KiaOptima Seccion 001

G 2.
4 DOHC > Información general > Información general > Información general
GENERAL INFORMATION
HOW TO USE THIS MANUAL
DEFINITION OF TERMS
Standard Value (Service standard)
Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part
or assembly is corrected and adjusted. It is given by a tolerance.
Service Limit
Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value
within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard
value.
WARNING , CAUTION, NOTE, ABBREVIATION
● WARNING
Information about an activity that could cause serious or severe personal injury or death to the driver, occupants or service
technician.
● CAUTION
Information about an activity that could cause damage to the vehicle, or cause some personal injury.
● NOTE
A point of information.
● ABBREVIATIONS
DOHC : Double Over Head Camshaft
V-6 : V-typed 6 Cylinder
VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number (VIN) is on the top of the firewall and on the lower side of the left front door pillar.
VEHICLE IDENTIFICATION NUMBER

Vehicle identification number consists of 17 digit.
1 to 3 (Make / Vehicle Type):

KNA - Kia Passenger Car
4 to 5 (Vehicle Line / Series):
GD - OPTIMA / MAGENTIS
6 to 7 (Body Type):
12 - 4Door Seden
8 (Engine):
2 - 2.0 DOHC 4 - V6 2.5 8 - V6 2.7
9 Transaxle (General Region):
2 - 5 Speed Manual
3 - 4 Speed Automatic
Check Digit (To be Calculated)
10 (Model Year):
2 - 2002MY, 3 - 2003MY
11 (Plant):
5 - Hwasung Plant
6 - Sohari Plant
12 to 17 (Sequential Numbers)
ENGINE IDENTIFICATION NUMBER LOCATION
1/19
G 2.4 DOHC > Información general > Información general > Información general
ENGINE IDENTIFICATION NUMBER
1. Engine fuel
G - Gasoline L - LPG D - Diesel
2. Engine range
4 - In line 4 cycle 4 cylinder
6 - V type 4 cycle 6 cylinder
3. Engine development order
B - V6 Engine
J - SIRIUS II DOHC Engine
4. Engine capacity
N - 1836 cc
P - 1997 cc, 1998 cc
S - 2351 cc
V - 2493 cc, 2497 cc
5. Product year
X - 1999 V - 2000 1 - 2001 2 - 2002 3 - 2003
6. Engine production sequence number
000001 - 999999
TRANSAXLE IDENTIFICATION NUMBER LOCATION
DESCRIPTION (MANUAL TRANSAXLE)
1. Model
L : M5G Series.
2. Product year
1 : 2001 2 : 2002 3 : 2003
3. Final gear ratio
1766 : 3,882
1665 : 4,063
4. Serial NO.
DESCRIPTION (AUTOMATIC TRANSAXLE)
2/19
1. Model
C : KM 175-5 D : KM 175-6 H : F4A33
2. Product year
1 : 2001 2 : 2002 3 : 2003
3. Final gear ration
F : 4.350 (KM 175-6) A : 3.958 (F4A33)
4. Classification of detail
AD : 2.4 Liter Engine BD : 2.0/ 2.5 Liter Engine
5. Spare
6. Serial No.
PROTECTION OF THE VEHICLE
The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment
to prevent the hood from falling and possibly injuring you.
Assure that the support rod has been released prior to closing the hood. Always double check to be sure the hood is firmly
latched before driving away.
BASIC SAFETY WARNINGS WHEN WORKING ON THE VEHICLE

1. Block wheels.
2. Use only specified jacking positions.
3. Support vehicle with safety stands (jack stands)
4. Never start the engine until you personally make certain the engine compartment is clear of tools and people. Never rely on
another person to make the inspection-make the inspection yourself.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT
SPECIAL TOOLS
REMOVAL OF PARTS
The failure to follow these instructions can lead to serious personal injury or death.
DISASSEMBLY
1. Inspection of parts
Each part when removed should be carefully inspected for malfunction, deformation, damage, and other problems.
2. Arrangement of parts
3/19
All disassembled parts should be carefully arranged for reassembly.

Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
3. Cleaning parts for reuse

All parts to be reused should be carefully and thoroughly cleaned by the appropriate method.
PARTS
If using non-factory parts, you must ensure that such parts are the equivalent quality of genuine factory parts to avoid
exposing customers to the risk of severe injury or death.
REASSEMBLY
If removed, these parts should be replaced with new ones.
1. Oil seals
2. Gaskets 3
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
Depending on where they are;

1. Sealant should be applied to gaskets.
2. Oil should be applied to moving components of parts.
3. Specified oil or grease should be applied at the prescribed locations (oil seals, etc.) before assembly.
ADJUSTMENT
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
4/19
2. Never pull on the wiring when disconnecting connectors.

3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully.
Be careful not to drop them or hit them against other parts.
RUBBER PARTS AND TUBING
BODY DIMENSION MEASUREMENT

1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimension and actual-measurement dimension are used in this manual.
PROJECTED DIMENSIONS
1. These are the dimensions measured when the measurement points are projected into the reference plane, and are the
reference dimensions used for body alterations.
2. If the length of the tracking gauge probes are adjustable, make the measurement by lengthening one probe by the amount
equivalent to the difference in height of the two surfaces.
ACTUAL-MEASUREMENT DIMENSIONS
1. These dimensions indicate the actual linear distance between measurement points, and are the reference dimensions for use
if a tracking gauge is used for measurement.
2. Measure by first adjusting both probes to the same length (A=A')
Check the probes and gauge itself to make sure there is no free play.
MEASUREMENT POINT
1. Measurements should be taken at the center of hole.
5/19
CHECKING CABLES AND WIRES
1. Check the terminal for tightness.

2. Check terminals and wires for corrosion by battery electrolyte, etc.
3. Check terminals and wires for open circuit or potential open circuit.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that wires are clamped so as to prevent contact with sharp corners of the vehicle body, etc. or hot parts (exhaust
manifold, pipe, etc.)
9. Check that wires are clamped firmly to secure enough clearance from the fan pulley, fan belt and other rotating or moving
parts.
10. Check that the wires between the fixed parts such as the vehicle body and the vibrating parts such as the engine are made
with adequate allowance for vehicle vibrations.
CHECKING FUSES
SERVICING THE ELECTRICAL SYSTEM

1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.
In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic code retained by the
computer will be cleared. Therefore, if necessary, read the diagnostic codes before removing the battery cable.
2. Secure the wiring harnesses by using clamps so that there is no slack. However, for any harness which passes to the engine
or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the
harness to come into contact with any of the surrounding parts, and then secure the harness by using a clamp.
6/19
3. If any section of a wiring harness interferes with the edge of a part, or a corner, wrap the section of the harness with tape or
something similar in order to protect it from damage.
4. When installing any of the vehicle parts, be careful not to pinch or damage any of the wiring harnesses.
5. Never throw the relays, sensors and electrical parts, or expose them to strong shocks.
6. The electronic parts used in the computer, relays, etc. are easily damaged by heat. If there is a need for service operations
that may cause the temperature to exceed 80°C (176°F), remove the electronic parts beforehand.
7. Loose connectors could troubles. Make sure that the connectors are connected securely.
8. When disconnecting a connector, be sure to pull only the connector, not the harness.
7/19
9. Disconnect connectors which have catches by pressing in the direction indicated by the arrows in the illustration.
10. Connect connectors which have catches by inserting the connectors until a "click" noise is heard.
11. When using a circuit tester to perform continuity or voltage checks on connector terminals, insert the test probe from the
harness side. If the connector is a sealed connector, insert the test probe in through the hole in the rubber cap for the
electrical wires, being careful not to damage the insulation of the wires and continue to insert the test probe until it contacts
the terminal.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into considerution, and determine
the appropriate wire size.
Permissible current
Nominal size SAE gauge No.
In engine compartment Other areas
0.3 mm² AWG 22 - 5A
0.5 mm² AWG 20 7A 13A
0.85 mm² AWG 18 9A 17A
1.25 mm² AWG 16 12A 22A
2.0 mm² AWG 14 16A 30A
3.0 mm² AWG 12 21A 40A
5.0 mm² AWG 10 31A 54A
PRECAUTIONS FOR A CATALYTIC CONVERTER
If large amounts of unburned gasoline vapors flow into the converter, the gasoline line may overheat and create a fire
hazard. To prevent this, observe the following precautions and explain them to your customer.
1. Use only unleaded gasoline.

2. Avoid prolonged idling.
Avoid running the engine at fast idle speed for more than 10 minutes and at idle speed for more than 20 minutes.
8/19
3. Avoid spark jump test.

Spark jump only when absolutely necessary. Perform this test as rapidly as possible and, while testing, never race the engine.
4. Avoid prolonged engine compression measurement. Engine compression tests must be made as rapidly as possible.
5. Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the
converter.
6. Avoid coasting with ignition turned off and prolonged braking.
7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
SRS SYSTEM COMPONENTS INFORMATION
Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly deploy
during servicing, possibly leading to a serious injury or death. Further, if a mistake is made in servicing the airbag system,
it is possible the airbag may fail to operate when required. Before performing servicing (including removal or installation of
parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure
described in the repair manual.
1. Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most important
source of information when troubleshooting. When troubleshooting the airbag system, always inspect the diagnostic codes
before disconnecting the battery.
2. Work must be started 30 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative
(-) terminal cable is disconnected from the battery. (The airbag system is equipped with a back-up power source so that work
is started immediately after disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.) When
the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So
before starting work, make a record of the contents memorized by the audio memory system. Then when work is finished,
reset the audio system as before and adjust the clock.
3. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
4. Never attempt to disassemble and repair the airbag modules, SRSCM, Clock spring and Air-bag wiring harness in order to
reuse it.
5. If the SRSCM or air-bag module have been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace them with new ones.
6. After work on the airbag system is completed, perform the SRS SRI check.
VEHICLE LIFT AND SUPPORT LOCATIONS
9/19
STANDARD PARTS TIGHTENING TORQUE TABLE

Torque Nm (kg.cm, lb.ft)
Bolt nominal diameter (mm) Pitch (mm)
Head Mark 4 Head Mark 7
M5 0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3)

M6 1.0 5-6 (50-60, 3.6-4.3) 9-11 (90-110, 6.5-8.0)
M8 1.25 12-15 (120-150, 9-11) 20-25 (200-250, 14.5-18.0)
M10 1.25 25-30 (250-300, 18-22) 30-50 (400-500, 29-36)
M12 1.25 35-45 (350-450, 25-32) 60-80 (600-800, 43-58)
M14 1.5 75-85 (750-850, 55-60) 120-140 (1,200-1,400, 85-100)
M16 1.5 110-130 (1,100-1,300, 80-95) 180-210 (1,800-2,100, 130-150)
M18 1.5 160-180 (1,600-1,800, 115-130) 260-300 (2,600-3,000, 190-215)
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M20 1.5 220-250 (2,200-2,500, 160-180) 360-420 (3,600-4,200, 260-300)

M22 1.5 290-330 (2,900-3,300, 210-240) 480-550 (4,800-5,500, 350-400)
M24 1.5 360-420 (3,600-4,200, 270-300) 610-700 (6,100-7,000, 440-505)
1. The torques shown in the table are standard values applicable to tightening performed under the following conditions:
1. Nuts and bolts are made of steel bar, and galvanized.
2. Galvanized plain steel washers are inserted.
3. All nuts, bolts, and plain washers are dry.
2. The torques shown in the table are not applicable:
1. Spring washers, toothed washers and the like are inserted.
2. If plastic parts are fastened.
3. If threads and surface are coated with oil.
4. If self-tapping screws or self-locking nuts are used.
3. It should be standard practice to reduce the torques given in the table to the percentage indicated below:
1. If spring washers are used. 85%
2. If threads and bearing surfaces are stained with oil. 85%
RECOMMENDED LUBRICANTS AND CAPACITIES

RECOMMENDED LUBRICANTS
Parts Specifications Remarks

Engine oil API classification SG or SG/CD For further details, refer to SAE viscosity
number
Manual transaxle Hypoid gear oil, API-GL-4 SAE grade number:
SAE 75W/ 90W
Automatic transaxle GENUINE
DIAMOND ATF SP-II M
Brake Conforming to DOT 3 or equivalent
Rear wheel bearing SAE J310a, Multipurpose grease NLGI
No.2 or equivalent.
Cooling system High quality ethylene glycol Concentration level 40%
Transaxle linkage, parking brake cable Multipurpose grease NLGI Grade #2
mechanism, hood lock and hook, door
latch, seat adjuster, trunk latch, door
hinges, trunk hinges
Door hinges, trunk hinges Engine oil
Power steering PSF-3
LUBRICANTS CAPACITIES
Description Capacities Remarks
Engine oil(For 2.0/ 2.4L DOHC Engine)
Oil pan 3.7 lit (3.91 U.S. qts., 3.26 Imp.qts.)
Oil filter 0.3 lit (0.32 U.S. qts., 0.26 Imp.qts.)
Total 4.0 lit (4.23 U.S. qts., 3.52 Imp.qts.)
Engine oil(For V6 Engine)
Oil pan 4.2 lit (4.44 U.S. qts.,3.69 lmp.qts.)
Oil filter 0.3 lit (0.32 U.S. qts.,0.26 Imp.qts.)
Total 4.5 lit (4.76 U.S. qts.,3.95 lmp.qts.)
Cooling system 5.5 lit (5.78 U.S. qts., 4.84 Imp.qts.)
Manual transaxle 2.1 lit (2.2 U.S. qts., 1.8 Imp.qts.)
Automatic transaxle 7.8 lit (8.2 U.S. qts., 6.9 Imp.qts.)
Power steering 1.0 lit (1.05 qts., 0.88 lmp.qts.)
11/19
MAINTENANCE SERVICE
CHECKING THE ENGINE OIL
1. Warm up the engine and turn the ignition off.
2. Remove the filler cap (on the rocker cover), then remove the drain plug and drain the engine oil.
3. Install the drain plug and tighten to specified torque.
Tightening torque - Drain plug : 35-45 Nm (350-450 kg·cm, 26-32 lb·ft)
4. Fill the crankcase with fresh oil through the filler port.
Lit (U.S.qts, lmp.qts.)
Drain and Refill
ENGINE Dry Fill
W/oil filter W/O oil filter
DOHC 4.3 (4.52, 3.76) 4.0 (4.23, 3.51) 3.7 (3.91, 3.25)
V-6 - 4.5 (4.76, 3.95) 4.2 (4.43, 3.69)
5. Pull the dipstick out in order to check the oil level.
6. Install the filler plug.

7. Recheck the level of the engine oil after a road test.
REPLACEMENT OF THE ENGINE OIL FILTER
1. Replace the oil filter at every oil change.
2. Use a filter wrench (available commercially) to remove the oil filter.
3. Drain the oil in the filter.
4. Lightly coat the O-ring (1) of the new oil filter with engine oil, and install the filter by hand.
REPLACEMENT OF THE AIR CLEANER FILTER

1. Disconnect the air cleaner filter cover clip.
2. Remove the air filter cover.
The air filter cover should be removed carefully because it includes the air-flow sensor.
12/19
3. Remove the air cleaner filter.

4. Install a new air cleaner filter and clamp the air cleaner filter cover.
CHECKING BELT TENSION
Standard value (For DOHC ENGINE)
Items New Used Inspection
Deflection mm (in.) 6.3 - 7.3 (0.24-0.29) 8.4 -10.6 (0.33-0.42) 7.7-12.3 (0.3-0.48)
Generator
Tension Kg (lb) 60 ± 5 (132±10) 40 ± 5 (88±10) 40 ±10 (88±20)
A/C Compressor Deflection mm (in.) 8.8 -11.0 (0.35-0.43) 12.5 -14.3 (0.5-0.56) 11.7-15.3 (0.46-0.6)
Standard value ( For V6 ENGINE)

The belt tension for V6 engine is automatically adjusted by the auto-tensioner.
ADJUSTMENT OF BELT TENSION

Refer to HA-Section. (For Compressor)
COOLING SYSTEM
Antifreeze
The engine cooling system is provided with a mixture of 50% ethylene glycol anti-freeze and 50% water at the time of
manufacture. (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 provide corrosion protection and freezing prevention.
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 antifreezing and engine cooling properties will decrease, adversely affecting the
engine. For these reasons, be sure to maintain the concentration level within the specified range.
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%. (Tropical Areas : 40%)
Replacement of the Coolant
1. Set the temperature control lever to the hot position.
2. Remove the radiator cap.
Remove cap slowly as the system is pressurized and the coolant may be hot.
Do not open the cap when engine is hot.
3. Loosen the drain plug to drain the coolant.

13/19
4. Drain the coolant from the reserve tank.

5. After draining the coolant, tighten the drain plug securely.
6. Supply the coolant into the radiator until it is filled up to its filler neck.
7. Supply the coolant into the reserve tank.
8. After warming the engine until the thermostat opens, remove the radiator cap and check the coolant level.
9. Supply the coolant into the radiator until it is filled up to its filler neck, and install the radiator cap securely.
10. Fill the reserve tank with coolant up to the "FULL" line.
REPLACEMENT OF IGNITION CABLES
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.
REPLACEMENT OXYGEN SENSOR
FUEL SYSTEM
Tank, Lines And Connections
1. Check for damage or leakage in the fuel lines and connections.
2. Inspect the surface or fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, checking, tears, cuts,
abrasions and excessive swelling indicate deterioration of the rubber.
3. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses should be changed.
MANUAL TRANSAXLE (Inspect oil level)
1. With the vehicle parked at a level place, remove the filler plug and make sure that oil level is the same level as the plug hole.
2. Check to be sure that the transaxle oil is not dirty.

TRANSAXLE OIL (Replace)
1. With the vehicle parked at a level place, remove the magnet plug to drain transaxle oil.
2. Replace packing with a new one and install the magnet plug.
3. Supply transaxle oil (through the filler plug part) until the oil level is the same level as the plug hole.
Transaxle oil total capacity :
2.1 liters (2.2 U.S. qts., 1.8 lmp. qts.)
INSPECT STEERING LINKAGE
1. Check steering wheel freeplay.
Maximum steering wheel freeplay : 30 mm (1.181 in.)
14/19
2. Check steering linkage for looseness and damage as follows.

(1) Tie rod ends do not have excessive play.
(2) Dust seals and boots are not damaged.
(3) Boot clamps are not loose.
POWER STEERING FLUID LEVEL
(Inspect fluid level)
1. Park the vehicle on a flat, 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 vehicle still idling, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for
foaming, check the fluid level, and 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 are 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 periodic lubrication. Damaged seals and
boots should be replaced to prevent leakage or contamination of the grease.
2. Inspect the dust cover and boots for proper sealing leakage and damage. Replace them if defective.
INSPECT BRAKE LINE
1. Check all brake pipes 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
If a squealing or scraping noise occurs from the brakes during driving, check the brake pad wear indicator to see if itis
contacting the brake disc. If the brake pad wear indicator is contacting the disc, the brake pad should be replaced.
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 "A" [Limit] : 2.0 mm (0.079 in.)
15/19
REAR DRUM BRAKE LININGS AND

REAR WHEEL CYLINDERS
1. Remove the brake drum and check the thickness of brake shoe lining for wear. 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 functioning,
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.)
(1) Checking the brake shoes for wear.
Thickness of lining "B" [Limit] : 0.8 mm (0.032 in.)
CHECKING THE BRAKE FLUID LEVEL

1. Visually 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" marks.
3. If the level is lower than the "MIN" marks, add fresh brake fluid up to the "MAX" mark.
CHANGING BRAKE FLUID
1. Refer to BR-Section 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 into a container to receive
the brake fluid.
3. With a vehicle equipped ABS (Anti-lock Breake System), refer to BR-section.

4. Depress the brake pedal a few times. Then loosen the bleeder (with the brake pedal still depressed), and tighten it after the
brake fluid stops flowing.
16/19
5. Repeat the above operation until to air bubbles are 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 equivalent
CHECKING OF THE TIRE INFLATION PRESSUE

Tire inflation pressure (Check with Tires Cool)
Tire size Front Rear
195/ 70 R 14
207 kPa (30 psi) 207 kPa (30 psi)
205/ 60 R 15
ROAD TEST
1. Check for oil, fluid, fuel, water and exhaust gas leaks.
2. Check free play of clutch pedal and brake pedal.
3. Check operation of brake booster.
4. Check operation of service brake and parking brake systems.
5. Check stroke of parking brake lever.
6. Check driveability of engine.
7. Check condition of instruments, gauges, indicators, exterior lamps, heater and ventilators.
8. Check abnormal noise of each part.
STEERING AND DRIVE SHAFT BOOTS
1. Aluminum wheels need special attention. If salt or chemicals have adhered to the wheels, they need to be rinsed off as soon
as possible. After cleaning the wheels, apply a coating of wax to prevent corrosion.
2. When cleaning the vehicle with steam, do not apply steam directly onto the aluminum wheels.
A. Clean the hub surface.
B. After finger tightening the wheel nuts, tighten them to specifications.
C. Do not use an impact wrench or push on the wrench with your foot to tighten the wheel nuts.
D. Do not apply oil to the threaded portions.
TIRE CHAINS AND SNOW TIRES

1. Use tire chains only on the front wheels. Do not use tire chains on rear wheels.
2. When using snow tires, use them on all four wheels for maneuverability and safety.
Maintenance Schedule (Except for europe)
17/19
Maintenance Schedule (For europe)
18/19
19/19

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G 2.

VEHICLE IDENTIFICATION NUMBER

1 to 3 (Make / Vehicle Type):

ENGINE IDENTIFICATION NUMBER

DESCRIPTION (MANUAL TRANSAXLE)

BASIC SAFETY WARNINGS WHEN WORKING ON THE VEHICLE

All disassembled parts should be carefully arranged for reassembly.

3. Cleaning parts for reuse

Depending on where they are;

2. Never pull on the wiring when disconnecting connectors.

BODY DIMENSION MEASUREMENT

CHECKING CABLES AND WIRES

1. Check the terminal for tightness.

SERVICING THE ELECTRICAL SYSTEM

PRECAUTIONS FOR A CATALYTIC CONVERTER

1. Use only unleaded gasoline.

3. Avoid spark jump test.

STANDARD PARTS TIGHTENING TORQUE TABLE

M5 0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3)

M20 1.5 220-250 (2,200-2,500, 160-180) 360-420 (3,600-4,200, 260-300)

RECOMMENDED LUBRICANTS AND CAPACITIES

Parts Specifications Remarks

3. Install the drain plug and tighten to specified torque.

Tightening torque - Drain plug : 35-45 Nm (350-450 kg·cm, 26-32 lb·ft)

5. Pull the dipstick out in order to check the oil level.

6. Install the filler plug.

REPLACEMENT OF THE AIR CLEANER FILTER

3. Remove the air cleaner filter.

Standard value ( For V6 ENGINE)

ADJUSTMENT OF BELT TENSION

Measurement of Antifreeze Concentration

3. Loosen the drain plug to drain the coolant.

4. Drain the coolant from the reserve tank.

REPLACEMENT OXYGEN SENSOR

2. Check to be sure that the transaxle oil is not dirty.

Maximum steering wheel freeplay : 30 mm (1.181 in.)

2. Check steering linkage for looseness and damage as follows.

2. Check all clamps for tightness.

Thickness of pad lining "A" [Limit] : 2.0 mm (0.079 in.)

REAR DRUM BRAKE LININGS AND

Thickness of lining "B" [Limit] : 0.8 mm (0.032 in.)

CHECKING THE BRAKE FLUID LEVEL

3. With a vehicle equipped ABS (Anti-lock Breake System), refer to BR-section.

Brake fluid : DOT 3 or equivalent

CHECKING OF THE TIRE INFLATION PRESSUE

TIRE CHAINS AND SNOW TIRES

Maintenance Schedule (For europe)

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