Maintenance operations¶

Engine¶

Cold engine operations

1. Replace timing belt¶

1. Remove the timing belt.
   • 3S-GTE (See Timing belt (3S-GTE))
   • 5S-FE (See Timing belt (5S-FE))
2. Install the timing belt.
   • 3S-GTE (See Timing belt (3S-GTE) › Installation of timing belt)
   • 5S-FE (See Timing belt (5S-FE) › Installation of timing belt)

2. Inspect drive belt¶

1. Visually check the drive belt for excessive wear, frayed cords etc. If necessary, replace the drive belt.

   Hint

   Cracks on the ribbed side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced.

   

2. Using a belt tension gauge, measure the drive belt tension.

   

   Belt tension gauge:

   • Nippondenso BTG-20 (95506-00020)
   • Borroughs No.BT-33-73F

   Drive belt tension:

   • Alternator
     • New belt – 120 ± 20 lb
     • Used belt – 104 ± 20 lb
   • A/C compressor
     • New belt – 160 ± 25 lb
     • Used belt – 100 ± 20 lb

   If necessary, adjust the drive belt tension.

   Hint

   • "New belt" refers to a belt which has been used 5 minutes or less on a running engine.
   • "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
   • After installing the belt, check that it fits properly in the ribbed grooves.
   • Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
   • After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.

   

3. Inspect air filter¶

1. Visually check that the air cleaner element is not excessively, damaged or oily.

   If necessary, replace the air cleaner element.

2. Clean the element with compressed air.

   First blow from the inside thoroughly, then blow off the outside of the element.

   

4. Replace air filter¶

Replace the air cleaner element with a new one.

5. Replace spark plugs¶

1. Disconnect the spark plug cords at the rubber boot. DO NOT pull on the cords.

   

2. Using a 16 mm plug wrench, remove the spark plugs.

   

3. (3S-GTE)

   Check the electrode gap of new spark plugs.

   Correct electrode gap: 0.8 mm (0.031 in.)

   Recommended spark plugs:

   • ND PK20R8
   • NGK BKR6EP8

   Hint

   If adjusting the gap of a new spark plug, bend only the base of the ground electrode. DO NOT touch the tip.

   

4. (5S-FE)

   Adjust the electrode gap of new spark plugs.

   Correct electrode gap: 1.1 mm (0.043 in.)

   Recommended spark plugs:

   • ND K16R-U11
   • NGK BKR5EYA11

   

5. Using a 16 mm plug wrench, install the spark plugs.

   Torque: 180 kg-cm (13 ft-lb, 18 N·m)

6. Connect the spark plug cords.

6. Replace engine oil and oil filter¶

(See page LU-7)

Oil grade: API grade SG, multigrade viscosity and fuel-efficient oil

Drain and refill capacity (3S-GTE):

• w/ oil filter change – 3.9 liters (4.1 US qts, 3.4 Imp. qts)
• w/o oil filter change – 3.6 liters (3.8 US qts, 3.2 Imp. qts)

Drain and refill capacity (5S-FE):

• w/ oil filter change – 4.2 liters (4.4 US qts, 3.7 Imp. qts)
• w/o oil filter change – 3.8 liters (4.0 US qts, 3.3 Imp. qts)

7. Replace engine coolant¶

(See page CO-5)

Coolant capacity (w/ heater):

• 3S-GTE – 13.6 liters (14.4 US qts, 12.0 Imp. qts)
• 5S-FE – 13.0 liters (13.7 US qts, 11.4 Imp. qts)

8. Inspect charcoal canister¶

1. Disconnect the hoses from the charcoal canister.

   Label hoses for correct installation.

2. Plug port A with your finger, and blow compressed air (3 kg/cm², 43 psi or 294 kPa) through port B (fuel tank side).

   • Check that air comes out of the bottom port C without resistance.
   • Check that no activated charcoal comes out.

   If necessary, replace the charcoal canister.

   Notice

   Do not attempt to wash the charcoal.

   

3. Reconnect the hoses to the charcoal canister.

9. Replace gasket in fuel tank cap¶

1. Remove the old gasket from the tank cap.

   Notice

   Do not damage the tank cap.

2. Install a new gasket by hand.

3. Check the cap for damage or cracks.

4. Install the cap and check the torque limiter.

   

10. Inspect fuel lines and connections¶

Visually check the fuel lines for cracks, leakage, loose connections, deformation or tank band looseness.

11. Inspect exhaust pipes and mountings¶

Visually check the pipes, hangers and connections for severe corrosion, leaks or damage.

12. Adjust valve clearance¶

• 3S-GTE (See Engine tune-up › Inspection and adjustment of valve clearance (3S-GTE))
• 5S-FE (See Engine tune-up › Inspection and adjustment of valve clearance (5S-FE))

Valve clearance (cold):

• 3S-GTE
  • Intake – 0.15 – 0.25 mm (0.006 – 0.010 in.)
  • Exhaust – 0.20 – 0.30 mm (0.008 – 0.012 in.)
• 5S-FE
  • Intake – 0.19 – 0.29 mm (0.007 – 0.011 in.)
  • Exhaust – 0.28 – 0.38 mm (0.011 – 0.015 in.)

Brakes¶

13. Inspect brake line pipes and hoses¶

1. Check all brake lines and hoses for:

   • Damage
   • Wear
   • Deformation
   • Cracks
   • Corrosion
   • Leaks
   • Bends
   • Twists

   

2. Check all clamps for tightness and connections for leakage.

3. Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system.
4. Check that the lines installed in grommets pass through the center of the grommets.

14. Inspect brake pads and discs¶

1. Check the thickness of the disc brake pads and check for irregular wear.

   Minimum pad thickness: 1.0 mm (0.039 in.)

   Hint

   If a squealing or scraping noise comes from the brake during driving, check the pad wear indicator to see if it is contacting the disc rotor. If so, the disc pad should be replaced.

   

2. Check the disc for wear or runout.

   Minimum disc thickness:

   • Front – 24.0 mm (0.787 in.)
   • Rear – 15.0 mm (0.590 in.)

   Maximum disc runout:

   • Front – 0.07 mm (0.0028 in.)
   • Rear – 0.10 mm (0.0039 in.)

   

Chassis¶

15. Inspect steering linkage¶

1. Check the steering wheel freeplay.

   Maximum steering wheel freeplay: 30 mm (1.18 in.)

   With the vehicle stopped and pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure.

   

2. Check the steering linkage for looseness or damage.

   Check that:

   • Tie rod ends do not have excessive play.
   • Dust seals and boots are not damaged.
   • Boot clamps are not loose.

   

16. Inspect SRS airbag¶

Visually check the steering wheel pad (airbag and inflater).

• Use the diagnosis check to check if there are abnormalities.
• Check that there are no cuts, cracks or noticeable color changes on the surface of the steering wheel pad or in the center groove of the pad.
• Remove the steering wheel pad from the vehicle and check the wiring and steering wheel for damage and corrosion due to rusting, etc.

If necessary, replace the pad.

17. Inspect steering gear housing oil¶

Check the steering gear box for oil leakage.

18. Inspect drive shaft boots¶

Check the drive shaft boots for clamp looseness, leakage or damage.

19. Inspect ball joints and dust covers¶

1. Inspect the ball joints for excessive looseness.

   • Jack up the front of the vehicle and place wooden blocks with a height of 180 – 200 mm (7.09 – 7.87 in.) under the front tires.
   • Lower the jack until there is about half a load on the front coil springs. Place stands under the vehicle for safety.
   • Check that the front wheels are in a straight forward position, and block them with chocks.
   • Using a lever, pry up the end of the lower arm, and check the amount of play.

   Maximum ball joint vertical play: 0 mm (0 in.)

   If there is play, replace the ball joint.

   

2. Check the dust cover for damage.

   

20. Check transaxle fluid¶

A. (M/T) Check manual transaxle oil (fluid)

1. Visually check the transaxle for oil (fluid) leakage.

   If leakage is found, check for the cause and repair.

2. Remove the filler plug and feel inside the hole with your finger. Check that the oil (fluid) comes to within 5 mm (0.20 in.) of the bottom edge of the filler hole.

   If the level is low, add oil (fluid) until it begins to run out the filler hole.

   • Transaxle oil (3S-GTE): See item 21 (A)
   • Transaxle fluid (5S-FE): See item 21 (A)

   

3. Reinstall the filler plug securely.

B. (A/T) Check automatic transaxle fluid

1. Visually check the transaxle for fluid leakage.

   If leakage is found, check for the cause and repair.

2. Check the fluid level.

   If the level is low, add fluid.

   Transmission fluid: See item 21 (B)

   

21. Replace transaxle oil (fluid)¶

A. (M/T) Replace transaxle oil (fluid)

1. Remove the filler and drain plugs, and drain the oil (fluid).
2. Reinstall the drain plug securely.

3. Add new oil (fluid) until it begins to run out of the filler hole.

   (3S-GTE)

   Transaxle oil: Transaxle oil E50 (088885-80206) or equivalent

   Recommended transaxle oil:

   • Oil grade: API GL-5
   • Viscosity: SAE 75W-90 or 80W-90
     • Above – 18°C (0°F) SAE 90
     • Below – 18°C (0°F) SAE 80W

   Capacity: 4.2 liters (4.4 US qts, 3.7 Imp. qts)

   (5S-FE)

   Transaxle fluid: ATF DEXRON II

   Capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts)

   

4. Reinstall the filler plug securely.

B. (A/T) Replace transaxle fluid

1. Remove the drain plugs, and drain the fluid.

2. Reinstall the drain plugs securely.

   

3. With the engine OFF, add new fluid through the dipstick tube.

   Transaxle fluid: ATF DEXRON II

   Drain and refill capacity: 3.3 liters (3.6 US qts, 2.9 Imp. qts)

4. Start the engine and shift the selector into all positions from "P" through "L", and then shift into "P".

5. With the engine idling, check the fluid level. Add fluid up to the "COOL" level on the dipstick.

   Notice

   Do not overfill. The transmission and differential are separate units.

   

6. Recheck the fluid level with the normal temperature (70 – 80°C (158 – 176°F)) and add as necessary.

22. Tighten bolts and nuts on chassis and body¶

Tighten the following parts:

• Front seats mount bolts

  Torque: 375 kg-cm (27 ft-lb, 37 N·m)

  

• Strut bar bracket-to-body mount bolts

  Torque: 740 kg-cm (54 ft-lb, 73 N·m)

• Rear suspension lower crossmember-to-body mount bolts

  Torque: 1,150 kg-cm (83 ft-lb, 113 N·m)

23. Body inspection¶

1. Check the body exterior for dents, scratches and rust.
2. Check the underbody for rust and damage.

24. Road test¶

1. Check the engine and chassis for abnormal noises.
2. Check that the vehicle does not wander or pull to one side.
3. Check that the brakes work properly and do not drag.

25. Final inspection¶

1. Check the operation of the body parts:

   • Hood
     • Auxiliary catch operates properly
     • Hood locks securely when closed
   • Front and rear doors
     • Door locks operate properly
     • Doors close properly
   • Luggage compartment door and back door
     • Door lock operates properly
   • Seats
     • Seat adjusts easily and locks securely in any position
     • Front seat back locks securely in any position
     • Fold-down rear seat backs lock securely

2. Be sure to deliver a clean car. Especially check:

   • Steering wheel
   • Shift lever knob
   • All switch knobs
   • Door handles
   • Seats