Maintenance

MAINTENANCE SERVICES ENGINECOMPARTMENT ENGINE OIL AND OIL FILTER ENGINE COOLINGSYSTEM BRAKES CLUTCH POWER STEERING MANUAL TRANSAXLE AUTOMATICTRANSAXLE AND FLUIDS OTHERLUBRICANTS AIR CLEANER WIPER BLADES BATTERY BELT TENSIONS SPARK PLUGS TYRES WHEELS LIGHT BULBS LUBRICANTSPECIFICATIONS TROUBLESHOOTING 7. 2 7. 9 7.11 7.14 7-18 7-20 7-20 7-21 7-22 7-24 7-25 7-27 7-29 7-30 7-32 7-34 7-97 7-37 7-43 7-45

7-1

MAINTENANCE SERVTCES

Maintenance Services
You shouldexercise the utmostcareto orevent damageto your vehicleand injuryto yourselfwheneverusing this manualfor maintenance or inspection. you haveany doubtsconcerning Should the inspection or servicing of your vehicle, we strongly recommend thatyou havea reliable and qualified service shopperform thiswork, preferablyan AuthorizedXedos Dealer. An AuthorizedXedos Dealer has factorytrained technicians and genuineXedosparts yourvehicle to service properly. For expert adviceand qualityservice, see an Authorized Xedos Dealer. lnadequate, incomplete, or insufficient servicing may resultin operational problems with yourvehicle that could even leadto vehicle damage, an accident,or personal InJury.

Owner'sResponsibility
Maintenance Services and Record Retentionare the owner's responsibility.

Scheduled Maintenance Services

i NOTE After80,000km (48,000 miles) or 48 months, 1 j continue to follow the described scheduled You shouldretain evrdence thatpropermain- maintenance items and intervals OeriodicallV j tenancehas beenperformed on yourvehic l e r n a c c o r d a n c e w i t h s c h e d u l e d Emission control and related systems: I marntenance, services chart starting on the The ignition and fuelsystems are vitally im-| page. following portantto the proper operation of the emis-| Detailed warranty information is alsoprovid- sioncontroland relatedsystems, as well as I ed with your Xedosvehicle. for efficient engineoperation. I Claimsmade duringthe warranty termwill not qualify underany warranty if theyresult from lack of maintenance rather thanfrom defective materialor workmanshio. We recommend thatsuchmaintenance be oerformedby an Authorized XedosDealer using genuineXedosparts.

7-2

SERVICES MAINTENANCE
of system'soperationor penormance measurement and/orfunctional I : lnspect:visual examination T: Tighten or change R: Replace replacement or in adjustment resutting Examination Adiust: A: ttutnU"r of months or km (miles), whichgve Months" km x1000 Miles x 1000 Exhaustmanifoldbolts and nuts Drive belts*2 timingbelt.3 Engine Enqineoil.a Oil filter.4 Coolingsystem(includingcoolantlevel adjustment) Enginecoolant

12 1.0 0.6 T
A R R R

10
6

20

30
18

24 40
24

50

12

30

36 60 36 A
R R

48

70 42

80
48

A Replace every 100,000 km (6o'oou. R R R R R R R R I RePlace every z years

T A

T A
R R R R I

,2 -3 .4

km (12'000 miles) Major serviceintervalat 12 months/20,000 servicebased on distanceonly 10,000km (6,000 miles)nottme LuUrication drive belt, if equipped and;;ter pump drive belt, power steeringand air conditioner Adjust alternator Failureto replacetiming belt may resultin damageto the engine' miles). (oo,ooo t<ri roo,ooo at every required is belt timing of Replacement thatihe ;ngine oil and oil filterbe changedmore oftenthan at usualrecomit is suggesteo lf the vehicleis operatedunderthe followingconditions, mended intervals. a) Drivingin dusty conditions. periodsof idling or low speed operation' ni ExtendeO or drivingonly shortdistanceregularly' in cold temperatures cj oriuingroi a protongeap"eriod

7-3

MAINTENANCE SERVICES
| : Inspect:Visualexamination and/or functional measurement of system'soperation or p, A: Adjust: Examination resulting ln adjustment or replacement R: Replaceor chanqe MAINTENANCE
----r-\ rrt r EnYALo

Number of months or km (miles), whichever comes first

I Months*l

MATNTENANCE ITEM

-----r----r,\

A A A E.G.R. system(2.0litre) I I Evaporativesystem I I Dash pot (1.6 litre) A A A Batterycondition I I All electrical systems.6 I I I I I . 1 Major serviceinterval (12,000 at 12 months/20,000 km miles) Lubrication servicebased on distanceonly 10,000 km (6,000miles)not time . 5 lf the vehicle is operatedin very dusty or sandy areas,inspectand, if necessary, replacemore oftenthan at usuatrecommended - 6 This is a full function intervars. check of all electrical systems,i.e., all lights,washerslinclJdingconditionof bladesjelectricwindows,sun roof, horn. erc..

ldle speed Air cleanerelement*s Fuel filter Fuel linesand hoses Initial ignition timing Sparkplugs

| km x 1OOO mt"s "1000

1.0 0.6

10
6

12 20 12
A

30
18

24 40 24
A R R

50 30

36 60 36
A I I I

48

70
42

80
48

A
R R I I

I I A I I A

7-4

SERVICES MAINTENANCE
or performance of system'soperation measurement and/orfunctional | : Inspect:Visualexamination change Replace or R: replacement or in adjustment resulting A: Adjust: Examination MAINTENANCE INTERVALS MAINTENANCE ITEM Head light alignment Clutch pedal Brake lines,hoses,and connections Brake pedal Brakeand clutchfluidParkingbrake Power brake unit and hoses Disc brakes Power steeringfluid Power steeringsystemand hoses Steeringand front suspension oil Manualtransaxle fluid level Automatictransaxle I Number ol months or km (miles), whichever comes first 36 24 12

Months*' km x1000 Miles x 1000

48

1.0 0.6

10
6

20
12

30
18 I

40 24 A
I I I R

50 30
I I

60 36
A

70
42

80
48 A I I I R

I I A I I I I I !

A
I I I I I

A I

R I

km (12,000miles) Major serviceintervalat 12 months/20,000 servicebased on distanceonly 10,000 km (6,000miles)nottime Lubrication Replaceevery 2 years. humid or the vehicleis operatedin extremely hard driving,mountaindriving,or if the brakesare used extensively lf there has been continuoug changed annually. be climates,the brakefluid shduld

7-5

SERVICES MAINTENANCE

measurement | : Inspect:Visualexamination and/or functional of system'soperationor performance in adjustment T: Tighten resulting or replacement A: Adjust:Examination MAINTENANCE INTERVALS MAINTENANCE ITEM Number of months or km (miles), whichever comes first

Months" km x1000 Miles x 1000

1.0 0.6 T

10
6

12 20 12 T

30
18

24 40 24
I

50 30

36 60 36
I

48

70 42

80
48

Drive shaftdust boots Boltsand nuts on chassisand bodv Body condition(for rust, corrosion,and perforation) Exhaustsvstemheat shield spare tyre, with inflationpressure Tyres (including adjustment) Hinoes and catches Undersideof vehicle Seat Belts Refrigerant system Air conditioner (if equipped) Compressor

T
Inspect annually I I

A
I I Inspect the operation annually

A
I I

amountannually Inspectthe refrigerant

I

Road test -.1 Major serviceintervalat 12 months/20,000 km (12,000miles) Lubrication servicebased on distanceonly 10,000km (6,000 miles)nottime

7-6

MAINTENANCE SERVICES RoutineService Maintenance Service Precautions

. Whenconnecting the battery cables,pay specialattention to theirpolarities. Never connecta positive cableto a negative terminal or a negativecable to a positive terminal. o Rememberthat the battery,ignitioncables,and vehicle wiringcarry high currentsor voltage.Be carefulnot to cause a short circuit. r When performing any checksin an enclosed space with the enginerunning, such as in a garage,be sure there is propqr ventilation. . There are strict environmentallaws regardingthe disposal of wasteoils and fluids.Please dispose of yourwastecarefully and with due regard to the environment. We recommendthat you entrustthe oil and fluidchanges of your vehicle to an Authorized XedosDealer. You shouldbe awarethat improper or incomplete servicing may result in operating problems. givesinstructions Thissection only for thoseitemsthatare relatively easyfor an owner to oerform.

that the follow- When performing It is stronglyrecommended any inspection or mainalwaysexering items be checked daily and/or weekly. tenancework on your vehicle, injury cisecareto reducethe riskof personal . Engine Oil Level or damageto the vehicle. ( p a g e7 - 1 1 ) Here are some general precautionsthat . Engine Coolant Level in carrying out shouldbe closely observed (page7-14) any serviceoperation. o Brake and Clutch Fluid Level o Do notworkon the engine (page 7-18) whileit is hot. . Washer Fluid Level Always turn it off and allow it to cool. . lf you mustworkwiththeengine (pa1e 7-24) running, . Tyre Inflation Pressure makesurethat no article of clothing, in(page 7-34) cludingneckties and handkerchiefs, can by any movingparts. becomeentangled Remove watches,bracelets, rings,necklaces,and similaritems.Keep hands, clothing, hair,and toolsawayfrom moving fans and drive belts. . Never get under the vehiclewhile it is supportedby a jack. lf it is necessary to workunderthe vehicle, usesafety stands. r Keep smoking materials, flames, and sparksawayfrom the battery and allfuel and fuel-related oarts. o Never connect or disconnect eitherthe batteryor any transistorized component whilethe ignition switchis ON(ll).

7-7

MAINTENANCE SERVICES

Performing maintenance do-it-yourself durand set the parking brake firmly. period yourwaringthewarranty mayaffect Unexpected and possibly sudden rantycoverage. Readthe separate Xedos vehicle movement may occur it Warranty statement for details andsuggesthese precautions are not taken. tions. lf in doubt about anyservicing, have o To avoid the possibility of perit doneby an Authorized Xedos Dealer. sonal injury, you should always turn off the ignition switch and reWARNING! move the key before working uno On vehicles equipped with an auder the bonnet unless the tomatic transaxle, do not release procedure specifically requires the bonnet latch until the selecotherwise. lf it requires running tor lever has been securely the engine while working under latched in P (Park) and the parkthe bonnet, do not permit any ing brake has been tirmly set. clothing, such as neckties or Turn the ignition switch off unhandkerchiefs, near the engine or less it is necessary to check syscooling fan. They can become entems with the engine running. If tangled in moving parts and rethe vehicle has a manual transaxsult in personal injury and le, do not release the bonnet latch damage to the vehicle. Also reunless the ignition switch is first move watches, bracelets, and turned off , the shift lever is rings for safety. placed in 1 (First), and the parking brake is firmly set. o With a manual transaxle, if it is necessary to check beneath the bonnet with the engine running, place the shift lever in NEUTRAL

7-8

ENGINE COMPARTM EN T

Overview EngineCompartment

Fuse block

washerreservoir Windshield

'\

*some modets. 7'9

ENGINECOMPARTMENT

Brake/clutch fluid reservoir Automatictransaxle fluid-level dipstick. Sparkptuss ///t I Fuse block

o-L"^n*,

Windshield wasnerreservorr:

Ri)t"rn",.

7'1O

*Somemodels.

ENGINE OIL AND OIL FILT ER Checking Engine Oil Level

1 Be sure the vehicleis on levelground. 3. Turn off the engineand wait 5 minutes 5. Pullthe dipstick outagainand checkthe Warmup the engineto the normal operfor the oil to returnto the oil oan. level.lf the levelis betweenF and L, it atingtemperature. 4. Pullout the dipstick, wipe it clean,and rs adeouate. reinsert it fully. lf it is nearor at L, addenough oilto bring the levelto F. Do not overtiil. NOTE The distance between L and F on the dipstickrepresents the following. 1.6-litre engine; 0.8 litre (0.85 US qt, 0.7 lmp qt) 2.0-litre engine: 1.0 litre (1.1US qt, 0.9 tmp qt)

7-11

ENG I N EO I L A N D OIL F IL T E R ChangingEngineOiland Filter

tothe according engine oilandfilter Change Maintenance on page 7-2 Scheduled 7-6. through WARNING! Continuous contact with USED Engine oil has caused skin cancer in Iaboratory mice. Protect your skin by washing with soap and water. Keep all engine oil out of the reach of children.

=-ffi
l\ :rgnlen
Drain plug

oit fitter
Loosen

Remove the engineoil filterwith an oil1. Warm up the enginefor a few minutes filterwrench. the oil{ller and thenturn it off. Remove 4 . Use a clean rag to cleanthe mounting cap. surface 2. Drainthe oil into a suitable containerafof the oil filteron the engine. of engine oilto the ter removing the oil{illercap and drain 6 Applya smallamount ptug. rubberseal of a new oil filter. the oil filterand tightenit. Both the oil and the engine are hot. o . Install (Please Do not burn yourself. referto the oilfiltercaution label instructions.) for tightening 7 . Replace the drainplugtightly after the oil has thoroughly drained. the enginewithnewoilto the F mark 8 . Refill on the dipstick. Do not overtiil.

7-12

ENGINE OIL AND OIL FILTER

cap securely. 9. Refitthe oilJiller 10. Startthe engineand inspectaroundthe oil filter seal for leaks. 11. Turnoff the engineand wait5 minutes for the oil to returnto the oil pan. Checkthe oil leveland fill to the F mark if necessary. Oil capacity 1.6-litreengine:
With oil filter Withoutoil lilter 3.6 litres (3.8 US qt, 3.2 lmp qt) 3.2 litres (3.4 US qt, 2.8 lmp qt)

NOTE Use only the specified engineoil (referto chart on page 7-43). CAUTION o Follow these instructions carefully. An improper oil filter installation can cause oil leakage and engine damage. r Although oil filters may have the same external appearance, their internal designs differ significantly. These filters are not interchangeable. To avoid potential engine damage, use only the specified filter for each application.

2.0-litre engine:
With oil filter Withoutoil filter 4.0 litres (4.2 US qt, 3.5 lmp qt) 3.7 litres (3.9 US qt, 3.3 lmp qt)

7-13

ENGINECOOLINGSYSTEM Engine Cooling System

sure has been released, press down on the cap-still using a cloth-turn it, and remove it. . Even if the engine is not operatprotection Checkthe antifreeze and coolant ing, do not remove the radiator levelat leastonce ayear-at the beginning cap or coolant filler cap while the of the winter season-and beforetravelino engine and radiator are hot. to a colderclimate. Scalding hot coolant and steam may still blow out under pressure; WARNING! this could cause serious injury.
. Never attempt to remove the radiator cap or coolant filler cap while the engine is operating. Doing so might lead to cooling system and engine damage and could result Checkthe condition and connections of all coolingsystem hosesand heater hoses.Replace any swollenor deteriorated hoses. Thecoolant levelshouldbe fullin the radiator and betweenF (full)and L (low)on the coolant levelgaugewhenthe engineis cool. The coolingsystem is a high-pressure type witha reservoir and is filledwithyear-round antifreeze coolantat the factory.

Checking Coolant Level

in serious personal injury from escaping hot coolant or steam. Turn oft the engine and wait until it has cooled. Even then, use extreme care when removing the radiator cap or coolant filler cap. Wrap a thick cloth around it, and turn it counterclockwise slowly to the lirst stop. Step back while the pressure is released from the cooling system. When you are sure all the pres-

7-14

ENGINE COOLING SYSTEM

Changing Coolant
Changecoolant according to the Scheduled Maintenance Charts. CAUTION . Use only soft (demineralized) water in the coolant mixture. o The engine in your vehicle has aluminium engine parts and must be protected by an ethylene-glycol based coolant to prevent corrosion and freezing. DO NOT USE alcohol or methanol antifreeze or mix them with the speciThe coolantdiostickis attachedto the reserfied coolant. voircap. Checkthe coolantlevelwiththe lev. Do not use a solution that contains el gauge. more than 60 percent antifreeze, 1. Remove the reservoir cap with the which would reduce the effectiveness diostick. of solution. 2 . Wioe it cleanand reinsert it. Pullthe dipstickout again.The coolant For mixturepercentage, referto the followlevel should be between L and F. ing table. lf the levelis nearor at L (low), add enough specified coolant to provide protection against freezing and corrosion and to bring the level to F (full).Do not overfill. ll frequentadditions arerequired, seean Authorized Xedos Dealer for a cooling system inspection.
Protection Above -16oC (3"F) Above -26"C (-1soF) Above -40"C (-40oF) Mixturepercentage (volume) Antifreeze solulion Water 65 55 45

WARNING! To preventburning yourself, do not remove the radiator cap or coolant tiller cap or loosen the drain plug if the engine is hot.

35
45 55

7-15

ENGINECOOLINGSYSTEM

EngineCoolingSystem
Thecoolingsystemis a high-pressure type witha reservoir and is filledwithyear-round antifreeze coolant at the factory. Checkthe antifreeze protection and coolant levelat leastonce a year-at the beginning of the winterseason-and beforetravelino to a colderclimate. WARNING! o Never attempt to remove the radiator cap or coolant filler cap while the engine is operating. Doing so might lead to cooling system and engine damage and could result

CheckingCoolantLevel
sure has been released, press dg*! on the cap-stiil using a cloth-turn it, and remove it. . Even if the engine is not operating, do not remove the radiator cap or coolant filler cap while the engine and radiator are hot. Scalding hot coolant and steam may still blow out under pressure; this could cause serious injury.

in serious personal injury from escaping hot coolant or steam. Turn off the engine and wait untit it has cooled. Even then, use extreme care when removing the radiator cap or coolant fiiler cap. Wrap a thick cloth around it, and turn it countercloclrwise slowty to the first stop. Step back while the pressure is releasedfrom the cooling system. When you are sure all the pres-

Checkthe condition and connections of all i coolingsystem hosesand heaterhoses. Re- I place any swollenor deteriorated hoses. I The coolant levelshouldbe fullin tne raOia. I tor and betweenF (full)and L (low)on the I coolantlevelgaugewhenthe engineis coot. I

7-14

BRAKES

Fluid CheckingBrake/Glutch Level

CheckingBrake Pedal

the clutch includes The brakefluidreservoir fluid reservoir. periodCheckthe fluidlevelin the reservoir ically; it shouldbe betweenMAX and MIN on tne reservolr. addingfluid,cleanthe areaaround Before the reservoircap thoroughlyto prevent fluidcontamination. brake/clutch lf the levelis low,add fluidto the MAXlevel. distance. The levelwillfallwithaccumulated with This is a normalconditionassociated lf the fluidlevel linings. wearof brake/clutch syslow,havethe brake/clutch is excessively tem checked by an Authorized Xedos Dealer.

CAUTION . Use only the specified brake/clutch fluid. (Refer to chart on page 7-43.) . Do not mix different types of fluid. o In the event the brake/clutch system requires lrequent supplies of fluid, the vehicle should be inspectedby an Authorized Xedos Dealer.

PEDAL FREEPLAY CHECKING the brake Turnoff the engineand depress pedalseveral the vacuum timesto deplete depress the in the powerbrakeunit.Gently the disbrakepedalby hand and measure is felt. tance it moves until slightresistance lf the free play is more or lessthan specified,havethe brakesadlustedby an AuthorizedXedosDealer. Pedalfreeplay:4-12mm (0.16-0.47 in)

7-18

BRAKES CheckingParkingBrake CheckingPower Brakes

Check the power brakes for proper ooeration. r Depress the brakepedala few timesand then hold it down.Startthe engineand the pedalshoulddrop slightly. . Depress the brake pedal,stop the engine,and holdthe pedaldownfor about 30 seconds.The pedal shouldneither drop nor rrse. o Restart the engine,let it run for about a minute,and turn it off. Then firmlydepressthe brakepedalseveral times.The pedal travelshoulddecreasewith each subsequent stroke.

CHECKING PEDAL CLEARANCE Startthe engineand checkthe brake pedal for smoothoperationand properclearance when it is fullydepressed (approximately 60 kg [132lb, 589 N]).The clearance is measured betweenthe centre of the upper surface of the brake pedal pad and the floorboardwithoutthe carpet. lf it is lessthan about 85mm (3.3 in),have the brakes adjusted by an Authorized Xedos Dealer. Clearance:about 85mm (3.3 in) min

Check the stroke of the parking brake by counting the numberof clicksheardwhile fullyapplyingit from the released position. Also,the parkingbrakealoneshouldsecure- lf the brakesdo not operateproperly,have ly hold the vehicle on a fairlysteepgrade. the brakesystem checkedby an Authorized lf the numberof clicksis more or lessthan Xedos Dealer. specified, have the parkingbrake adjusted by an AuthorizedXedos Dealer. Stroke: 5-7 clicks at a force of 10 kg (221b, 98 N)

7-19

CLUTCH,POWERSTEERING Checking Clutch Fluid Level

fluid level Referto page 7-18 brake/clutch

CheckingPowerSteering Fluid Level

Check the fluid level in the power steering periodically; reservoir it shouldbe between HIGH and LOW on the reservoir. lf the levelis low,add fluidto the HIGHlevel.

CAUTION To avoid damage to the power steering pump, do not operate the vehicle for prolonged periods with a low power steering fluid level.

In the eventthe power steeringsystemrequires frequent supplies of fluid,the vehicle NOTE powersteering shouldbe inspected by an Authorized Xedos Useonlyspecified fluid.(ReDealer. fer to chart on page 7-43.)

7-20

TRANSAXLE MANUAL CheckingManualTransaxle Oil Level ManualTransaxle Changing oil

1.6-litreengine on levelgroundand set 1. Parkthe vehicle Turnthe engine brakefirmly. the parking off. consensor the speedometer 2. Disconnect sensor the speedometer nector.Remove from the transaxle. sensor clean and 3. Wipethe speedometer reinsertit. 4. Pullit out again.The oil levelshouldbe betweenL and F, as illustrated. lf the levelis low, checkfor leaksbeforeaddingoil. Do not overfill.

1.6-litreengine 2.0-litre engine sensor conthe speedometer stands 1. Disconnect levelon safety 1. Position the vehicle sensor the speedometer nector.Remove or a chassishoist.Setthe parkingbrake from the transaxle. firmly. the drainplug and the washer 2. Removethe oil levelplug from the trans- z . Remove case. from the bottomof the transaxle axte case. reinAfterthe oil hasdrainedcompletely, The oil levelshould 3. Checkthe oil level. the drain and tighten stalla new washer be within6mm (0.24in) of the oil-level ptug. ptug. A sensor Add oilthroughthe speedometer hole until it reachesthe specifiedlevel. lf the levelis low, checkfor leaksbeforeadlnstall the soeedometersensor to the dingoil. senthe speedometer Connect transaxle. Do not overtill. sor connector.

7-21

MANUAL TRANSAXLE,AUTOMATICTRANSAXLE

CheckingAutomatic TransaxleFluid Level

2.0-litreengine 1. Remove the oil levelplug and washer. 2. Remove the drainplug and the washer from the bottom of the transaxlecase. rein3. Afterthe oil has drainedcompletely, stalla new washerand tightenthe drain plug. plugholeuntil 4. Add oilthrough theoillevel it reachesthe specifiedlevel. 5. Reinstall the oil level plug and new wasner. NOTE manual transaxle oil.(ReUseonlyspecified fer to chart on page 7-43.) The automatic transaxle fluidlevelshouldbe checked regularly. Take the following orecautions to measure the fluid level properly. The volume of the transaxle fluid changes with the temperature. For that reason,it is best to check the level after having driven the vehiclefor 30 minutes.lf necessary, however,the fluidcan alsobe checkedwhenthe vehiclehas not been driven. WARNING!

To avoid sudden movement of the vehicle, set the parking brake and depressthe brakepedal while shifting the selector lever.
CAUTION o Low fluid level causes transaxle slippage. Overfilling can cause foaming, loss of fluid, and transaxle malfunction. o The use of a nonspecified fluid could result in transaxle malfunction and failure.

Parkthe vehicle on levelgroundand set the parkingbrakefirmly. ldlethe engine for about2 minutes. Depressthe brake pedal; move the selector leverthroughall rangesand set it in P (Park)position. Withthe engine stillidling,pulloutthe dipstick,wipe it clean,and reinsert it fully. 4 . Pullthe dipstick out again.

7-22

AUTOMATIC TRANSAXLE

The properfluid levelis marked as follows. Use fluid scale @: lf the vehicle has beendrivenand the fluid is warmedto normaloperating temperature of approximately 65oC(149"F), the fluid level must be withinthe ($scale. Use fluid scale @: lf the enginehas not beenrunningand the outside temperature is approximately 20oC (68oF), the fluidlevelmustbe withinthe @ scale, NOTE Usethe cold scaleas a rough reference only. lf the outsidetemperature is lower than 20oC (68oF), startthe engineand measurethe fluidlevelafterletting the engine reach operatingtemperature. lf the vehiclehas been drivenfor an extended period at high speeds or in city trafficin hot weather,it is usuallybest to measure the fluid levelafterstoppingthe engineand allowing the fluidto cool for 30 minutes.

When inserting the dipstick, be sureto insertit completely. Whenaddingfluid,do so whilemeasuring with the dipstick to make surethe fluid leveldoes not go beyondthe Full position. Do not overfill. NOTE Use only the specifiedautomatic transaxle fluid.(Refer to chart on page 7-43.)

7-23

O TH ERL U B R I C A N T S A N D F L U ID S Checking Washer Fluid Level

Body Lubrication
All movingpoints of the body,suchas door and bonnethrngesand locks,should be lubricatedeach time the engine oil is changed.Use a nonfreezing lubricant on locksduringcold weather. Makesurethe enginebonnet's secondary latchkeepsthe bonnetfromopening when the primarylatch is released.

Checkfluid levelin the washerfluid reservoir and add fluid if necessary. Thetop of thefloatshouldbe between FULL and LOW. Plainwatermay be used if washerfluid is notavailable. However, usewashersolution in cold climates to prevent freezing.

WARNING! Do not use radiator coolant or antilreeze in the washer fluid reseruoir. Radiator coolant can severely affect visibility when sprayed on the windshield and may cause damage to paint and body trim.

7-24

AIR CLEANER Air Cleaner

ELEMENTREPLACEMENT A viscouspaperair cleaner filteris used.lt must be replacedwhen necessary, and it shouldnot be cleanedand reused.

1.6-litre engine 1. Unfasten the clamps of the air cleaner cover. 2. Wipethe inside of the aircleaner and cover with a damp cloth.

3. Replace the air cleaner element. 4. Installin the reverseorder of removal. Replace the element according to the Scheduled Maintenance Charts.

7-25

AIR CLEANER

2.0-litre engine 1. Removethe attachingbolts of the air cleanercover. of the aircleaner and cov2. Wipethe inside er with a damp cloth.

the air cleaner element. 3. Replace 4. lnstallin the reverseorder of removal. Replace the element according to the Maintenance Charts. Scheduled

NOTE dusty lf the vehicleis operatedin extremely or sandy areas,replacethis elementmore often than at the usual recommendedintervals. CAUTION Do not drive with the air cleaner removed or excessive engine wear will result. Driving without an air cleaner encourages backfiring, which could cause a fire in the engine compartment.

7-26

WIPER BLADES WiperBlades

WIPER BLADE MAINTENANCE CAUTION Gommercial hot waxes applied by automatic car washes have been known to affect the cleanability of the window. WINDSHIELD WIPERBLADE REPLACEMENT Whenthe wipersno longer cleanadequately,the wiperbladesmay be wornor cracked, requiring replacement.

CAUTION Contamination of eitherthe windowor the To prevent damage to the wiper arms or wiperbladeswith foreignmatter can reduce other components, do not attempt to the effectiveness of the windowwipers. Com- move the wipers manually. mon sourcesof contamination are insects, tree sap, and hot wax treatments used by somecommercial car washes. lf the blades are notwipingproperly, cleanboththe window and the bladeswitha good cleaner or mild detergent, and rinsethoroughly with clear water. Repeat if necessary. CAUTION To prevent damage to wiper blades, do not use petrol, kerosene,paint thinner, or other solvents on or near them.

1. Raisethe wiperarm and turn the wiper blade assemblyto expose the plastic lockingclip. Compress the clipand slidethe bladeassemblydownward; thenliftit offthe arm. CAUTION Do not allow the wiper arm to fall against the windshield.

7-27

WIPER BLADES

2. Fimly grasptheendofthebladerubber 3. Removethe metal retainers from the and pulluntilthetabsarefreeof the metal blade rubber and installthem in new support. blade rubber. CAUTION Do not bend the metal retainers.

4. Carefully insert a new bladerubberand install the bladeassemblyin the reverse order of removal. NOTE Install the bladeso that the tabs are toward the bottomof the wiper arm.

7-28

BATTERY Battery
hasa maintenance free YourXedosvehicle area. lf you teel a pain or a burnwabattery so you neverhaveto add distilled ing sensation, get medical attenter to it. tion immediately. lf you haveany problems withyour battery, c When working near a battery, Xedos have it checkedat your Authorized wear eye protection. Always proDealer. vide ventilation. WARNING! o KeeP lighted

cigarettes

and all

other flames or sparks away from the battery. Hydrogen, which is a highly combustible gas, is always present in battery cells. o Keep batteries out of the reach of children because batteries contain SULPHURIC ACID. Prevent its contact with skin, eyes, clothing, and the vehiele. It electrolyte gets into your eyes, tlush them with clean water tor at least 15 minutes and get immediate medical attention. If possible, continue to apply water with a sponge or cloth while en route to the medical office. lf electrolyte gets on your skin, thoroughly wash the contacted

When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners.

MAINTENANCE For best batteryservice: o Keep battery mounted. securely o Keep battery top cleanand dry. . Keepterminals and connections clean, jellyor tight,and coatedwith petroleum grease. terminal Rinse any spilledelectrolyte fromthe batteryimmediately witha solution of water
^^t dt ru h^t,l^^ ^^i^ udnil rg JUUd.

lf the vehicle is not goingto be usedfor an extended time,disconnect the battery caotes.

7-29

BATTERY,BELT TENSIONS

CheckingBelt Tensions
NOTE o Beforeperforming maintenance the battery,turn off all accessories and stopthe engrne. o The negative(-) batterycable must be removedfirstand installed lastif the battery is disconnected. (approxiApply moderate thumb pressure mately10 kg, 22 lbs,98N)midwaybetween pulleys,and check the deflection. WAHMNG! . Remove the key from

(1.6-litre engine)

the ignition switch before checking belt tension. Keep hair, loose clothing, neckties, necklaces,and similar articles away from drive belts, especially when the engine is running. ALWAYS REMOVE ALL ALTERNATOR DRIVE BELT TOOLS from the enginecompartDeflection ment before attempting to start New Used the engine. Any of the above itemscould becomeentangledin B-9mm 9-1Omm (0.31-0.35 in) (0.35-0.39 in) the belts and cause severepersonalinjury or damageto the veAdjustment hicle. or both.

NOTE lf thedrive worn, beltbecomes cracked, or frayed, it should be replaced.

1. Loosen the alternator mounting boltand adjusting bolt. 2. Movethe alternator to obtainproper belt tension. 3. Tighten the bolts and recheck the deflection.

7-30

BELTTENSIONS (2.0-litre engine)

POWER STEERTNG (P/S) PUMP DR|VE BELT

Deflection
New

(A/C) AND POWER A|R-CONDIT|ONER STEER|NG(P/S) PUMP DRTVE BELT*

Detlection New 8-9mm (0.31-0.35 in) Used 9-10mm (0.35-0.s9 in)

ALTERNATOR DRIVE BELT

Dellection New Used

B-9mm (0.31-0.35 in)

Used 9-10mm (0.35-0.39 in)

6-7mm (0.24-0.28 in)

7-Bmm (0.28-0.31 in)

Adiustment '1 . Loosenthe mountingbolt and locknuts. 2. f urn the adjustingbolt until the correct tensionis obtained. 3. Tightenthe locknuts and mountingbolt and recheck the deflection.

Adjustment Adjustment 1. Loosen the locknut. 1. Loosen the mounting boltand locknuts. 2" Turnthe adjusting bolt untilthe correct 2. Turn the adjusting bolt untilthe correct tensionis obtained. tensionis obtained. 3. Tightenthe locknut and recheckthe 3. Tighten the locknuts and mounting bolt deflection. and recheckthe deflection.

*somemodets. 7'31

BELT TENSIONS,SPARK PLUGS

SparkPlugs

Insulator

POWERSTEERTNG (P/S) PUMP DRTVE A|R-CONDtTtONER (A/C) AND BELT ALTERNAToR DRIVE BELT*
Deflection New Used 6-7mm 7-8mm (o.24-o.28 in) (0.28-0.31 in) Deflection New Used 5.5-6.5mm 6.5-7.5mm (0.22-0.26 in) (0 26-0.30 in)

lf necessary, cleanthe electrodes witha fine wirebrushand carefully scrape the carbon off the insulator with a smallfile. Thesparkplugsshouldthen be blownclean withcompressed air and the upper insulator wiped clean.

Adjustment 1. Loosenthe locknut. 2. f urn the adjusting bolt untilthe correct tensionis obtained. 3. Tighten the locknut and recheck the deflection.

Adjustment 1. Loosenthe locknut. 2. Turn the adjusting bolt untilthe correct tensionis obtained. 3. Tightenthe locknut and recheck the deflection.

7-32

*some modets.

SPARK PLUGS

SPARK PLUGS REPLACING WARNING!

The sparkplugs may be hot. Do not burn yourself.

thesparkplug 1. Clean anydirtfromaround base of each spark plug. 2. Remove the plugs with a spark plug wrench. each new plug by hand as far as 3. Install a spark plug it will go. lf necessary, lf CAUTION an extension. used as may be wrench remove r The spark plugs must be securely a plug does notturn in smoothly, tightened, but not overtightened. A it and try againto ensurethe correctenplug that's too loose can get very hot gagementof the threadson the spark and possibly damage the engine; one head. plug withthethreads in the cylinder that's too tight could damage the 4. Tighten the plugs with a spark plug threads in the cylinder head. wrench.Do not overtlghten. 5. Make surethe spark plug leadsare in- . Be sure the socket wrench is fit squarely over the spark p!ug. stalled in the correct order. Fastenthe overthe end of each plug. boot squarely

NOTE o Whenremoving the spark or unfastening plug cable leads,pullthe boot, not the lead itself. . When installing the plugs,use a small a m o u n t o f a n t i s e i z ec o m p o u n d o r on molybdenum-based threadlubricant the firstfew threads.

7-33

SPARK PLUGS, TYRES

Tyre Care
For proper performance, safety,and maximum fueleconomy,you mustalwaysmain1.6-litre engine tain recommended tyre inflationpressures and staywithin the loadlimits and weightdisNGK B K R s E 1 1B ,KR6E11 tribution recommended for vehicle. vour NIPPONDENSO K 1 6 P R - U 1K 1, 2OPR-U11 2.0-litre engine
BKRsE11 ,KR6E11 B B K R T E -1 1 K 1 6 P R . U 1K 1, 2OPR.U11 NIPPONDENSO K22PR-U11 NGK

RECOMMENDED SPARK PLUGS

CAUTION Never use spark plugs with an improper heat range; they will adversely affect engine performance and durability.

INFLATIONPRESSURES All tyre pressures(includingthe spare) shouldbe checkedmonthly whenthe tyres pressures arecold. Recommended mustbe maintained for the bestride,top vehicle handling,and minimumtyre wear. Refer to tyre inflation pressure charton page 9-4. NOTE . Warm tyres normally exceed recommended pressures.Do not releaseair from warm tyres to adjustthe pressure.

7-34

TYRES

wear, resultsin excessive Underinflation poor handling, reducedfuel economy, of blowoutsof overand the possibility can heatedtyres.Also,low tyre pressure of the tyre bead,lf the causepoorsealing low, wheel tyre pressureis excessively deformationand/or tyre separationare possible. at So keep your tyre pressures the proper levels.lf a tyre frequently have it checked by an needs refilling, Xedos Dealeror a tyre shop. Authorized producesa harshride,hanOverinflation dling problems,excessivewear at the TYRE ROTATION tread wear,it is recommended centre of the tyre tread, and a greater To equalize possibility of damagefrom road hazards. that the tyres be rotatedevery 10,000 km (6,000 miles)sooner if irregularwear develops. During rotation, check the tyresfor WARNING! Overinllation or underinflation can correct balance.

Use of unidirectional tyres of tyre rotationis decidedacThe direction cording to the tread pattern,which affects in wet conditions. the tyre's performance acThe unidirectional tyresmustbe installed These direction marks. to the rolling cording marks are molded into the side wall of the

ryres.
CAUTION Unidirectional tyres cannot be rotated from the right side of the vehicle to the left. lf they are rotated from right to left, tyre performancemay be reduced in wet conditions. NOTE Disc brake pads should be inspectedfor wear whenevertyres are rotated. CAUTION Rotate radial tyres that have an asymmetric tread pattern only from front to rear and not from right to left.

reduce tyre life, adversely affect vehicle handling, and lead to sudden tyre failure. This could result in loss of vehicle control.

When rotating tyres,checkfor unevenwear and damage. Abnormalwear is usually improper tyre pressure, causedby incorrect wheels,or wheel alignment, out-of-balance severe braking. Afterrotation, be sureto bringthe frontand rear tyre pressuresto specificationand check lug nut tightness.

7-35

TYRES SpareTyre
Tread wear indrcator

New tread

Worn tread

TYRE REPLACEMENT lf the tyre is worn evenly, a treadwearindicatorwill appear as a soild band acrossthe tread.Replace the tyrewhen this happens. Replacement of an unevenlyworn tyre may be necessarybeforean indicatorband appears across the entyretread.

wheels are the same size and Checkthe sparetyre at leastmonthlyto be have the same load-carrying ca- sure it is properly inflatedand stored sepacity. Use only tyre and wheel curery. combinations recommendedon the tyre label or by an Authorized Xedos Dealer. Failure to follow these precautionscan adversely affect the satety and handling of your vehicle. The useof any other tyre size or type may seriously aftect ride, handling, ground clearance, tyre clearance,and speedometer calibration. Driving on worn-out tyres is very hazardous and will reduce braking effectiveness, steering accuracy, and traction.

. When replacing tyres, never mix radial, bias-belted,and bias-type tyres. Useonly the tyre sizes listed on the tyre label attached to your vehicle, an the driver's door. Make sure that all tyres and 7-36

WARNING!

WHEELS, LIGHTBULBS Wheels

WHEEL REPLACEMENT When replacingwheels for any reason, make surethe new wheelsare eouivalent to original factory unitsin diameter, rim width, and offset. provides Proper tyrebalancing the bestriding comfort and helps reduce tyre tread wear.Out-of-balance tyrescan causeannoying vibration and uneventyre wear,such as cupping and flat spots. CAUTION A wrong-sized wheel may adversely affect wheel life and bearing life, braking and stopping abilities, handling characteristics, ground clearance, body-to-tyre clearance, snow chain clearance, speedometer calibration, headlight aim, and bumper height.

Headlights
Yourvehicle's headlights havereplaceable halogenbulbs.A burned-out bulb can be replacedwithoutdisturbing the headlight body.

HALOGENBULBS gas thal Halogenbulbscontainpressurized willproduce flyingpieces of glassif broken. Always handle them carefullyand avoid scratches and abrasion. lf the bulbsare lit, avoidtheircontact withliquids. Nevertouch the glasswith barehands. Residual oil may causethe bulb to overheat and burstwhen lit.A bulbshouldbe operated onlywheninin a headlight. stalled lf a bulbbecomes damaged or cracked, replaceit immediately and carefully dispose of it. Keep bulbs out of the reach of children.

7-37

LI G HTBU L BS

HALOGENHEADLIGHTBULB REPLACEMENT WARNING! Wear eye protection when changing a bulb. Allow the bulb to cool before handling it. 1. Makesure the headlight switchis off. 2. Lift the bonnet and locatethe bulb installed in the rearof the headlight body. 3. Unfasten the clip of the sealinocover.

4 . Pinchthe snapringand,cgrefully remove the headlight bulbfrom its socketin the reflector by gentlypullingit straight backward out of the socket.Do not rotate the bulb while removing it. ( Remove the electrical connector fromthe bulb by pullingit. 6. Install the new bulb in the reverse order of removal.

7-38

LIGHTBULBS

5j'

NOTE . Do not touch the glassportionof the bulb. o Install the bulb properly. o Installthe sealingcover properly. . Checkthe aim of the headlights and adjust if necessary. . Use the protective cover and carton to promptly disposeof the old bulb. . Your Xedos Dealerwill be oleasedto carry out this operationon your behalf.

7-39

LI G HT B U L BS Bulb Replacement(Front)

7'4O

*Some models

LIGHTBULBS (Rear) Bulb Replacement

\,----_---_-

ffi

*some modets. 7'41

LI G HT BU L BS

Bulb Replacement (lnterior)

7-42

LUBRICANT SPECI FICATIONS Recommended Lubricants

Lubricant Engine oil. Manualtransaxle oil* Automatic transaxle fluio Power steeringf l u i d Brake/clutch fluid Classification API ServiceSG API ServiceGL-4 or GL-5 ATF M-lll or Dexron-ll ATF M-lll or Dexron'll To helpachieveproperengineand powertrainperformance and durability, use only lubricaling oilsof the properquality. Thecorrect oils also help promoteengine efficiency that resultsin improvedfuel economy. Engine oils labeledEnergyConserving Oil are now available.They contributeto fuel economy by reducingthe amount of fuel necessary to overcomeenginefrictionand in otherways. Oftentheseimprovements are difficult to measure in everyday driving, but in a year'stime,theycan offersignificant cost and energy savings. Theseoils are recommended for use in conjunction with the recommendedAPI classif ication.

SAE J1703 or FMVSS116 DOT-3 * Referto the recommendedSAE viscositynumbers on the next page.

7-43

LUBRICANTSPECIFICATIONS

Recommended SAE ViscosityNumbers

Temperature Rangefor SAE ViscosityNumbers
-U lemperalure ,^-. '

-30 -20

-20 0

-10 20

0 40

10 60

20

30 80

40 1oo

(-r)

50 120

Engineoil

llii]llr::,1: rrii:1rrll:tl irlll:li:lill

<--

lomo

:c"isl

:rir;llilrta itrllllllr a,r:ar:i.:1ii: ,,,lll,,l:ll, i;ilai't:i,til

Manualtransaxle oil

l:fil.rl

t;,t:t::,1

chart.

Engineoil viscosity (thickness) hasan effect on fuel economyand cold-weather operation(starting and oilflow).Lower-viscosity engine oils can provide betterfuel economy performance; and cold-weather however, higher-temperature weatherconditionsrequirehigher-viscosity engineoilsfor satisfactory lubrication. Using oils of any viscosity otherthanthoserecommended could result in enginedamage. Whenchoosing an oil, consider the range of temperature your vehiclewill be operated in before the next oil change.Then selectthe recommended oil viscosity from the

l i I I | I I I I | | I

CAUTIONBEFORECHECKINGLUBRICANTS Alwaysbe sureto cleanthe area aroundany fillerplug, drainplug,and dipstick before checking or draining any lubricant. Thisis especially important in dusty/sandy areasand whenthe vehicle is usedon unpavedroads. Cleaning the plugand dipstick areas willprevent dirt and grit from entering the engineand other mechanisms thev could damaoe.

7-44

I I

TROUBLESHOOTING MinorTroublaahootlng Gulde

pro<:or lttter:trrayltelp lf any of The following the problemslis:[rtllrekrw clrolrlrloccur These suggesli<lrrrr rlre lnlcrrrlerJ only as emergency mo{ll}urriEi lf you are In doubt whetherthe protrkrnr In frrllynnrrccled, see your AuthorizorJ Xnrtrc l)celeree Boonas possible. MinorprolrlenrGi rnHylecd to serious ones, if no6;ltxller l, ENGINESTARTS, BUT ... lf the oil pressure warning light comes on, inspect these items: 1. Engineoil level. 2. Electric circuitand switch. lf accelerationis poor, inspect theseitems: 1. lgnition including system spark plugs. 2. Air cleanerelement. 3. Fuelline and intakeair system.

lf overheatingoccurs, inspecttheseitems: 1. Radiator level. coolant lf the alternatorwarning light comes on, 2. Restriction of airflowthrough radiator. inspectthese items: 3. Drive belt tensionand condition. ENGINEWILL NOT ETART 1. Drivebelt,to see that it is not broken 4. Radiator electric coolingfan. or does not need adjustment. 5. Engineoil level. lf the englne wlll not lurn ovlr, Inepect 2. Alternator. 6. Thermostat. these items: 3. Batteryand connections. 1. lgnition swilclr, lf a flat spot occurs when acceleratingn 2. Fuses, inchrrllrrg ttteelilrmkIn tho en- lf stalling occurs while idling, inspect inspect these items: gine comprrtlitiettt, theseitems: 1. Fuellinesand filter. 3. Battery 1. Sparkplugs. ancit:orrrrecllstrs, 2. Air cleanerelement. 4. Cable conrror;liorrc 2. Throttle body (adjustment by an Autho- 3. Throttlebody (by an Authorized Xedos lR clcrter, rized Xedos Dealer). Dealer). lf engine turnr ovrr lrre;ta:l lhoeeitems: 3. Fuelline and intakeair system. 1. Fuelgaul;tt, kt eeethat tlte tank is not ll full engine power is not obtained, inlf idling is rough, lnspectthese items: empty. spect these items: 2 . l g n i t i o n s y u l o r r r r l l a t r l b u t o r l e a d s ,1 c .o i lA . ircleanerelement. 1. Alrcleanerelementandfu f ie l tl e r . 3. SparkplLrgtr. 2. Sparkplugs. 2. Sparkplugs and ignition system. 4. Fuel linontttl lttlakcelr ayetem. 3. Throttlebody(adjustmentbyanAutho3. Fuelline and intakeair system. rizedXedos Dealer).

7-45

TROUBLESHOOTING

ELECTRICAL SYSTEMPROBLEMS... lf a light does not come on, inspect these rtems. 1. Bulb and fuse. 2. Terminal connections and svstem ground. lf Braking-Steering coordination is poor... The braking and steeringsystemsform an integrated system.lf you detect a malfunction in any of their components,have your vehicle inspected immediately at yourAuthorized Xedos Dealer.

7-46