L GROUP-O

L(JBRIC:ATlON -’
AND
MAINTENANCE.
CONTENTS

GENERAL INFORMATION ............................... 2 ENGINE OIL FILTER ................................... 12

CRANKCASE VENTILATION SYSTEM ...... 13
SCHEDULED MAINTENANCE TABLE ......... .:. . 3
EVAPORATIVE EMISSION CONTROL
LUBRICANT CAPACITIES TABLE AND SYSTEM .......................................................... 14
RECOMMENDED LUBRICANTS ....................... 6 DRIVE BELTS ............................................... 15
COOLING SYSTEM ....................................... 15
MAINTENANCE SERVICE ................................ 8
BRAKE FLUID ........... . .................................. 16
JET VALVE CLEARANCE
ADJUSTMENT ................................................ 8 BRAKE HOSES .............................................. 17
VALVE CLEARANCE ADJUSTMENT ......... 8 BRAKES .......................................................... 17
BASIC IGNITION TIMING ADJUSTMENT.. 9 FRONT AXLE ‘AND REAR AXLE ............. 18
CARBURETOR CHOKE MECHANISM FRONT WHEEL BEARINGS ........................ 18
AND LINKAGE .............................................. 10 BALL JOINT SEALS, STEERING
FUEL FILTER ............................................... 10 LINKAGE SEALS AND DRIVE SHAFT
BOOTS ............................................................ 18
FUEL SYSTEM .............................................. 10
UPPER CONTROL ARM BUSHINGS ............. 18
IGNITION CABLES ....................................... 11
MANUAL TRANSMISSION AND .
SPARK PLUGS ............................................... 11 TRANSFER CASE ......................................... 18
AIR CLEANER FILTER ............................... 11 AUTOMATIC TRANSMISSION AND
ENGINE OIL .................................................. 12 TRANSFER CASE ........ ................................. 18

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mI GENERAL INFORMATION

Maintenance and lubrication service recomme d da- GEAR LUBRICANTS

tions have been compiled to provide maximum pro- The SAE grade number also indicates the viscosity of
tection for the vehicle owner’s investment.against all multipurpose gear lubricants.
reasonable types of driving conditions. The API classification system defines gear lubricants
Since these conditions .vary with the individual. in terms of usage. Gear lubricants conforming to API
vehicle owner’s driving habits, the area in which the GL-4 or GL5 with a viscosity of SAE 80W or SAE 90
vehicle is operated and the type of driving to wl.ich are usually recommended for the manual transmission
the vehicle is subjected, it is necessary to prescribe .and rear axle (conventional differential), and MITSU-
lubrication and maintenance service on a tme BISHI genuine gear oil Part No. 8149630EX or
frequency as well as mileage interval basis. Mopar Hypoid Gear Lubricant Part No. 3744994 or
Oils, lubricants and greases are classified and graded 3744995 plus Mopar Hypoid Gear Oil Additive/
according to standards recommended by the Society Friction Modifier Part No. 4057100, or equivalent,
of Automotive. Engineers (SAE), the American Pe- for a limited slip differential.
troleum Institute (API) and, the National Lubrica.ring
Grease Institute (NLGI). LUBRICANTS - GREASES
MAINTENANCE SCHEDULES Semi-solid lubricants bear the NLGI designation and
are further classified as grades 0, 1, 2, 3, etc.
Information for service maintenance is provi ed Whenever “Chassis Lubricant” is specified, Multipur-
in the “SCHEDULED MAINTENANCE TABLE’ . pose Grease NLGI grade #2EP should be used.
Three schedules are provided: one for “Requ red
Maintenance”, one for “General Maintenance” e nd FUEL USAGE STATEMENT
one-for “Severe Usage Service”. Use gasoline h,aving a minimum anti-knock ‘index
SEVERE *SERVICE . ‘. (Octane Value) of 87 (R + M)/2. This designation is
comparable to a Research Octane.Number ‘of 91. ‘_
Vehicles operated under severe service condit:ons Unleaded gasoline only must be used. All vehicles so
will require more frequent service. equipped have labels located on the instrument panel
Component service information is included in ap- and. on the back of fuel filler lid that %tate; “UN-
propriate units for vehicles operated under one or LEADED GASOLINE ONLY”. These vehicles also
more of the following conditions: have fuel filler tubes designed to accept only the
( 1) Trailer towing or police, taxi, smaller diameter unleaded.gasoline dispensing nozzles.
operation
MATERIALS ADDED TO FUEL ’ ’
(2) Operation of vehicle:
(a) Short-trip -operation at Indiscriminate use of% fuel .system cleaning agents
(engine not thoroughly should be. avoided: Many of these materials intended
k (b) More .than 50% for gum and varnish removal may contain highly
traffic during hot active solvents or similar ingredients that can be
(c) Extensive idling ., ’ harmful to gasket and diaphragm materials used in
(d) Driving in sandy areas fuel system component parts.
(e) Driving in salty areas ‘.
:
(f) Driving in dusty tionditions . , ‘- 1
(g) Off-road driving :
‘* . . .
ANGIE ‘01~ I . . . .
The SAE grade number indii;ates the viscosity of
.
engine oils, for example SAE 30, which is a s:ngle
grade oil. Engine oils are also identified by a
number, for example SAE 1 OW-30, which
multigrade oil.
The API classification system defines oil
in terms of engine usage.
,“For Service SE” or “For
ble, should be used. These oils
chemical additives to provide maximum
protection. Both the SAE grade
tion can be found on the container.
 SCHEDULED~ MAINTENANCE TABLE

Scheduled Maintenance Services for Emission Control and Proper Vehicle Performance
Inspection and Service should be performed anytime a malfunction’is observed or suspect&d. Retain receipts for
vehicle emission services to protect your emission warranty.

EMISSION- MILEAGE IN THOUSANDS 7.5 15 22.5‘

CONTROL SYSTEM SERVICE
MAINTENANCE INTERVALS
KILOMETERS IN THOUSANDS 12 24 36

CHANGE ENGINE OIL EVERY 12 MONTHS I OR x x x

REPLACE ENGINE OIL FILTER EVERY 12 MONTHS OR x

CHECK CONDITION OF DRIVE BELT (FOR WATER PUMP

X
AND ALTERNATOR) AND ADJUST TENSION AS REQUIRED AT

REPLACE DRIVE BELT (FOR WATER PUMP AND ALTERNATOR) AT

CHECK VALVE CLEARANCE AND ADJUST AS REQUIRED AT X

CHECK IGNITION
EVERY 5 YEARS

CLEAN CARBURETOR
TIMING AND ADJUST AS REQUIRED

CHOKE MECHANISM AND LINKAGE

c- I I I

REPLACE FUEL FILTER (EXCEPT FILTER IN FUEL TANK)

CHECK FUEL SYSTEM* (CAP, TANK, LINE, AND CONNECTIONS)

ATI
OR
i
c I I lx
FOR LEAKS EVERY 5 YEARS
I
I
I Ix
I

T
I
I

REPLACE AIR CLEANER FILTER AT

AT! I I
1
REPLACE SPARK PLUGS

REPLACE IGNITION CABLES* EVERY 5 YEARS OR I I Ix

x
REPLACE VACUUM HOSES, SECONDARY AIR HOSES, AND OR
CRANKCASE VENTILATION HOSES EVERY 5 YEARS I I ,Ix
REPLACE FUEL HOSES, WATER HOSES, AND FUEL VAPOR

&Id=
OR X
HOSES* EVERY 5 YEARS

CHECK CRANKCASE EMISSION CONTROL SYSTEM OR X

AND CLEAN AS REQUIRED EVERY 5 YEARS

CHECK EVAPORATIVE EMISSION CONTROL SYSTEM (EXCEPT OR

CANISTER) FOR LEAKS AND CLOGGING EVERY 5 YEARS

REPLACE CANISTER AT
-l--L-L
Note: *For California vehicles, this maintenance is recommended by Mitsubishi Motor Sales of America, Inc., but is not required
by the warranty on these parts (except water hoses).

\.
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,.

SCHEDULEC /lAINTENANCETABLE

General Maintenance Service for Proper Vehicle I formance

GENERAL

COOLING
MAINTENANCE

SYSTEM
7
SERVICE
:NTERVALS

:HECK AND SE 0CE AS

REQUIRED EV Y 12 MONTHS
I
I I I.! ’ ’
I I
DRAIN, FLUSE
EVERY 24 MOI

CHECK FLUID 3VELAND AT

INSPECT FOR AKS
BRAKE FLUID
CHANGE EVEE 4 YEARS

FRONT DISC BRAKE PADS INSPECT FOR ’ <AR AT

REAR DRUM BRAKE LININGS INSPECT FOR ’ :AR AND AT

AND REAR WHEEL CYLINDERS LEAKS

CHECK FOR D ERIORA- AT

BRAKE HOSES TION OR LEAI

BALL JOINT AND STEERING INSPECT FOR LEASE

LINKAGE SEALS, AND DRIVE AT
LEAKS OR DA iGE
SHAFT BOOTS I
I I I
I I I
UPPER CONTROL ARM LUBRICATE G CASE AT
BUSHINGS

INSPECT FOR EASE AT

FRONT WHEEL BEARINGS LEAKS

FRONT AXLE AND CHECK OIL LE EL AT

REAR AXLE*’

MANUAL TRANSMISSION AND CHANGE OIL ( NER&

TRANSFER CASE USAGE COND ONS ONLY) AT

AUTOMATIC TRANSMISSION CHANGE FLU AT

AND TRANSFER CASE

REAR AXLE *’ CHANGE OIL AT

Note: *l Not applicable to vehicles with a limited slip fferential

*’ Applicable only to vehicles with a limited sli lifferential

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 I
SCHEDULED MAINTENANCE TABLE cu

Severe Usage Service

The maintenance items should be performed according to the following table:

MILEAGE INTERVALS-
SEVERE USAGE
KILOMETERS IN THOUSANDS CONDITIONS
SERVICE TO BE (MILES IN THOUSANDS)
MAINTENANCE ITEM
PERFORMED
-
12 24 36 48 60 72 go ABCDEFGH
(7.5) (15) (22.5) (30) (37.5) (45) (50)

ENGINE OIL CHANGE 0 0 0 0

EVERY 3 MONTHS OR- EVERY 4,800 KM (3,000 MILES) 0

ENGINE OIL FILTER REPLACE 0 0 0 0

EVERY 6 MONTHS OR- EVERY 9,600 KM (6,000 MILES) 0

AIR CLEANER FILTER REPLACE MORE FREQUENTLY 0 0

CRANKCASE EMISSION CHECK AND CLEAN

CONTROL SYSTEM MORE FREQUENTLY 0
AS REQUIRED

SPARK PLUGS REPLACE 0 0 a 0 0

FRONT DISC BRAKE PADS INSPECT FOR WEAR MORE FREQUENTLY 0 0

REAR DRUM BRAKE

LININGS AND REAR INSPECT FOR WEAR
OR LEAKS MORE FREQUENTLY 0 0
WHEEL CYLINDERS

MANUAL TRANSMISSION
AND TRANSFER CASE CHANGE OIL 0 0 0 0

UPPER CONTROL ARM

BUSHINGS LUBRICATE GREASE EVERY 12,000 KM (7,500 MILES) o 00 0

Sever usage conditions

A - Driving in dusty conditions
B - Police, taxi, or commercial type operation
C - Extensive idling
D - Short-trip operation at freezing temperatures (engine not thoroughly warmed up)
E - Driving in sandy areas
F - Driving in salty areas
G -More than 50% operation in heavy city traffic during hot weather above 32’C (90’F)
H - Off-road driving

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 LUBRICANT CAPACITIES TABLE AND RECOMMENDED LUBRICANTS

LUBRICANT CAPACITIES TABLE

Description Metric measure U.S. measure Imperial measure.

Engine oil
Crankcase (including oil filter) 5.8 liters 6.1 qts. 5.1 qts.
Oil filter 0.50 liter 0.53 qt. 0.44 qt.
Cooling system (including heater, and 8.0 liters 8.45 qts. 7.04 qts.
coolant reservoir)
Manual transmission 2.2 liters 4.6 pints 3.9 pints
Automatic transmission ’ 6.8 liters 14.4 pints 12.0 pints
Transfer case 2.2 liters 4.6 pints 3.9 pints
Front axle 1.1 liters 2.3 pints 1.9 pints
Rear axle 1.8 liters 3.8 pints 3.2 pints
Power steering 0.9 liter 1.9 pints 1.6 pints
Fuel tank 60 liters 15.9 gals. 13.2 gals.

RECOMMENDED LUBRICANTS

Component Lubricant specification Remarks

Engine API classification For further details, refer to SAE viscosity number
SE or SF

Power steering Automatic ‘transmission fluid ATF

“DEXRON” or “DEXRON II” type

Manual transmission API classification SAE grade number: SAE 75W-85W

GL-4 SAE 80W

Automatic transmission Automatic transmission fluid ATF

“DEXRON” or “DEXRON II” type

Transfer case API classification SAE grade number: SAE 75W-85W

GL-4 SAE 80W .’

Front axle API classification For further details, refer to SAE viscosity number
GG4 or GL-5

Rear axle API classification

(conventional differential) GL-4 or GL-5

Rear axle MITSUBISHI genuine gear oil Part No. 8 149630EX

(limited slip differential) or Moper Hypoid Gear Lubricant Part No. 3744994
or 3744995 plus Moper Hypoid Gear Oil Additive/
Friction Modifier Part No. 4057100 or equivalent

Brake and clutch Conforming to DOT 3

Front wheel bearing Multipurpose grease

NLGI grade #2EP

Cooling system High quality ethylene glycol Concentration level: 50%

Transmission linkage, parking brake Multipurpose grease

cable mechanism, hood lock and NLGI grade #2EP
hook, door latch, hatch latch, seat
~-;”.’ adjuster

Door hinges Engine oil

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 LUBRICANT CAPACITIES TABLE AND RECOMMENDED LUBRICANTS

SELECTION OF LUBRICANTS Front Axle/Rear Axle (Conventional differential)

Engine Oil
API classification
Lubricant GL-4 or GL-5
Temperature range
Recommended SAE
anticipated before
viscosity grades Anticipated temperature
next oil change
Viscosity range
range
“C OF
49 120 Above -23°C (-10°F) SAE 90
SAE 85W-90
SAE 8OW-90
38 100
-23°C to -34°C SAE 8OW
27 80 (-lOoF to -30°F) SAE 8OW-90
Below -34°C (-30°F) SAE 75w
16 60

0 32

-12 10

-23 -10

-29 -20

53E531
* SAE 5W-20 is not recommended for sustained high speed vehicle
operation.

COOLANT
‘?
Relation Between Antifreeze Concentration and Specific Gravity

Coolant temperature “C (“F) and specific gravity

-45 (-49) 60 %

NOTE: The information in the table pertains to the antifreeze used by the manufacturer
Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at a coolant tem-
perature of 20°C (68” F).

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 MAINTENANCE SERVICE

JET VALVE CLEARANCE ADJUSTMENT

Adjustment condition:
Normal operating temperature [Coolant temperature 80-
90°C (176-194”F)]
Caution
1. An incorrect jet valve clearance will affect the emission
levels and could also cause engine troubles.
2. Adjust the jet valve clearance before adjusting the intake
valve clearance.
3. The jet valve clearance should be adjusted with the intake
valve adjusting screw fully loosened.
Adjusting procedure: 3EM041
1. Place piston of No. 1 cylinder at top dead center of com-
pression stroke to adjust valve clearances marked @ of
intake valve side is shown. (5EN062)
2. Back off the intake valve adjusting screw (two or more
turns).
3. Loosen the lock nut on the jet valve adjusting screw.
4. Back off the jet valve adjusting screw and place a 0.25
mm (.OlO in.) leaf of a feeler gauge between the top
end of the jet valve stem and the bottom; end of the
adjusting screw. (3EM040)

Jet valve clearance (on hot engine) .............

0.25 mm (.OlO in.)

5. Screw in the adjusting screw (clockwise) until the bottom

end of the adjusting screw touches the feeler gauge.
Since the jet valve spring has a low spring force, use
special care not to compress the spring. Be particularly
careful if the adjusting screw is hard to turn. (3EM134)
6. While holding the adjusting screw in place with a screw-
driver, tighten the lock nut firmly.
7. Check with a feeler gauge lead to ensure a clearance of
0.25 mm (.OlO in.)
8. Adjust the intake valve clearance.
9. Place piston of in No. 4 cylinder at top dead center on
compression stroke to adjust valve clearances marked @
of intake‘valve side. (5EN062)
10. Adjust by repeating Steps 2 through 8.

VALVE CLEARANCE ADJUSTMENT

Adjustment condition:
Normal operating temperature [Coolant temperature 80-
9O”C, (176-194”F)l
1. Place piston of No. 1 cylinder at top dead center of com-
pression stroke to adjust valve clearances marked @ .
(5EN062) Forward

Intakevalves
5EN062

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 \
MAINTENANCE SERVICE

2. Loosen nut and adjust to specification with adjusting

screw. Then retighten nut. (5EN008)

Valve clearance (on hot engine):

Intake. .. . . . . . . . . . . . . . . . . . . . 0.15 mm (.006 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . 0.25 mm (.OlO in.)

3. After nut has been retightened, recheck to ensure clear-

ance is correct.
4. Place piston of No. 4 cylinder at top dead center on com-
pression stroke to adjust valve clearances marked @ .
(5EN062)
5. Adjust by repeating Steps 2 and 3.
6. Check idle speed and readjust if necessary.
BASIC IGNITION TIMING ADJUSTMENT
Adjustment condition:
Lights and all accessories off, transmission in neutral and
parking brake pulled.
1. Run the cold engine at fast idle until the coolant tem-
perature is 85-95” C (185-205°F).
2. Disconnect the white stripe vacuum hose from the dis-
tributor and temporarily plug the hoses.
3. Run the engine at the specified curb idle speed.

Curb idle speed:

First500km(300miles) . . . . . . . . . . 675’_!20, rpm
After 500 km (300 miles) . . . . . . . . . 750 + 150 rpm

4. Using a timing light, check the ignition timing.

If it does not meet specifications, adjust the ignition
timing by rotating the distributor after loosening the
distributor lock nut.

Basic timing . . . . . . . . . . . . . . . . . . . . . 7”BTDC f 2”

5. Reconnect the white stripe vacuum hose to the dis-

tributor.

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 I
LEI MAINTENANCE SERVICE

CARBURETOR CHOKE MECHANISM AND LINKAGE Choke pino

*;c:st
The choke mechanism is used to facilitate engine starting Chyke valve
’ /\: ~h~fh~!breaker
during cold weather. Spray solvent into the end of the auto-
choke and throttle valves (where they pass through the air
horn) to prevent the choke from .becoming stuck ‘from
Cooian;. inlet ti intakl
gum deposits on the shaft. At the.same time, spray a solvent Strangler spring
lever
to clean dirt from the fast idle cam and link.

.,.

Fast idle cam

Throttle valve

Tamper-Proof Automatic Choke

All carburetors have tamper-proof
parts are factory-adjusted.
choke. The choke-related I.
Wax-stroke

.-
adjusting
screw
YO364C
‘i/O3641

FUEL FILTER (Replace) - except in-tank fuel filter

The fuel filter should be replaced regularly because its per-
formance is reduced by dirt and water collected, over an ex-
tended period of use. Replace as required.

FUEL SYSTEM (Check for leaks)

Cap, Tank, Lines and Connections
Check for damage or leakage in the fuel lines and connec-
tions, and for looseness of the fuel tank cap.
Inspect the surface of fuel hoses for heat and mechanical
damage. Hard and brittle rubber, cracking, checking, tears,
cuts, abrasions and excessive swelling indicate deterioration
of the rubber.
If the fabric casing of the rubber hose is exposed by cracks
and abrasions in the fuel system, the hoses should be
changed.

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 MAINTENANCE SERVICE

IGNITION CABLES (Check and replace)

The ignition cables should be kept clean and properly
connected.
Cracked, damaged or faulty cables must be replaced.
NOTE
When disconnecting an ignition cable, be sure to hold cable
cap. If the cable is disconnected by pulling on the cable
alone, an open circuit might result.

Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 16 kSl /m

I 3E LO2-

SPARK PLUGS (Replace)

1. ‘Spark plugs must fire properly to assure proper engine
performance and emission-control. They should operate
satisfactorily in normal vehicle service for the specified
maintenance interval or they should be replaced.
2. The new plugs should be checked for the proper gap.
( 1EL022)

1 E LO75

AIR CLEANER FILTER (Relpace)

1. Remove the wing nut. Use pliers only if the wing nut is
difficult to remove.
2. Unsnap the clips and remove air cleaner cover.
3. Remove the filter and replace it with a new filter.
(533520)

4. Remount the cover, taking care that the arrows are

aligned. (53Y.540)
5. Tighten the wing nut by hand.
 MAINTENANCE SERVICE

Cleaning I /
Remove the filter and clean the inside by using compressed
air. (Dust can also be removed by gently tapping the filter by
hand.)

ENGINE OIL (Change)

Always use lubricants which (1) conform to the requirements
of the API classification “For Service SE” or “For Service
SF” when available, and (2) have the proper SAE grade
number for the expected temperature range.
Never use nondetergent or straight mineral oil. ! ,

ENGINE OIL FILTER (Replace)

The quality of replacement filters varies considekably. Only
high quality filters should be used to assure most efficient
service. Genuine oil filters require that the filter be capable
of withstanding a pressure of 256 psi and are recommended
as follows:

Oil Filter Part Number ......................

Mitsubishi Genuine Parts MD03.1805 or equivalent

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 MAINTENANCE SERVICE

CRANKCASE VENTILATION SYSTEM (Check, and clean

as required)
A closed-type crankcase ventilation system is utilized to pre-
vent the blow-by gas from escaping into the atmosphere. This
system has a positive crankcase vent valve (PCV valve) at the
rocker arm cover.
This system supplies fresh air to the crankcase through the air
cleaner. Inside the crankcase, the fresh air is mixed with
blow-by gases, and this mixture passes through the PCV valve Blow-by gas -
Fresh air ~~~-
into the induction system.

Ventilation
hose

Inspection and Service Procedure

1. Remove PCV valve from rocker cover. If the valve is not
clogged, a hissing noise will be heard as air passes through
the valve, and a strong vacuum should be felt when a
finger is placed over the valve inlet.

2. Disconnect ventilation hose from the PCV valve.

3. Blow from the threaded end of PCV valve. If you cannot
blow through it, the PCV valve is plugged. (53Y543)
4. If the ventilation system is restricted, clean the hose and
PCV valve with appropriate solvent for dissolving carbon,
oil, sludge, etc.
cuI MAINTENANCE SERVICE

EVAPORATIVE EMISSION CONTROL SYSTEM i

Fuel check valve

Air cleaner Purge control valve (Required by FMVSS 301)

float
Overfill limiter
Int

Fuel filler cap

Bowl vent valve

Fuel filler pipe A

- Fuel vapor To carburetor -

--- Purge air

Fuel tank
,(I Filter Fuel gauge unit

03152

Checking Evaporative Emission Control System - (Except

canister)
If the fuel-vapor vent line is clogged or damaged, a fuel-vapor
mixture will escape into the atmosphere.
Disconnect the line at both ends and blow it clean with com-
pressed air. Remove the filler cap from the tiller pipe and
check to see if there is any problem with the sealing surface
to the filler pipe.
The over-fill limiter (2-way valve) installed in the vapor line
between the canister intake and fuel tank outlet should be
checked for correct operation.
The purge control valve installed on the vaper line between
canister and intake manifold should be checked for correct
operation.
Canister (Replace)
If the canister filter becomes clogged, the purge air volume
will decrease and, consequently, the canister capacity will be
reduced.

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 I
MAINTENANCE SERVICE c!u
DRIVE BELTS (Check, and adjust or replace)
100N
Water pump pulley-
Inspect the drive belts for cuts and cracks (22 Ibs.)
necessary. 7-10 mm
Check for proper tension. (.28-.39 in.)

tension as follows:

point halfway between alternator pulley a

pulley and the other belt at a point halfw
power steering pulley and crankshaft pulley.
limits of the belt deflection are shown in t
2. If belt deflection is not within specified
alternator support bolt, alternator brace b pump pulley
steering pump brace bolt, and move a
power steering pump to obtain proper be1
100 N (22 lbs.) of force. (Y.53546)
3. After adjustment, tighten the alternator su
ternator brace bolt and power steering pu
to specified torque.

Alternator support bolt

Alternator brace bolt
Power steering oil pump
brace bolt

COOLING SYSTEM (Check and service)

Coolant Change

Caution
When removing the radiator cap, use care to
with hot coolant or steam. Place a shop towe
and turn the cap counterclockwise a little t
escape through the vinyl tube.
pressure, remove the cap by slowly turning it
wise.

cleaning fluid.
4. After the flushing is completed, complete
cleaning fluid and install the radiator and

glycol antifreeze. A convenient mixture i

(-32.8”F)l. Reinstall radiator cap.

6. After running the engine a while, check the
and add coolant until the specified coo
maintained.

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 MAINTENANCE SERVICE

.
7. Add coolant to the reserve tank between the “FULL”
and “LOW” mark if necessary.
Caution
Do not overfill the reserve tank. I
Antifreeze
t
Since the cylinder head and water pump body are made of .’
aluminum alloy casting, be sure to use a 50% ethylene glycol
antifreeze cpolant to provide corrosion protection and
freezing prevention. .
Recommended antifreeze Quantity .

Permanent type antifreeze 50%. or more :

by volume

Measurement of Antifreeze Concentration

Run the engine until coolant is fully mixed. Drain some
coolant (antifreeze), and measure temperature and specific
gravity of the coolant. Determine concentration and safe
working temperature. If the coolant is short of antifreeze,
add antifreeze up to a concentration of 50%.

NOTE
As the antifreeze also serves as a corrosion inhibitor, be sure
to maintain its concentration at 50% even when temperature
is high.

BRAKE FLUID (Check fluid level and inspect for leaks) .

1. Check to make certain that the brake fluid is between the
“MAX” and “A” markings on the fluid reservoir. Fill as
required. (72WO25)
2. With disc brakes the fluid level can be expected to fall as
the brake pads wear. A rapid fluid loss indicates a leak in
the brake system which should be inspected and repaired
immediately.
Caution
Take care in handling brake fluid as it may cause damage to
pain ted surfaces.
Fluid Change
1. Check the brake system for leakage before replacing
brake fluid. Completely drain the brake fluid with the
bleeder screws loosened on each brake and -refill the
brake system with new brake fluid.

Recommended fluid ............ .. .... ... ...

Brake fluid conforming to DOT3 ’

2. The reservoir cap must be fully tightened to avoid con-

tamination from foreign matter or moisture.
DO NOT ALLOW PETROLEUM BASE FLUID TO CON-
TAMINATE THE BRAKE FLUID - SEAL DAMAGE WILL
RESULT -

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 MAINTENANCE SERVICE

BRAKE HOSES (Check for deterioration or leaks)

Inspection of brake hoses and tubes should be included in *
all brake service operations. The hoses should be checked for:
(1) Correct length, and for severe surface cracking, pulling,
scuffing or worn spots. (If the fabric casing of the hoses
is exposed by cracks or abrasion in the rubber hose cover,
the hoses should be replaced.)
(2) Faulty installation, case twisting or friction against
wheels, tires or chassis.

BRAKES
1. Inspect the disc brakes for pad wear and proper oper-
ation, and the rear brake linings and wheel cylinders foi
wear and leaks respectively. If the vehicle is driven in
dusty or salty areas, it should be inspected more fre-
quently.
2. The frequency of these inspections depends upon driving
conditions, such as traffic or terrain, and upon the driving
habits of the owner.
--
Front Disc Brake Pads (Inspect for wear)
Check for fluid contamination and wear. Replace complete

-T?-
:.
set of pads if defective. (14E525)
Caution
The pads for the right and left wheels should be replaced at
the same time. Never split or intermix brake pad sets. All
four pads must be replaced as a complete set.

Thickness of lining “A”

Standard value . . . . . . . . . . . . . 10.5 mm (.41 in.)
Service limit . . . . . . . . . . . . . . . . 1 .O mm (.04 in.)

Rear Drum Brake Linings and Wheel Cylinders

(Inspect for wear and leaks)
1. Remove the brake drum and check
brake shoe lining for wear. (14F094)

Thickness of lining “B”

the thickness

Standard value . . . . . . . . . . . . . . . . . . 4.6 (. 18 in.)

of

1
ill 14E525

Service limit . . . . . . . . . . . . . . . . . . . . 1.0 (.04 in.)

Check the automatic brake adjusting system by hand to

see if it operates smoothly. Also see if the gears are in
proper mesh with each other. To assure smooth function-
ing, apply a very thin coat of grease to the friction
surface of adjuster and link shaft.
2. Inspect the wheel cylinder boots for evidence of a brake
fluid leak. Visually check the boots for cuts, tears or
heat cracks. (A slight amount of fluid on the boot may
not be a leak, but may be preservative fluid used at
assembly.) I 14FO94

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 MAINTENANCE SERVICE

FRONT AXLE AND REAR AXLE (Check oil level)

Remove the filler plug and check the oil level. (DO903 1)

Front axle oil level (A) ...... Within 8 mm (.3 1 in.)

Rear axle oil level (A) ...... Within 14 mm (.55 in.)

FRONT WHEEL BEARINGS (Inspect for grease leaks)

Inspect for evidence of grease leakage about the hub c’apand
the back of the hub.
If there is leakage of grease, remove the hub and its oil seal
and check for damage.
Clean the grease off the hub and bearing, and repack with the
specified new grease.

Recommended multipurpose grease . . . . . . . : . . . .

SAE 53 lOa, NLG! grade #2EP

BALL JOINT SEALS, STEERING LINKAGE SEALS

AND DRIVE SHAFT BOOTS (Inspect for ,leaks and
damage)
These components are permanently lubricated at the factory
and do not require periodic lubrication.
Damaged seals and boots should be replaced to prevent leak-
age or contamination of the grease.
Inspect the dust cover and boots for proper sealing, and
check for leakage or damage. Replace if defective:
UPPER CONTROL ARM BUSHINGS
Supply grease at the grease nipple until the grease comes out
of ihhe.dust seal of the upper arm shaft.
Lubricate the upper control arm bushings with Multipurpose
Grease,,NLGI Grade 2 EP.
‘MANUAL TRANSMISSIqN AND TRANSFER CASE
(Oil change)
Fluid replacement is required every 48,000 km ,(30,060
miles) if the vehicle is used in severe usage conditions.

AUTOMATIC TRANSMIS$ION AND TRANSl?ER C&SE

,(Fluid change) I’
‘Fluid replacement is required every 48,000.km (30,000 miles).

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