Maintenance: Fundamentals and Basics
MAINTENANCECHANGING ENGINE OIL
1. If the engine is cold, run the engine until it reaches normal operating temperature.
2. Turn off the engine.
3. Remove the oil filler cap and drain plug. Drain the engine oil.
4. Tighten the drain plug to the specified torque.
Tightening torque
Oil pan drain plug
35 - 45 Nm (350 - 450 kg.cm, 25 - 33 lb.ft)
NOTE: Whenever tightening the oil drain plug, use a new drain plug gasket.
5. Fill new engine oil through the oil filler cap opening.
NOTE: Do not overfill, this will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.
7. Start and run the engine.
8. Turn off the engine and then check the oil level. Add oil if necessary.
REPLACING THE ENGINE OIL FILTER
1. Use a filter wrench to remove the oil filter.
2. Before installing a new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
3. Tighten the oil filter to the specified torque.
Tightening torque
Oil filter: 12 - 16 Nm (120 - 160 kg.cm, 9 - 12 lb.ft)
4. Start and run the engine and check for engine oil leaks.
5. After turning off the engine, check the oil level and add oil as necessary.
REPLACING THE AIR CLEANER FILTER
The air cleaner filter will become dirty during use and the filtering efficiency will be substantially reduced Replace with a new one as needed.
1. Disconnect the clip holding air cleaner filter cover.
2. Remove the air filter cover.
3. Remove the air cleaner filter.
4. Install a new air cleaner filter and replace the air cleaner filter cover.
ADJUSTING BELT TENSION
COOLING SYSTEM
Check the cooling system for damaged hoses, loose or leaking connections, or other possible causes of coolant leaks.
ANTIFREEZE
The engine cooling system is provided with a mixture of 50% ethylene glycol anti-freeze and 50% water (For the vehicles of tropical area, the engine cooling system is provided with a mixture of 40% ethylene glycol anti-freeze and 60% water at the time of manufacture.)
Since the cylinder head and water pump body are made of aluminum alloy casting, be sure to use a 30 to 60% ethylene glycol antifreeze coolant to assure corrosion protection and freezing prevention.
CAUTION: If the concentration of the antifreeze is below 30%, the anticorrosion property will be adversely affected. In addition, if the concentration is above 60%, both the antifreeze and engine cooling properties will decrease, adversely affecting the engine. For these reasons, be sure to maintain the concentration level within the specified range.
MEASURING OF ANTIFREEZE CONCENTRATION
Run the engine until the coolant is fully mixed. Drain some coolant (antifreeze), and then measure the temperature and specific gravity of the coolant. Determine it's concentration and safe working temperature. If the coolant is short of antifreeze, add antifreeze to a concentration of 50%. (Tropical Areas : 40%)
REPLACING THE COOLANT
1. Set the temperature control lever to the hot position.
2. Remove the radiator cap.
CAUTION: Remove the cap slowly. The system is pressurized and the coolant may be hot. Do not open the cap when the engine is hot.
3. Loosen the drain plug to drain the coolant.
4. Drain the coolant from the reserve tank.
5. After draining the coolant, tighten the drain plug securely.
6. Fill the radiator with the coolant up to its filler neck.
7. Fill the reserve tank with coolant to the MAX. line.
8. Warm up the engine until the thermostat opens, remove the radiator cap and check the coolant level.
9. When the radiator is filled up to its filler neck, install the radiator cap securely.
10. Fill the reserve tank with coolant up to the "FULL" line.
REPLACING IGNITION CABLES
Ignition cables should be replaced periodically with new ones. After replacing, make sure that the ignition cables and terminals are properly connected and fully seated.
NOTE: When disconnecting an ignition cable, be sure to hold the cable cap. If the cable is disconnected by pulling on the cable alone, an open circuit might result.
REPLACING OXYGEN SENSOR
The oxygen sensor is a device which helps control the fuel mixture If the oxygen sensor is damaged, the exhaust-gas cleaning efficiency as well as driveability deteriorates Therefore, it should be replaced periodically with a new one.
MANUAL TRANSAXLE (INSPECT OIL LEVEL)
Inspect for leakage in each component and check the oil level by removing the filler plug If the oil is contaminated, replace it with new oil.
1. With the vehicle parked on a level surface, remove the filler plug and make sure that the oil level is the same level as the plug hole
2. Check that the transaxle oil is not dirty
TRANSAXLE OIL (REPLACE)
1. With the vehicle parked on a level surface, remove the magnetic plug to drain transaxle oil
2. Replace the washer with a new one and reinstall the magnet plug
3. Fill with transaxle oil (through the filler plug part) until the oil level is the same level as the plug hole
INSPECTING STEERING LINKAGE
1. Check the steering wheel freeplay.
Maximum steering wheel freeplay: 30 mm (1.181 in)
2. Check the steering linkage for looseness and damage.
a. Tie rod ends must not have excessive play.
b. Dust seals and boots must not be damaged.
c. Boot clamps must be not loose.
POWER STEERING FLUID LEVEL (INSPECT FLUID LEVEL)
1. Park the vehicle on a level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 °C (122 °F).
2. With the engine idling, turn the wheel all the way to the left and right several times Check the fluid in the oil reservoir for foaming, and its level Replenish the fluid in the oil reservoir through the oil filter if necessary.
POWER STEERING HOSES (CHECK FOR DETERIORATION OR LEAKS)
1. Check the hose connections for fluid leaks.
2. The power steering hoses should be replaced if there is severe surface cracking, pulling, scuffing or worn steps Deterioration of the hoses could cause premature failure.
BALL JOINT AND STEERING LINKAGE SEALS, STEERING AND DRIVE SHAFT BOOTS
1. These components, which are permanently lubricated at the factory, do not require lubrication. Damaged seals and boots should be replaced to prevent leakage or contamination of the grease.
2. Inspect the dust covers and boots for proper sealing, leakage and damage. Replace them if defective.
INSPECTING BRAKE LINES
1. Check all brake lines and hoses for damage, wear, cracks, corrosion, leaks, bends, twists.
2. Check all clamps for tightness.
3. Check that the lines are clear of sharp edges, moving parts and the exhaust system.
FRONT DISC BRAKE PADS
Check for fluid contamination and wear. Always replace brake pads in complete sets.
NOTE: If a squealing or scraping noise occurs from the brake during driving, check if the pad wear indicator is contacting the disc, if it is, the brake pad should be replaced.
CAUTION: The pads for the right and left wheels should be replaced at the same time. Never split or intermix brake pad sets. All pads must be replaced as a complete set.
Thickness of pad lining [Limit]: 2.0 mm (0.079 in.)
CHECKING THE BRAKE FLUID LEVEL
1. Check the level of the brake fluid in the reserve tank of the master cylinder.
2. The level should be between the "MAX" and "MIN" mark.
3. If the level is lower than the "MIN" mark, add fresh brake fluid up to the "MAX" mark.
CHANGING BRAKE FLUID
1. Refer to "Brake Bleeding" for air-bleeding procedures.
2. Connect a vinyl tube to the bleeder screw of each wheel cylinder. Put the other end of the vinyl tube in a vessel for receiving the brake fluid.
3. With a vehicle equipped with ABS (Anti-lock Brake System), refer to "Brake Bleeding".
4. Depress the brake pedal a few times. Then loosen the bleeder screw (with the brake pedal still depressed), and tighten it after the brake fluid stops flowing
5. Repeat the above operation until air bubbles are not in the brake fluid.
6. Repeat these steps for the other cylinders.
7. Add fresh brake fluid up to the "MAX" level in the reserve tank
Brake fluid : DOT 3 or DOT 4
CHECKING TIRE INFLATION PRESSURE
Check the tire inflation pressures as follows.
TIRE INFLATION PRESSURE (CHECK WITH TIRES COOL)
Tire size: 205/55 R 16, 215/45 R 17
Tire pressure : 2.1 kg/sq.cm (30 PSI)
ROAD TEST
Drive the vehicle and check for abnormal conditions
1. Check oil, fluid, fuel, water and exhaust gas leaks.
2. Check free play of clutch pedal and brake pedal
3. Check the operation of brake booster.
4. Check the operation of service brake and parking brake systems.
5. Check the stroke of parking brake lever.
6. Check the driveability of engine.
7. Check the condition of instruments, gauges, indicators, exterior lamps, heater and ventilators
8. Check for abnormal noises from each part.