure that parking brake is fully
Open and close door several times to insure that
effective when the car is stopped on the slop
the oil has worked in effectively.
and brake lever is pulled all the way.
[Gearshift control lever and shaft joint] 5) Steering
Lubricate lever seat and shaft bushings with Check to ensure that steering wheel is free
water resistant chassis grease. Refer to p. 12-3 of from instability, or abnormally heavy feeling
SECTION 12 for lubrication points. while driving.

6) Engine
37. TEST DRIVE • Check that engine responds readily at all
Upon completion of all periodical checks, speed.
through 36, carry out road test in safe place. ED Check that engine is free from abnormal

noise and abnormal vibration.

WARNING:
When carrying out the following road 7) Body, Wheels and Power Transmitting System
tests, select a safe place where no man or Check that body, wheels and power trans-
no running car is seen so as to prevent any mitting system are free from abnormal
accident. noise and abnormal vibration or any other
abnormal condition.
1) Engine start
Check engine start for readiness. 8) Meters and Gauge
Check that speedometer, odometer, fuel
NOTICE: meter, and temperature gauge are operating
In the cold weather, sta.rt to operate engine by accurately.
pulling choke control knob, ..,."-
9) Oil R.ressu'te and charging indicator lights
2) Clutch Mak~S'(.Jre that these lights stay off while
Check the following: engine is operating. If either of,them comes
., that clutch is completely released when on during engin~ operation, it means that
depressing clutch pedal, something is wrong with engine lubrication
" that no slipping clutch occurs when releas- system or charging system, and consequently
ing pedal and accelerating, immediate inspection is necessary .
• anq that clutch itself is free from any
abnormal condition. 10) Seat Belt
Check that seat belt is securely locked at
3) Gearshift Lever (Transmission) hard braking.
Check gearshift lever for smooth shifting
to all positions and for good performance of WARNING:
transmission in any position. For this test, select a safe place without
any running car so as to prevent any
accident. And again make sure that no man
or no other car is seen in front or behind
and use great care to the surroundings
when carrying out the test