MARUTI SUZUKI Zen Estilo 2018 User manual

Volume 1
Precautions ........................................................ 00-i
Precautions ......................................................... 00-1
General Information ............................................ 0-i
General Information ........................................... 0A-1
Maintenance and Lubrication............................. 0B-1
Engine ................................................................... 1-i
Precautions .......................................................... 1-1
Engine General Information and Diagnosis....... 1A-1
Aux. Emission Control Devices .......................... 1B-1
Engine Electrical ................................................ 1C-1
Engine Mechanical ............................................ 1D-1
Engine Lubrication System ................................ 1E-1
Engine Cooling System ...................................... 1F-1
Fuel System ....................................................... 1G-1
Ignition System .................................................. 1H-1
Starting System ................................................... 1I-1
Charging System ................................................ 1J-1
Exhaust System .................................................. 1K-1
Suspension .......................................................... 2-i
Precautions ........................................................... 2-1
Suspension General Diagnosis .......................... 2A-2
Front Suspension ............................................... 2B-1
Rear Suspension ............................................... 2C-1
Wheels and Tires ............................................... 2D-1
Front Drive Shaft ................................................. 3-i
Front Drive Shaft ................................................ 3A-1
Brakes ................................................................... 4-i
Brakes ................................................................... 4-1
Brakes (With ABS) .............................................. 4A-1
ABS ..................................................................... 4B-1
Transmission ....................................................... 5-i
Manual Transmission .......................................... 5B-1
Clutch ................................................................. 5C-1
Volume 2
Precautions ........................................................ 00-i
Precautions ........................................................ 00-1
Steering ................................................................ 6-i
Steering General Diagnosis ............................... 6A-1
Steering Wheel and Column .............................. 6B-1
Electrical Power Steering System ..................... 6C-1
HVAC ...................................................................... 7-i
Precautions ........................................................... 7-1
Heater and Ventilation ........................................ 7A-1
Air Conditioning System ..................................... 7B-1
Restraint ............................................................... 8-i
Seat Belts ............................................................ 8A-1
Air Bag System ................................................... 8B-1
Body, Cab and Accessories ............................... 9-i
Precautions ........................................................... 9-1
Wiring Systems .................................................. 9A-**
(Refer wiring Diagram manual Part
No.99512M59K00-74E)
Lighting Systems ................................................ 9B-1
Instrumentation / Driver Info. / Horn .................. 9C-1
Wipers / Washers ............................................... 9D-1
Glass / Windows / Mirrors................................... 9E-1
Security and Locks ............................................. 9F-1
Seats .................................................................. 9G-1
Interior Trim ........................................................ 9H-1
Hood / Fenders / Doors ...................................... 9J-1
Body Structure .................................................... 9K-1
Paint / Coatings................................................... 9L-1
TABLE OF CONTENTS

IMPORTANT
Warning/Caution/Note
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted
bythese signal words.
Warning:
Indicates a potential hazard that could result in death or injury.
Caution:
Indicates a potential hazard that could result in vehicle damage.
Note:
Indicates special information to make maintenance easier or instructions clearer.
Warning:
This service manual is intended for authorized MARUTI dealers and qualified service technicians
only. Inexperienced technicians or technicians without the proper tools and equipment may not be
able to properly perform the services described in this manual.
Improper repair may result in injury to the technician and may render the vehicle unsafe for the
driverand passengers.
Warning:
For vehicles equipped with a Supplemental Restraint or Air Bag System:
••
••
•Service on and around the air bag system components or wiring must be performed only by an
authorized MARUTI dealer. Refer to “Air Bag System Components and Wiring Location View” un-
der “General Description” in air bag system section in order to confirm whether you are perform-
ing service on or near the air bag system components or wiring. Please observe all WARNINGS
and “Service Precautions” under “On-Vehicle Service” in air bag system section before perform-
ing service on or around the air bag system components or wiring. Failure to follow WARNINGS
could result in unintentional activation of the system or could render the system inoperative.
Either of these twoconditions may result in severe injury.
••
••
•If the air bag system and another vehicle system both need repair, MARUTI recommends that the
air bag system be repaired first, to help avoid unintended air bag system activation.
••
••
•Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
••
••
•If the vehicle will be exposed to temperatures over 93°C (200°F), for example, during a paint bak-
ing process, remove the air bag system components, that is air bag or inflator modules, SDM and/
or seat belt with pretensioner, beforehand to avoid component damage or unintended activation.

FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major components
(Unit Repair-Overhaul).
VOLUME 1 contains General information, Engine, Suspension, Drive/Shaft, Brakes and Transmission/sections
(Sections 0 – 5).
VOLUME 2 contains Steering, HVAC, Restraint and Body/Cab/Accessories and
Control Systems sections (Sections 6 – 9).
Applicable model:
ZEN Estilo(PK 410) vehicles on and after following vehicle identification numbers (VINs).
The contents are classified into sections each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use MARUTI genuine parts, tools
and service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product
information
available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
MARUTI UDYOG LIMITED
SERVICE DIVISION

TABLE OF CONTENTS 00-i
Section 00
Precautions
CONTENTS
Precautions ....................................................... 00-1
Precautions .................................................... 00-1
Precautions for Vehicles Equipped with ....... 00-1
General Precautions .................................... 00-4
Precautions for Catalytic Converter ............. 00-6
Precautions for Electrical Circuit Service ..... 00-7
Electrical Circuit Inspections Procedure ...... 00-8
Intermittent and Poor Connection
Inspection ................................................... 00-11
Air Bag Warning ......................................... 00-13
Air Bag System Service Warning ............... 00-13
Fastener Caution ........................................ 00-13
Suspension Caution ................................... 00-13
Wheels and Tires Caution .......................... 00-14
Brake Caution ............................................ 00-14

Precautions 00-1
Precautions
Precautions
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
Warning:
••
••
•The configuration of air bag system parts are as shown in the figure. When it is necessary to
service (remove, reinstall and inspect) these parts, be sure to follow procedures described in Air
Bag System section. Failure to follow proper procedures could result in possible air bag system
activation, personal injury, damage to parts or air bag system being unable to activate when
necessary.
••
••
•If the air bag system and another vehicle system both need repair, MARUTI recommends that the
air bag system be repaired first, to help avoid unintended air bag system activation.
••
••
•Do not modify the steering wheel, dashboard, or any other air bag system components.
Modifications can adversely affect air bag system performance and lead to injury.
••
••
•If the vehicle will be exposed to temperatures over 93 °C (200 °F) (for example, during a paint
baking process), remove the air bag system components beforehand to avoid component damage
or unintended air bag system activation.
Diagnosis
••
••
•When troubleshooting air bag system, be sure to follow
“Diagnosis” in Air Bag System section. Bypassing these
procedures may result in extended diagnostic time,
incorrect diagnosis, and incorrectparts replacement.
••
••
•Never use electrical test equipment other than that
specified.
Warning:
Never attempt to measure the resistance of the air bag
(inflator) modules (driver and passenger) and seat belt
pretensioners (driver and passenger). It is very
dangerous as the electric current from the tester may
deploy the air bag or activate the pretensioner.
Example

00-2 Precautions
••
••
•For handling and storage of a live air bag (inflator)
module,select a place where the ambient temperature below
65 °C (150 °F),without high humidity and away from electric
noise.
••
••
•When carrying a live air bag (inflator) module, make sure the
bag opening is pointed away from you. In case of an accidental
deployment, the bag will then deploy with minimal chance of
injury. Never carry the air bag (inflator) module by the wires
or connector on the underside of the module. When placing
a live air bag (inflator) module on a bench or other surface,
always face the bag up, away from the surface. As the live
passenger air bag (inflator) module must be placed with its
bag (trim cover) facing up, place it on the workbench with a
slit (1) or use the workbench vise (2) to hold it securely at its
lower mounting bracket (3). It is also prohibited to place
anything on top of the trim cover and stack air bag (inflator)
modules. This is necessary so that a free space is provided
to allow the air bag to expand in the unlikely event of
accidental deployment. Otherwise, personal injury may result.
••
••
•Never dispose of live (undeployed) air bag (inflator) modules
(driver and passenger). If disposal is necessary, be sure to
deploy them according to deployment procedures described
in “Air Bag (Inflator) Module and Seat Belt Pretensioner
Disposal: in Section 8B” before disposal.
••
••
•The air bag (inflator) module immediately after deployment
is very hot. Wait for at least half an hour to cool it off
beforeproceeding the work.
••
••
•After an air bag (inflator) module has been deployed, the
surface of the air bag may contain a powdery residue. This
powder consists primarily of cornstarch (used to lubricate
the bag as it inflates) and byproducts of the chemical reaction.
As with many service procedures, gloves and safety glasses
should be worn.
Servicing and Handling
Warning:
Many of service procedures require disconnection of “A/BAG”
fuse and all air bag (inflator) module(s) from initiator circuit to
avoid an accidental deployment. Driver, Passenger, Side and
Curtain Air Bag (Inflator) Modules

Precautions 00-3
Warning:
SDM
••
••
•For handling and storage of a SDM, select a place where the ambient temperature below 65 °C
(150°F), without high humidity and away from electric noise.
••
••
•During service procedures, be very careful when handling a Sensing and Diagnostic Module
(SDM). Never strike or jar the SDM.
••
••
•Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM
and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward
the front of the vehicle to ensure proper operation of the air bag system. The SDM could be
activated when powered while not rigidly attached to the vehicle which could cause deployment
and result in personal injury.
Warning:
Driver and Passenger Seat Belt
••
••
•For handling and storage of a live seat belt pretensioner, select a place where the ambient
temperature below 65 °C (150 °F), without high humidity and away from electric noise.
••
••
•Never carry seat belt pretensioner by wire or connector of pretensioner. When placing a live seat
belt pretensioner on the workbench or some place like that, never put something on seat belt
pretensioner. Otherwise, personal injury may result.
••
••
•Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If disposal is
necessary, be sure to activate them according to activation procedures described in “Air Bag
(Inflator) Module and Seat Belt Pretensioner Disposal: in Section 8B” before disposal.
••
••
•The seat belt pretensioner immediately after activation is very hot.Wait for at least half an hour to
cool it off before proceeding the work.
••
••
•With many service procedures, gloves and safety glasses should be worn to prevent any possible
irritation of the skin or eyes.
••
••
•Even when the accident was light enough not to cause air bags to activate, be sure to inspect
system parts and other related parts according to instructions under “Repair and Inspection
Required after Accident: in Section 8B”.
••
••
•When servicing parts other than air bag system, if shocks may be applied to air bag system
component parts, remove those parts beforehand.
••
••
•When handling the air bag (inflator) modules (driver and passenger), seat belt pretensioners
(driver and passenger), forward sensor or SDM, be careful not to drop it or apply an impact to it.
If an excessive impact was applied, never attempt disassembly or repair but replace it with a new
one.
••
••
•When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and
passenger) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry
cloth.
••
••
•Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire harness
branched off from floor and instrument panel wire harnesses can be identified easily as it is
covered with a yellow protection tube and it has yellow connectors. Be very careful when handling
it.
••
••
•When an open in air bag wire harness, damaged wire harness, connector or terminal is found,
replace wire harness, connectors and terminals as an assembly.
••
••
•Do not apply power to the air bag system unless all components are connected or a diagnostic
flow requests it, as this will set a DTC.
••
••
•Never use air bag system component parts from another vehicle.
••
••
•When using electric welding, be sure to disconnect all air bag (inflator) module connectors and
pretensioner
connectors from air bag wire harness respectively.
••
••
•Never expose air bag system component parts directly to hot air (drying or baking the vehicle
after painting) or flames.
••
••
•WARNING / CAUTION labels are attached on each part of air bag system components. Be sure to
follow the instructions.
••
••
•After vehicle is completely repaired, perform “Air Bag Diagnostic System Check: in Section 8B”.

00-4 Precautions
Precautions
General Precautions
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.
Warning:
••
••
•Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” on SECTION 0A.
••
••
•When it is necessary to do service work with the engine running, make sure that the parking
brake is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park
(for automatic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan
and belts when the engine is running.
•When it is necessary to run the engine indoors, make sure that the exhaust gas is forced to
stream outdoors.
•Do not perform service work in areas where combustible materials can come in contact with a
hot exhaust system. When working with toxic or flammable materials (such as gasoline and
refrigerant), make sure that the area you work in is well-ventilated.
•To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.
•New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new
or used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory
animals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine
oil, wear a long-sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when
changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder
any clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.
Caution:
•Before starting any service work, cover fenders, seats
and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g. buttons) may cause damage to the vehicle’s
finish.
•When performing service to electrical parts that does
not require use of battery power, disconnect the
negative cable of the battery.

Precautions 00-5
Caution:
•When removing the battery, be sure to disconnect the
negative cable first and then the positive cable.When
reconnecting the battery, connect the positive cable
first and then the negative cable, and replace the
terminal cover.
•When removing parts that are to be reused, be sure
to keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and
position.
•Whenever you use oil seals, gaskets, packing, O-rings,
locking washers, split pins, self-locking nuts, and
certain other parts as specified, be sure to use new
ones. Also, before installing new gaskets, packing,
etc., be sure to remove any residual material form the
mating surfaces.
•Make sure that all parts used in reassembly are
perfectly clean.
•When use of a certain type of lubricant, bond or
sealant is specified, be sure to use the specified type.
“A”: Sealant 99000-31150
•Be sure to use special tools when instructed.
Special Tool
(A): 09917M98221
(B): 09916M58210

00-6 Precautions
Caution:
•When disconnecting vacuum hoses, attach a tag
describing the correct installation positions so that
the hoses can be reinstalled correctly.
•After servicing fuel, oil, coolant, vacuum, exhaust or
brake systems, check all lines related to the system
for leaks.
•For vehicles equipped with fuel injection systems,
never disconnect the fuel line between the fuel pump
and injector without first releasing the fuel pressure,
or fuel can be sprayed out under pressure.
Precautions For Catalytic Converter
For vehicles equipped with a catalytic converter, use only
unleaded gasoline and be careful not to let a large amount
of unburned gasoline enter the converter or it can be
damaged.
– Conduct a spark jump test only when necessary, make
it as short as possible, and do not open the throttle.
– Conduct engine compression checks within the
shortest possible time.
– Avoid situations which can result in engine misfire.
(e.g. starting the engine when the fuel tank is nearly
empty.)

Precautions 00-7
Precautions For Electrical Circuit Service
•When disconnecting and connecting coupler, make
sure to turn ignition switch OFF, or electronic parts
may get damaged.
•Be careful not to touch the electrical terminals of parts
which use microcomputers (e.g. electronic control
unit like as ECM, PCM, P/S controller, etc.).The static
electricity from your body can damage these parts.
•When disconnecting couplers, don’t pull wire harness
but make sure to hold coupler itself. With lock type
coupler, be sure to unlock before disconnection.
Attempt to disconnect coupler without unlocking may
result in damage to coupler. When connecting lock
type coupler, insert it till clicking sound is heard and
connect it securely.
•Never connect any tester (voltmeter, ohmmeter, or
whatever) to electronic control unit when its coupler
is disconnected. Attempt to do it may cause damage
to it.
•Never connect an ohmmeter to electronic control unit
with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.
•Be sure to use a specified voltmeter/ohmmeter.
Otherwise, accurate measurements may not be
obtained or personal injury may result. If not specified,
use a voltmeter with high impedance (Mˆ´V minimum)
or a digital type voltmeter.
•When taking measurements at electrical connectors
using a tester probe, be sure to insert the probe (2)
from the wire harness side (backside) of the connector
(1).

00-8 Precautions
•When connecting meter probe (2) from terminal side
of coupler (1) Since it can’t be connected from
harness side, use extra care not to bend male terminal
of coupler or force its female terminal open for
connection.
In case of such coupler as shown, connect probe as
shown to avoid opening female terminal.
Never connect probe where (3) male terminal is
supposed to fit.
•When checking connection of terminals, check its
male half for bend and female half for excessive
opening and both for locking (looseness), corrosion,
dust, etc.
•Before measuring voltage at each terminal, check to
make sure that battery voltage is 11V or higher. Such
terminal voltage check at low battery voltage will lead
to erroneous diagnosis.
Electrical Circuit Inspections Procedure
While there are various electrical circuit inspection methods,
described here is a general method to check its open and short
circuit by using an ohmmeter and a voltmeter.
Open Circuit Check
Possible causes for the open circuit are as follows. As the cause
is in the connector or terminal in many cases, they need to be
checked particularly carefully.
•Loose connection of connector
•Poor contact of terminal (due to dirt, corrosion or rust
on it, poor contact tension, entry of foreign object
etc.)
•Wire harness being open

Precautions 00-9
When checking system circuits including an electronic control
unit such as ECM, TCM, ABS control module, etc., it is important
to perform careful check, starting with items which are easier to
check.
1) Disconnect negative cable from battery.
2) Check each connector at both ends of the circuit being checked
for loose connection. Also check lock condition of connector if
equipped with connector lock.
3) Using a test male terminal, check all terminals of the coupler.
Check each terminal visually for poor contact (possibly caused
by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.
4) Using continuity check or voltage check procedure described
in the following, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.
Continuity check
1) Measure resistance between connector terminals at both ends
of the circuit being checked (between A-1 and C-1 in the figure).
If no continuity is indicated i. e. renistance is (infinity or over
limit), that means that the circuit is open between terminals A-
1 and C-1.
2) Disconnect the connector included in the circuit (connector-B
in the figure) and measure resistance between terminals A-1
and B-1.
If no continuity is indicated, that means that the circuit is open
between terminals A-1 and B-1. If continuity is indicated, there
is an open circuit between terminals B-1 and C-1 or an
abnormality in connector-B.

00-10 Precautions
Voltage check
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
1) With all connectors connected and voltage applied to the circuit
being checked, measure voltage between each terminal and
body ground.
If measurements were taken as shown in the figure at the left and
results were as listed below, it means that the circuit is open
between terminals B-1 and A-1.
Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: 0V
Also, if measured values were as listed below, it means that there
is a resistance (abnormality) of such level that corresponds to the
voltage drop in the circuit between terminals A-1 and B-1.
Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V 2V voltage drop
A-1 and body ground: Approx. 3V
Short Circuit CHECK (Wire harness to ground)
1) Disconnect negative cable from battery.
2) Disconnect connectors at both ends of the circuit to be checked.
Note:
If the circuit to be checked is connected to other parts,
disconnect all connectors of those parts.
Otherwise, diagnosis will be misled.
3) Measure resistance between terminal at one end of circuit (A-
1 terminal in figure) and body ground. If continuity is indicated,
it means that there is a short to ground between terminals A-
1 and C-1 of the circuit.

Precautions 00-11
4) Disconnect the connector included in circuit (connector B) and
measure resistance between A-1 and body ground.
If continuity is indicated, it means that the circuit is shorted to
the ground between terminals A-1 and B-1.
Other wise it means that circuit is shorted to the ground
between terminals B-1 and C-1.
Intermittents And Poor Connection
Most intermittents are caused by faulty electrical connections or
wiring, although a sticking relay or solenoid can occasionally be
at fault. When checking it for proper connection, perform careful
check of suspect circuits for:
•Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
•Dirt or corrosion on the terminals. The terminals must be
clean and free of any foreign material which could impede
proper terminal contact.
However, cleaning the terminal with a sand paper or the
like is prohibited.
•Damaged connector body, exposing the terminals to
moisture and dirt, as well as not maintaining proper
terminal orientation with the component or mating
connector.

00-12 Precautions
•Improperly formed or damaged terminals.
Check each connector terminal in problem circuits
carefully to ensure good contact tension by using the
corresponding mating terminal.
If contact tension is not enough, reform it to increase
contact tension or replace.
•Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor
connection by shaking it by hand lightly. If any abnormal
condition is found, repair or replace.
•Wire insulation which is rubbed through, causing an
intermittent short as the bare area touches other wiring
or parts of the vehicle.
•Wiring broken inside the insulation. This condition could
cause continuity check to show a good circuit, but if only
1 or 2 strands of a multi-strand-type wire are intact,
resistance could be far too high.
If any abnormality is found, repair or replace.

Precautions 00-13
Air Bag Warning
Warning:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
••
••
•Service on and around the air bag system components or wiring must be performed only by an
authorized MARUTI dealer. Refer to “Air Bag System Components, Wiring and Connectors Location:
in Section 8B” in order to confirm whether you are performing service on or near the air bag system
components or wiring. Please observe all WARNINGS and “Precautions on Service and Diagnosis of
Air Bag System: in Section 8B” before performing service on or around the air bag system components
or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could
render the system inoperative. Either of these two conditions may result in severe injury.
••
••
•Technical service work must be started at least 90 seconds after the ignition switch is turned to the
LOCK position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
Air Bag System Service Warning
Warning:
••
••
•Service on or around the air bag system components or wiring must be performed only by an
authorized MARUTI dealer. Please observe all WARNINGS in Air Bag System and “Precautions on
Service and Diagnosis of Air Bag System: in Section 8B” before performing service on or around the
air bag system components or wiring. Failure to follow WARNINGS could result in unintended
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.
••
••
•The procedures in the air bag system section must be followed in the order listed to disable the air
bag system temporarily and prevent false DTCs from setting. Failure to follow procedures could
result in possible activation of the air bag system, personal injury or otherwise unneeded air bag
system repairs.
Fastener Caution
Caution:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the
conditions are not followed, parts or system damage couldm result.
Suspension Caution
Caution:
••
••
•All suspension fasteners are an important attaching part in that it could affect the performance of
vital parts and systems, and/or could result in major repair expense.They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of this part.
••
••
•Never attempt to heat, quench or straighten any suspension part. Replace it with a new part or
damage to the part may result.

00-14 Precautions
Wheels and Tires Caution
Caution:
All wheel fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/ or could result in major repair expense. They must be replaced with one of
the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.
Brake Caution
Caution:
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.

TABLE OF CONTENTS 0A-i
General Information ........................................ 0A-1
General Description ..................................... 0A-1
Abbreviations ............................................... 0A-1
Symbols....................................................... 0A-3
Metric Information ........................................ 0A-4
Vehicle Lifting Points.................................... 0A-6
Vehicle Identification Number ...................... 0A-8
Engine Identification Number ...................... 0A-8
Maintenance and Lubrication ......................... 0B-1
Periodic Maintenance Schedule ..................... 0B-1
Maintenance Service .................................... 0B-4
Water Pump Belt Inspection and
Replacement ............................................... 0B-4
A/C Compressor Belt Inspection and
Replacement ............................................... 0B-4
Camshaft Timing Belt Replacement ............ 0B-5
Valve Lash (Clearance) Inspection .............. 0B-5
Engine Oil and Filter Change ...................... 0B-5
Engine Coolant Change .............................. 0B-7
Exhaust System Inspection ......................... 0B-7
Spark Plug Replacement ............................. 0B-9
Air Cleaner Filter Inspection ........................ 0B-9
Air Cleaner Filter Replacement ................... 0B-9
Fuel Lines Inspection .................................. 0B-9
Fuel Filter Replacement .............................. 0B-9
Fuel Tank Inspection .................................. 0B-10
PCV Valve Inspection ................................ 0B-10
Fuel Evaporative Emission Control System
Inspection .................................................. 0B-10
Brake Discs and Pads (Front) and Brake
Drums and Shoes (Rear) Inspection ......... 0B-10
Brake Hoses and Pipes Inspection............ 0B-11
Brake Fluid Replacement .......................... 0B-11
Brake Lever and Cable Inspection ............. 0B-12
Clutch Pedal Height Inspection
(Cable type only) ....................................... 0B-12
Tires and Wheel discs Inspection .............. 0B-12
Wheel Discs Inspection ............................. 0B-13
Wheel Bearing Inspection ......................... 0B-13
Drive Shaft (Axle) Boots Inspection ........... 0B-13
Suspension System Inspection ................. 0B-13
Steering System Inspection ....................... 0B-14
Manual Transmission Oil Inspection and
change....................................................... 0B-15
All Latches, Hinges and Locks Inspection . 0B-15
Final Inspection ......................................... 0B-16
Recommended Fluids and Lubricants ..... 0B-17
Section 0A
General Information
CONTENTS