MAINTENANCE - Tune Up & Maintenance

Recommended lubricants and fluids:

Engine oil
Type - API grade or SF/CC multi-grade and fuel efficient oil.
Capacity(approx) - 4.0 litres.
Fuel
Type - Unleaded gasoline, 87 or higher on GSL models, and highest available for GSR Turbo models recommended (at least 95 octane)
Transmission
Automatic transmission fluid - Dexron II automatic transmission fluid
Total capacity (approx) - 5.71 litres
Refill capacity after fluid change (approx) - 4.0 litres
Manual transmission fluid - API GL-5 SAE 75/85W gear oil
Capacity (approx) - 2.0 litres
Brakes
Brake fluid type - DOT 3 brake fluid
Other
Power steering system fluid - Dexron II automatic transmission fluid
Real wheel bearing grease - NLGI No.2 EP wheel bearing grease

Ignition system
Spark plugs
Type
G62B 1.8L and G32B 1.6L engines - BPR7ES-11
All others - BPR6ES-11
Gap
Turbos - 0.7 to 0.8mm
Non-turbo - 1.0 to 1.1mm
Firing order - 1-3-4-2 (number 1 cylinder is at drive-belt end of engine)

Cooling System
Coolant capacity - 5.0 Litres
Thermostat rating
Starts to open - 88 degrees C (190 degrees F)
Fully open - 100 degrees C (212 degrees F)
Drive-belt deflection
1/4 to 3/8 inch (7 to 9mm)

Clutch (cable-operated)
Clutch pedal free-play - 1 inch (25mm)
Adjusting nut to insulator projection clearance - 1/8inch (3.175mm)

Brakes
Disc brake pad lining thickness (minimum) - 1/8 inch (3.175mm)
Drum brake shoe lining thickness - 1/8 inch (3.175mm)

Steering wheel free-play limit - 1 inch (26mm)

Valve clearances (engine hot)
Intake valve - 0.006 inches (0.15mm)
Exhaust valve - 0.010 inches (0.25mm)
Jet valve - 0.010 (0.25mm)

Torque Specifications
Automatic transmission
Pan bolts - 8
Filter bolts - 7
Drain plug - 25
Manual transmission drain and filter plugs - 25
Engine oil pan drain plug - 33
Spark plugs - 15 to 21
Wheel lug nuts - 65 to 80
Rear wheel bearing spindle nut
Step 1 - 12
Step 2 - Loosen to 0
Step 3 - 4 to 7
Self locking nut - 72 to 108

If, from the time the vehicle was new, the routine maintenance schedule is followed closely and frequent checks are made of fluid levels and high wear items, the engine will be kept in relatively good running condition and the need for additional work will be minimized.
More likely than not, however, there will be times when the engine is running poorly due to the lack of regular maintenance. In such cases, an engine tune-up will be needed outside of the regular routine maintenance intervals. The first step in any tune-up or diagnostic procedure to help correct a poor running engine is a cylinder compression check. This check will help determine the condition of the internal engine components and should be used as a guide for tune-up and repair procedures. For instance, if a compression check indicates serious internal engine wear, a conventional tune-up will not improve the performance of the engine and would be a waste of time and money. Because of its importance, the compression check should be done by someone with the right equipment and the knowledge to use it properly.
The following procedures are those often needed to bring a generally poor engine back into a proper state of tune.

 

Minor tune-up

Clean, inspect and test the battery
Check all engine related fluids
Check and adjust the drive-belts
Replace the spark plugs
Inspect the distributor cap and rotor
Inspect the spark plug and coil wires
Check and adjust the idle speed
Check the PCV valve
Check the air filter
Check the cooling system
Check all under-hood hoses

 

Major tune-up

All items listed under minor tune-up plus....
Check the EGR system
Check the ignition system
Check the charging system
Check the fuel system
Replace the air filter
Replace the distributor cap and rotor
Replace spark plug wires

Scott,
BOOSTU