10473228

SERVICE STANDARDS

Position a vehicle on a level surface.

Turn off the engine.

note

If a vehicle that has not been used for a prolonged period, run the engine for several minutes.

Turn off the engine and wait for 5 minutes at least, and then check the oil level.

Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is found to have fallen to the lowerlimit (the "L" mark), refill to the "F" mark.

note

When refilling, use the proper grade of engine oil.

Check that the oil is not dirty or mixed with coolant or gasoline and it has the proper viscosity.

Run the engine until it reaches normal operating temperature.

Turn off the engine.

Remove the oil filler cap and the drain plug. Drain the engine oil.

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.

Fill new engine oil through the oil filler cap opening.

Capacity :

Drain and refill : 5.4 lit (5.7 U.S.qts., 4.75 lmp.qts.)

Oil filter : 0.5 lit (0.53 U.S.qts., 0.44 lmp.qus.)

note

Do not overfill. This will cause oil aeration and loss of oil pressure.

Install the oil filler cap.

Start and run the engine.

Turn off the engine and then check the oil level. Add oil if necessary.

After loosening the drain plug and copper washer, drain a small quantity of oil from the filter.

After loosening the plastic upper cap until the O - ring in the lower case is visible, completely drain oil from the filter. (Use filter wrench.09263 - 27100)

Remove the upper cap. Be sure that the oil filter element is removed with the plastic upper cap simultaneously.

Replace the oil filter element and O - ring with new ones.

Tighten the oil filter upper cap to the specified torque.

Oil filter : 23 - 25 Nm (230 - 250 kg.cm, 17 - 18 lb.ft)

After replacing the copper washer in drain plug with a new one, install to the aluminum lower case.

8 - 10 Nm (80 - 100 kg.cm, 5.9 - 7.4 lb.ft)

Star and run the engine and check for engine oil leak.

After turning off the engine, check the oil level and add oil if necessary.

Loosen the radiator cap.

Confirm that the coolant level is up to the filler neck.

Install a radiator cap tester to the radiator filler neck and apply 150 KPa (21psi, 1.53 kg/cm²) pressure. Hold it for two minutes in that condition while checking for leakage from the radiator, hoses or connections.

note

Radiator coolant may be extremely hot. Do not open the system because hot, or scalding water could gush out causing personal injury. Allow the vehicleto cool before servicing this system.

When the tester is removed, be careful not to spill any coolant from it.

Be sure to clean away completely any from the area.

Be careful when installing and removing the tester and when testing, not to deform the filler neck of the radiator.

If there is leakage, repair or replace with the appropriate part.

Use an adapter to attach the cap to the tester.

Increase the pressure until the gauge stops moving.

Main valve opening pressure :

107.9kPa±14.7kPa (1.1±0.15 kg/cm², 15.64±2.13)

Main valve closing pressure :

83.4 kPa (0.85 kg/cm², 12.1 psi)

Check that the pressure level is maintained at or above the limit.

Replace the radiator cap if the reading does not remain at or above the limit.

note

Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an incorrect reading.

Measure the specific gravity of the coolant with a hydrometer.

Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and temperature, using the followingtable for reference.

RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY

●

If the concentration of the coolant is below 30%, its anti-corrosion properties will be adversely affected.

●

if the concentration is above 60%, both the anti-freeze and engine cooling property will decrease, affecting the engine adversely. For these reasons,be sure to maintain the concentration level within the specified range.

●

Do not mix types of anti-freeze.

RECOMMENDED COOLANT

Before checking engine compression, check the engine oil level. Also check that the starter motor and battery are all in normal operating condition.

Start the engine and wait until the engine coolant temperature reaches 80-95°C (176-205°F).

Turn off the engine and remove the aircleaner element.

Remove the injectors.

Crank the engine to remove any foreign material in the cylinders.

Insert the compression gauge (09351 - 27000) into the injector hole.

Crank the engine and read the gauge.

Standard value : 2942 kpa (30 Kg/cm², 426 psi)

Repeat steps 6 to 7 for all cylinders, ensuring that the pressure difference for each of the cylinders is within the specified limit.

Limit :

Max. 100 kpa (1.0 kg/cm² ,14 psi) between cylinders

If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil through the injector hole, and repeatsteps 6 to 8.

(1)

If the addition of oil causes the compression to rise, it is likely that there may be wear between the piston ring and cylinder wall.

(2)

If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder head gasket are all possible causes.

Check that the belts are not damaged and are properly placed for the pulley grooves.

Install the belt in the following order.

[Alternator ⇒ Power steering ⇒ Idler ⇒ Air conditioner pulley ⇒ Crankshaft pully]

When installing the belt on the pulley, make sure it is centered on the pulley

caution

When installing the V-ribbed belt, check that the V-ribs are properly aligned.

If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact surface, and check the pulley for scoring.Also check the amount that the belt is deflected.

The tensioner mark should be between the "*" position.

If not, replace the belt.

Satisfy the requirements of the API classification.

Have the proper SAE grade number for expected ambient temperature range.

Item	Nm	kg·cm	lb·ft
Engine mount insulator bolt	90 - 110	900 - 1100	65 - 80
Engine mounting bracket nuts	60 - 80	600 - 800	43 - 58
Engine mounting bracket bolts	60 - 80	600 - 800	43 - 58
Engine Support bracket bolt and nut	43 - 55	430 - 550	32 - 40
Front roll stopper bracket to cross member bolts	40 - 55	400 - 550	29 - 40
Front roll stopper insulator bolt and nut	50 - 65	500 - 650	36 - 47
Rear roll stopper bracket to cross member bolts	50 - 65	500 - 650	36 - 47
Rear roll stopper insulator bolt and nut	50 - 65	500 - 650	36 - 47
Transaxle mounting bracket bolts	60 - 80	600 - 800	43 - 58
Transaxle mounting insulator bolt	90 - 110	900 - 1100	65 - 80
Front exhaust pipe to exhaust manifold	30 - 40	300 - 400	22 - 29
Head cover bolt	8 - 10	80 - 100	6 - 7
Camshaft sprocket bolt	125 - 140	1250 - 1400	92 - 103
Camshaft bearing cap bolt	26.5 - 29.5	265 - 295	20 - 22
Crankshaft position sensor	7 - 11	70 - 110	5 - 8
Crankshaft sprocket bolt	185 - 195	1850 - 1950	136 - 144
Damper pulley to crankshaft sprocket	30 - 34	300 - 340	22 - 25
Cylinder head bolt (cold engine)	50 + 120° + 90°	500 + 120° + 90°	36 + 120° + 90°
Timing belt auto tensioner bolt	50 - 55	500 - 550	36 - 40
Drive blet Auto tensioner bolt	26 - 31	260 - 310	19 - 23
Timing belt auto tensioner adjustable bolt	10 - 12	100 - 120	7 - 9
Drive belt idler bolt	46 - 51	460 - 510	34 - 38
Front exhaust pipe clamp bolt	20 - 30	200 - 300	14 - 22
Oil pan	10 - 12	100 - 120	7 - 9
Oil pan drain plug	35 - 45	350 - 450	25 - 33
Oil screen	10 - 12	100 - 120	7 - 9
Oil pressure switch	15 - 22	150 - 220	11 - 16
Oil screen bracket bolt	34 - 38	340 - 380	25 - 28
Oil pump bolt	20 - 27	200 - 270	15 - 20
Oil seal case bolt	10 - 12	100 - 120	7 - 9
Plug cap	20 - 27	200 - 270	14 - 20
Oil jet bolt	9 - 13	90 - 130	7 - 10
Oil pump rotor bolt	8 - 10	80 - 100	6 - 97
Timing belt upper cover	8 - 12	80 - 120	6 - 9
Timing belt lower cover	8 - 12	80 - 120	6 - 9
Relief plug	42 - 52	420 - 520	31 - 38
Flywheel	70 - 80	700 - 800	52 - 59
Drive plate	70 - 80	700 - 800	52 - 59
Connecting rod cap bolt	25 + 90°	250 + 90°	18 + 90°
Engine coolant pump to cylinder block bolt
14 mm	48 - 52	480 - 520	35 - 38
10 mm	10 - 12	100 - 120	7 - 9
Engine coolant temperature sensor	40 - 55	400 - 550	30 - 41
Engine coolant inlet fiting attaching bolt	20 - 25	200 - 250	15 - 18
Air cleaner mounting bolts	8 - 10	80 - 100	6 - 7
Resonator mounting bolt (Nut)	8 - 10	80 - 100	6 - 7
Intake manifold mounting bolt (M8)	15 - 20	150 - 200	11 - 14
Hanger bolt to body	10-15	100 - 150	7 - 11
Hanger bolt to main muffler	10 - 15	100 - 150	7 - 11
Exhaust manifold nuts	25 - 38	250 - 380	18 - 28
Heat protector bolt to exhaust manifold	15 - 20	150 - 200	11 - 14
Air cleaner bracket bolt	10 - 13	100 - 130	7 - 9
Oil level gauge	10 - 12	100 - 120	7 - 9
Balance shaft bolt	53 - 57	530 - 570	39 - 42
Starter bolt to cylinder block	48 - 52	480 - 520	35 - 38
Turbocharger support bolt	35 - 45	350 - 450	26 - 33
Crankshaft bedplate bolt
15 mm	28 - 32 + 120°	280 - 320 + 120°	20.65 - 23.6 + 120°
12 mm	33.7 - 37.7	337 - 377	24.9 - 27.8

Coolant temperature °C (°F) and specific gravity					Freezing temperature °C (°F)	Safe operating temperature °C (°F)	Coolant concentration (Specific volume)
10 (50)	20 (68)	30 (86)	40 (104)	50 (122)	Freezing temperature °C (°F)	Safe operating temperature °C (°F)	Coolant concentration (Specific volume)
1.054	1.050	1.046	1.042	1.036	-16 (3.2)	-11 (12.2)	30%
1.063	1.058	1.054	1.049	1.044	-20 (-4)	-15 (5)	35%
1.071	1.067	1.062	1.057	1.052	-25 (-13)	-20 (-4)	40%
1.079	1.074	1.069	1.064	1.058	-30 (-22)	-25 (-13)	45%
1.087	1.082	1.076	1.070	1.064	-36 (-32.8)	-31 (-23.8)	50%
1.095	1.090	1.084	1.077	1.070	-42 (-44)	-37 (-35)	55%
1.103	1.098	1.092	1.084	1.076	-50 (-58)	-45 (-49)	60%