92Rocky-MA-Maintenance-Part1
| 
| 
|
|
DAIHATSU
Rocky
MAINTENANCE
MAINTENANCE SCHEDULE MA- 2 COLD ENGINE OPERATIONS MA- 7 HOT ENGINE OPERATIONS MA-13 CLUTCH PEDAL MA-15 BRAKE LININGS AND DRUMS MA-16 BRAKE PADS AND DISCS MA-16 BRAKE LINES AND HOSES MA-17 STEERING LINKAGE MA-17 STEERING GEAR BOX MA-18 TRANSMISSION, TRANSFER AND
DIFFERENTIAL OIL MA-19 WHEEL BEARING MA-19 STEERING KNUCKLE & LINKAGE
CHASSIS GREASE MA-20 PROPELLER SHAFTS GREASE MA-21 BOLTS AND NUTS ON
CHASSIS AND BODY MA-21
WRUQO-MAOOW
|
|
MAINTENANCE
MAINTENANCE SCHEDULE
GENERAL NOTES
Every service item in the periodic maintenance list must be performed otherwise failure to perform even one item can cause poor engine running and increased exhaust emissions.
NORMAL CONDITION SCHEDULE
Maintenance operations:
and adjust as necessary; I=Inspecticn and correct or replace as necessary; R=Replace, change
or lubricate
[Use odometer reading or
hwonthswhichevercofnesfirstl OFMOWS 9 18 27 1136;; 45 54 63
108
117 120 126 132 13
Page
ENGINE COMPONENTS AND EMISSION CONTROL SXSTEMS
MA- 7
A
MA-13
Engine oil and oil filter*
Engine coolant*
__ Catalytic converter
Exhaust pipfés and mountings
MA-14
10 Fuel filter
Il
11 § Fuel lines ana connections
II
MA-12
13 Spark plug wires anq distributor
14 spark plugs*
15 “Positive crankcase ventilaiion (PCV) system _
EGR system
Rep
lace at initial 80,000 m
iles
MA-13
CHASSIS AND BODY
19 Clutch pedal 7
MA-16
22 Brake lines and hoses
MA-18
Steering gear box
MA-19
25 Transmission,transferanddifferenlialoil MM
26 Wheel bearing U J W MA
MA-20
27 Wheel beaf
MA-20
Wheel bearing grease 28
Steering knuckle & linkage chassis grease R
MA-20
29
Propeller shafts grease R
MA-21
30 Bolts and nuts on chassis and body
MA-22
Performance of the maintenance services indicated by * is a condition of the Emission Control System
Warranty.
See Warranty information Book for complete Warranty information.
*...F%ecommended in California
(NOTE)
After 120,000 miles, the maintenance services should be performed at the same intervals.
|
|
MAINTENANCE
Follow the severe condition schedule if vehicle is operated mainly under one or more ot the following severe conditions: 0 Towing a trailer - Operating when outside temperature remains below freezing 0 Repeated snort trips less than 5 miles idling for extended periods and/or lovv speed operation tor long distance such as police, taxi, door-to-door
delivery or daily rental service Operating in dusty, rough, muddy or salt sprayed roads 0 Operating daily for a maximum of 15 miles or less, or continuously for 30 minutes or less
Maintenance operations: A=Cneck and adjust as necessary; l=|nspection and correct or replace as necessary; R=Replace, change or lubricate. f Q '
Service interval: 1000 miles 3.75 5 7.5 10 11.25 15 18.75 20 22,5 25 26.25 30 [Use odometer reading or M' (months) Whichever Comes fi,-St] Ol' 4.5 6 (_ 12 13.5 18 22.5 24 27 30 31.5 36
ENGINE COMPONENTS AND EMISSION CONTROL SYSTEMS
3 CHASSIS AND BODY
Timing beit
2. Valve clearance*
3. Drive- hens Uv" belts) '_
W
4. Engine on and 0nf1|rer(see NQTE1) R WR “_
R R W RW R R 5. Engine coolant *I
L
6. Catalytic converter N
M
7. Exhaust pipes and mountings (see NOTE 1) W _ K W
8. ld\e speed I
A
A vm
9. /1111111121 (see NOTE 2)* M W
1 1 "
1 1 f
1 W”
10. 1Iue1f111e1 "_
W"
11. Fuel lines and connections M
12. Fuel tank cap gasket
13. Spark plug wires and distributor
14. Spark plugs* _
R 15, Positive crankcase ventilation (POV) system ' W I Tie. EGR System
17. Charcoal canister
? 18. Oxygen sensor** Replace at initial 80,000 miles
19. Clutch pedal
20. Brake linings and drums
21. Brake pads and discs
22. Brake lines and hoses | _
I _
23. steering rmkage W
1 | M M
24. Steering gear box
25, Transmission, transfer and differential oil
26. Wheel bearing 27. Wheel bearing grease KF? f 28. Steering knuckle & linkage chassis grease ME. *mn
R R 29. Fropeller ghafts grease R U N
R R
30. Bolts and nuts on chassis and body _k (see NOTE 2) ' I I
|
|
MAINTENANCE
Maintenance operations:
A=Check and adjust as necessary; l=|nspection and correct or replace as necessary; R=Replace, change or iubricate.
Servioeintervalz ><1000 miles 33.75 35 37.5 40 41.25 45 48.75 50 52.5 55 56.25 60
[Useodometerreadingor __ , __ __ (_ _ "
ENGINE COMPONENTS AND EMISSION CONTROL SYSTEMS
1, Timing ben O 2. Vaive clearance* _
A
3. Drive be-ns cv" mens) S O' W" V
4. Engine on and on finer (see NOTE 1) *MR R R R R N
R
Engine coolant M M “_A
atalytic converter nm _Exhaust pipes and mountings (see NOTE 1) _ W 7 _M
I 8. lclle speed I F
A 9. A1rf111e1<See NOTE 5)* 1 l 1 1 1 ~ 1 10. Fuel filter ll. Fuel lines and eonnectlons
12. Fuel tank cap gasket
13. Spark plug wires and distributor 14. Spark plugs; U _M _“Mm
R 75. Positive crahkcase vemimmon (Pcv) system 'I _
1
16. EGR W W Charcoal
I8. Oxygen sensor** Replace at Initial 80,000 miles CHASSIS AND BODY
I9. cmcn pedas I I “S
I 20. Brake Imings and drums I I I W 21. _Brake pads and discs I I I
22. lines aed hoses
23, Steering linkage I
24. Steering gear box
25. Transmission, transfer and differential oii
26. Wheel bearing 27. Wlweelébearlng 28. Steering knuckle & linkage chassis grease 7 A 7 _
R R
29. Propeller shafts grease R R R
30. Bolts and nuts on chassis and body | i | I (see NOTE 2)
Performance of the maintenance services indicated by * is a condition ot the Emission control system Warranty. See Warranty information Book for comioiete Warranty information. *.._Reoommended in California
(NOTE)
1. Applicable when you mainly operate your vehicle on rough and/or muddy road. lf not, apply the
schedule for NORMAL driving. 2. Applicable when you mainly operate your vehicle on dusty roads. If not, apply the schedule for
NORMAL driving. . 3. After 120,000 miles, the maintenance services should be performed at the same intervals.
|
|
MAINTENANCE
SEVERE CONDITION SCHEDULE (2)
|\/laintenance operations:
A=Check and adjust as necessary; l=lnspection and correct or replace as necessary; R:Replace, change
or lubricate.
ENGINE COMPONENTS AND EMISSION CONTROL SYSTEMS
1. Timing belt
3. Drive belts beits)
Engine oil and oil fi1ter (see NOTE 1)
I
atalytic converter
xhaust pipes and mountings (see NOTE 1)
8. Idle speed A A
"I
10. Fuel filter
11. Fuel lines and connections W _
_i2. Fuel tank cap gasket
13. Spark plug wires and distributor H
15. Positive crankcase ventilation (POV) system
16. EGR system
17. Charcoal canister
Replace at initial 80,000 miles
19. Clutch pedal I
U20. Brake unmgs and drums I
21. Brake pads and discs *I M
22. Brakeflines and hoses M i
23. Steering linkage é 7
I
24. Steering gear box
25. Transmission, transfer and differential oil H W"
I
é
28. Steering knuckle & linkage chassis grease
? 29. Propeller shafts grease R
Bolts and nuts on chassis and body I e NOTE 2)
I
|
|
MAINTENANCE
Maintenance operations: A=Check and adjust as necessary; !=-.inspection and correct or replace as necessary; R=RepIace, change or lubricate.
Se-rviceintervalz ><1000mi1es 93.75 95 97,5 100 101.25 105 108.75 110 112.5 115 116.25 120
ENGINE COMPONENTS AND EMISSION CONTROL SYSTEMS O
1. Timing new
2. Valve clearance* K 3. Drive belts belts) MM
4. Engine on and onfiiremsee NOTE 1) H R R R R R M
R
5. Engine coolant
6. Catalytic converter
7. Exhaust pipes and mountings (see NOTE 1) I
8. Idle speed A
9. Air filter (see NOTE 2)* I I I I I
10. Fuel filter
11. Fuel lines and connections
12. Fuel tank cap gasket
13. Spark ptug wires and distributor
14. Spark plugs* R
15. Positive crankcase ventilation (PCV) system I
16. EGR system
17. Charcoai canister
18. Oxygen sensor** RepIaoe at initial 80,000 miles
CHASSIS AND BODY
19. Clutch pedal I I I
20. Brake linings and drums i I I
l
21. Brake pads and discs I I I
22. Brake lines and hoses
23, Steering Hnmkage I an
I I
M24 Steering gearbox
I I i
25. Transmission, transfer and differential oil R R 7 W
R
26. Wheel bearing I 27. vvneer grease N ”
28, Steering knuckie & linkage chassis grease R R R
29. Propeller shafts grease R R R
30, Bolts and nuts on chassis and body "ww i I (see NOTE 2)
I I
Performance of the maintenance services indicated by * is a condition ot the Emission control system Warranty. See Warranty information Book for compiete warranty information. ~k...RecommendeoI in California
(NOTE) 1. Applicable when you mainly operate your vehicle on rough and/or muddy road. lf not, apply the
schedule for NORMAL driving. 2. Applicable when you mainly operate your vehicle on dusty roads. If not, apply the schedule for
NORMAL driving. 3. After 120,000 miles, the maintenance services should be performed at the same intervals.
|
|
MAINTE
NANCE
MAINTENANCE OPERATIONS
COLD ENGINE OPERATIONS 1. Replacement of timing belt (1) Remove the timing belt.
(See section EM) (2) Install the timing belt. (See section
2. Inspection of drive belt (V-ribbed belt)
(1) Visually check the belt for separation of the adhesive
rubber above and below the core, core separation from the belt side, severed core, separation of the rib from the adhesive rubber, cracks or separation of the ribs, torn cr worn ribs or cracks in the inner ridges of the ribs. If necessary, replace the drive beit. XX*
(2) Measure the amount of the drive belt deflection when the midpoint of the drive belt between the alternator and the water pump pulley is pushed with a force of 22 lb (10 kg). Specified Belt Deflection
New belt:
4 - 5 mm (0.16 - 0.20 inch) [with a force of 10 kg (22 lb) applied at the point shown in the figure.] Used belt:
5 - 6 mm (0.20 - 0.24 inch) [with a force of 10 kg (22 lb) applied at the point shown in the figure.]
If necessary, adjust the drive belt tension. NOTE: v “New belt" refers to a belt which has been used on a
running engine for less than five minutes. - “Used belt” refers to a belt which has been used on a
running engine for five minutes or more. - After replacing the drive belt, check that it fits properly in the ribbed grooves, especially in the places difficult to
see. - After installing a new belt, run the engine for about five
minutes and then recheck the tension.
3. Replacement of spark plugs
(1) Remove the air chamber. G) Uniock the clamps. Remove the bolts.
Water pump DUHGY
|
|
MAINTENANCE
(2) Disconnect the spark plug wire at the spark plug side. (3) Remove the spark plug, using the following SST.
SST: 09268-87703-000
(4) Using a plug gap gauge, check the air gap on the new
spark plugs. Specified Air Gap:
NOTE: When adjusting the gap ofa new plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used spark plug. Make sure that all four spark plugs are of the same manufac- turer and have the same heating range.
(5) Install the spark plug, using the following SST.
SST: 09268-87703-OOO Specified Tightening Torque:
1.5 - 2.2 kg-m (10.8 - 15.9 ft-Ib, 14.7 - 21.6 N-m)
NOTE: Since the insulator strength of a small spark plug is com- paratively smaller than that of regular spark plugs, when tightening, be sure to use the tool exclusively used for this application. Also, when tightening, never use the wrench in a crooked way.
(6) Connect the spark plug wire to the spark plug.
MA-8
|
|
MAINTENANCE
tion of air filter _ noval of the air filter eiement from the air cleaner f _ Wi' / /
5. Inspec
(1) Removal of the air filter eiement from the air cleaner /"iff
Replace the air filter element, if necessary.
CAUT!ON: The air pressure to be usezd for this cleaning operation
should not exceed 4.0 kg/cm* (56.9 psi).
Replace the air filter element, if necessary.
/
tall the air cleaner filter element in the air cleaner
(4) Ins
case using the installing nut.
|
|
MAINTENANCE
6. Engine oil change and oil filter replacement
(See section
Oil grade: APl grade SG or SF, multigrade viscosity
and fuel-efficient oil Engine oil capacity
Drain and refill: 3.3 liters (3.5 U.S. qts.) Drain and refill with oil filter replacement: 3.5 liters (3.7 U.S. qts.)
7. Engine coolant change
CAUTION As regards water to be used as cooling water, use soft water which does not contain salt or minerals, calcium, mag- nesium and so forth.
Remove the radiator cap. Drain the coolant from the radiator drain plug. Ciose the drain plug. Fill the radiator with water. Repeat the steps (2) to (4). Drain the coolant of the reserve tank.
(7) Pour ‘rne radiator and reserve tank with ethylene-giycoi base antifreeze of a good brand. The mixing ratio
should be decided according to the manufaoturer’s in- structions of manufacturer of autifreeze solution. Reference:
Coolant Capacity
5.5 liters (5.8 U.S. qts) [excluding 1.0 liter (1.1 U.S. qts.) for reserve
tank]
CAUTRON Use a good brand of ethylene-glycol base antifreeze solu- tion.
(8) Fill the radiator with vvater. (9) Fill the reserve tank with Water up tothe full Ievel. (10) Start the engine. Check to see if the coolant level in the
radiator drops. If the coolant level drops, replenish the water, (11) lnstall the radiator cap and reserve tank cap.
MA-10
