Maintenance

NOT OFFICIAL

Lubrication Points

For the details of lubrication points and types of lubricants to be applied, refer to the Illustrated Index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

No. LUBRICATION POINTS LUBRICANT

1 Engine API Service Grade: SE or SF
SAE viscosity: 10 W - 30 recommended
Fuel Efficient Oil:
Identified by the words, "Energy Conserving II"
SAE Viscosity: See chart below.

2 Transmission API Service Grade: SE
SAE Viscosity: 10 W - 30 See chart below.
Magnatec recommended

3 Brake Line (including anti-lock brake system) Brake fluid DOT3 or DOT4

4 Clutch Line Brake fluid DOT3

5
Shift lever pivots Silicone grease with molybdenum disulfide

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Steering boots
Brake master cylinder pushrod
Steering grearbox
Steering column bushing
Pedal linkage
Trunk hinges and latch
Door hinges upper and lower
Door opening detents
Front hood latch
Front hood hinges
Fuel filler lid
Shift cable end
Clutch release arm
Suspention ball joints
Steering ball joints

Intermediate shaft
Clutch master cylinder pushrod
Parking brake cable end
Throttle cable end
Multi-purpose grease

21 - -

- Caliper
(Pistone seal, Dust seal, Caliper pin, Piston) Silicone grease

No.	LUBRICATION POINTS	LUBRICANT
1	Engine	API Service Grade: SE or SF SAE viscosity: 10 W - 30 recommended Fuel Efficient Oil: Identified by the words, "Energy Conserving II" SAE Viscosity: See chart below.
2	Transmission	API Service Grade: SE SAE Viscosity: 10 W - 30 See chart below. Magnatec recommended
3	Brake Line (including anti-lock brake system)	Brake fluid DOT3 or DOT4
4	Clutch Line	Brake fluid DOT3
5	Shift lever pivots	Silicone grease with molybdenum disulfide
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20	Steering boots Brake master cylinder pushrod Steering grearbox Steering column bushing Pedal linkage Trunk hinges and latch Door hinges upper and lower Door opening detents Front hood latch Front hood hinges Fuel filler lid Shift cable end Clutch release arm Suspention ball joints Steering ball joints Intermediate shaft Clutch master cylinder pushrod Parking brake cable end Throttle cable end	Multi-purpose grease
21	-	-
-	Caliper (Pistone seal, Dust seal, Caliper pin, Piston)	Silicone grease

Recommended Engine Oil
API Service Grade: SE or SF
Fuel Efficient Oil:
Identified by the words, "Energy Conserving II"


       ---------------------------------\
       |                                 \
       |              10W-30             /
       ---------------------------------/
 /----------------
/                |
\     5W-30      |
 \----------------
--+----+----+----+----+----+----+----+
-30  -20  -10    0   10   20   30   40 ^oC

Recommended Manual Transmission Oil
API Service Grade: SE


            ----------------------------\
            |                            \
            |        30                  /
            ----------------------------/
       ---------------------------------\
       |                                 \
       |          20W-40                 /
       ---------------------------------/
 /--------------------------------------\
/                                        \
\     10W-30           10W-40            /
 \--------------------------------------/
--+----+----+----+----+----+----+----+
-30  -20  -10    0   10   20   30   40 ^oC

Maintenance Schedule

R = Replace I = Inspect After inspection, clean, adjust, repair or replace if necessary

MAINTENANCE ITEM Service at the interval listed x 1,000 km or after that number of mounts, whichever comes first	NOTES	MAINTENANCE INTERVALS
		12	24	36	48	60	72	84	96	108	120	132	144	(x 1,000 km)
		6	12	18	24	30	36	42	48	54	60	66	72	(months)
Emissoin Related
Air cleaner element	-	-	-	-	R	-	-	-	R	-	-	-	R
Idle speed	1200 +- 50 rpm	-	-	-	-	-	-	-	I	-	-	-	-
Idle CO	Check with CO meter	-	-	-	-	-	-	-	I	-	-	-	-
Evaporative emission control system	-	-	-	-	-	-	-	-	I	-	-	-	-
Ignition timing	20 +- 2 deg. (Red) BTDC	-	-	-	-	-	-	-	I	-	-	-	-
Positive crankcase ventilation valve	If clicking sound is heard as you pinch the PCV hose between the PCV valve and intake manifold, valve is OK.	-	-	-	-	-	-	-	I	-	-	-	-
Valve clearance (cold)	Intake: 0.13 - 0.17 mm Exhaust: 0.23 - 0.27 mm	-	I	-	I	-	I	-	I	-	I	-	I
Fuel filter	-	-	-	-	-	-	-	-	R	-	-	-	-
Fuel line and connection	Check the fuel tank for damage. Leaks or defomation. Check all fuel system hoses for damage leaks or deterioration. Check all hose and pipe clamps.	-	-	-	I *1	-	-	-	I	-	-	-	I
Spark plugs	NGK: BKR6E-11(STD.)/BKR7E-11 ND: K20PR-U11(STD.)/K22PR-U11 Gap: 1.0 - 1.1 mm	-	-	-	-	-	-	-	R *2	-	-	-	-
Engine oil	2.7 liter with filter change	R	R	R	R	R	R	R	R	R	R	R	R
Engine oil filter	-	R	R	R	R	R	R	R	R	R	R	R	R
Alternator drive belt	6.5 - 8.0 mm @ 98 N tension	-	-	-	I *3	-	-	-	I	-	-	-	I
Cooling system hoses and connections	-	-	-	-	I	-	-	-	I	-	-	-	I
Radiator coolant	Cooling system capacity: 4.7 liter Check specific gravity for freezing point	-	-	-	-	-	R	-	-	-	R *4	-	-
Manual transmission oil	1.2 litre	-	-	-	R	-	-	-	R	-	-	-	R

Check oil and coolant level at each fuel stop.
Under severe driving conditions, service these items more often.
*1 For cars sold in California, this service is recommended only, other areas, it is required.
*2 Replace every 6 years or 96,000 km, whichever comes first.
*3 Tension adjust only.
*4 Thereafter, replace every 2 years or 48,000 km, whichever comes first

R = Replace I = Inspect After inspection, clean, adjust, repair or replace if necessary

MAINTENANCE ITEM
Service at the interval listed x 1,000 km or after that number of mounts, whichever comes first NOTES MAINTENANCE INTERVALS

12 24 36 48 60 72 84 96 108 120 132 144 (x 1,000 km)

6 12 18 24 30 36 42 48 54 60 66 72 (months)

Engine (Non-Emission Related)

Timing belt - - - - - - - - - - - - R

Water pump - - - - - - - - - - - - I

Catalytic converter heat shield Check condition and tightness - - - - - - - I - - - -

Exhaust pipe and muffler Check condition and tightness - I - I - I - I - I - I

Brakes (Non-Emission Related)

Front brake pads Min. thickness: 1.6 mm I I I I I I I I I I I I

Front brake discs and calipers Min. thickness: 8.0 mm - I - I - I - I - I - I

Rear brake discs, calipers and pads Min. thickness: Discs 8.0 mm
Pads 1.6 mm - I - I - I - I - I - I

Brake hoses and lines (including Anti-lock brake system) Check for leaks, damage, interference or twisting. - I - I - I - I - I - I

Parking brake Fully engaged 19 clicks. - I - I - - - I - - - I

Brake fluid (including Anti-lock brake system) Use only DOT3 or 4 fluid. Check that brake fluid label is between the upper and lower marks on the reservoir. - - - R - - - R - - - R

Anti-lock brake system operation Function test
Wheel sensor signal confirmation
Anti-lock brake system light circuit - - - I - - - I - - - I

Anti-lock brake system high pressure hose Bleed high pressure fluid - - - - - - - R - - - -

Steering and Suspension (Non-Emission Related)

Front wheel alignment - - I - I - I - I - I - I

Steering operation, tie rod ends, steering gearbox and boots Check rack grease and steering linkage.
Check the boot for damage or leaking grease. - I - I - - - I - - - I

Suspension mounting bolts Check tightness of bolts. - I - I - I - I - I - I

MAINTENANCE ITEM Service at the interval listed x 1,000 km or after that number of mounts, whichever comes first	NOTES	MAINTENANCE INTERVALS
12	24	36	48	60	72	84	96	108	120	132	144	(x 1,000 km)
6	12	18	24	30	36	42	48	54	60	66	72	(months)
Engine (Non-Emission Related)
Timing belt	-	-	-	-	-	-	-	-	-	-	-	-	R
Water pump	-	-	-	-	-	-	-	-	-	-	-	-	I
Catalytic converter heat shield	Check condition and tightness	-	-	-	-	-	-	-	I	-	-	-	-
Exhaust pipe and muffler	Check condition and tightness	-	I	-	I	-	I	-	I	-	I	-	I
Brakes (Non-Emission Related)
Front brake pads	Min. thickness: 1.6 mm	I	I	I	I	I	I	I	I	I	I	I	I
Front brake discs and calipers	Min. thickness: 8.0 mm	-	I	-	I	-	I	-	I	-	I	-	I
Rear brake discs, calipers and pads	Min. thickness: Discs 8.0 mm Pads 1.6 mm	-	I	-	I	-	I	-	I	-	I	-	I
Brake hoses and lines (including Anti-lock brake system)	Check for leaks, damage, interference or twisting.	-	I	-	I	-	I	-	I	-	I	-	I
Parking brake	Fully engaged 19 clicks.	-	I	-	I	-	-	-	I	-	-	-	I
Brake fluid (including Anti-lock brake system)	Use only DOT3 or 4 fluid. Check that brake fluid label is between the upper and lower marks on the reservoir.	-	-	-	R	-	-	-	R	-	-	-	R
Anti-lock brake system operation	Function test Wheel sensor signal confirmation Anti-lock brake system light circuit	-	-	-	I	-	-	-	I	-	-	-	I
Anti-lock brake system high pressure hose	Bleed high pressure fluid	-	-	-	-	-	-	-	R	-	-	-	-
Steering and Suspension (Non-Emission Related)
Front wheel alignment	-	-	I	-	I	-	I	-	I	-	I	-	I
Steering operation, tie rod ends, steering gearbox and boots	Check rack grease and steering linkage. Check the boot for damage or leaking grease.	-	I	-	I	-	-	-	I	-	-	-	I
Suspension mounting bolts	Check tightness of bolts.	-	I	-	I	-	I	-	I	-	I	-	I

Severe Driving Conditions
Items with "R" or "I" in the cart will need service more often, if you drive in some severe conditions.

The conditions are:
A. Repeated short distance driving.
B. Dusty conditions.
C. Severe cold weather.
D. Areas with road salt or other corrosive materials.
E. Rough or muddy roads.

The services are:
- Cean the air cleaner element every 12,000 km or 6 months and replace every 48,000 km or 24 months under condition B or E.
- Replace engine oil and oil filter every 6,000 km or 3 months under condition A or B.
- Inspect front and rear brake discs and calipers, and rear brake pads every 12,000 km or 6 months uner condition A, B, D, E.

Un-official information

You must check distributor frequently. If it is hard to turn, you must change it. Worst case, timing belt will snap, engine will be seize.
Magnetic clutch - air conditioner, seldom breaks, but if it does air conditioner won't work and engine will over heat as radiator fan uses the same fuse.
You had better change timing belt earlier than specified intervals. Some BEAT's timing belt have snapped before 50,000km!!!