LUBRICATION

AND
MAINTENANCE
Return to Main Table of Contents
SCHEDULED MAINTENANCE TABLE . . . . . . . . . . . . . . . . . . 2
RECOMMENDED LUBRICANTS AND CAPACITIES . . . . 4
MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
 SCHEDULED MAINTENANCE TABLE

SCHEDULED MAINTENANCE TABLE

RECOMMENDED CUSTOMER MAINTENANCE
The following maintenance services must be performed to assure proper emission control and performance. Keep
receipts for all vehicle emission service to keep your emission warranty in force.

Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.

R : REPLACE
l : INSPECT AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY

R : REPLACE
I : INSPECT AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
 SCHEDULED MAINTENANCE TABLE 10-3

MAINTENANCE UNDER SEVERE USAGE CONDITIONS

The following items must be serviced more frequently on vehicles normally used under severe driving conditions.
Refer to the chart below for the appropriate maintenance intervals.
(I = Inspect, correct or replace if necessary. R = Replace.)

MAINTENANCE DRIVING
MAINTENANCE ITEM MAINTENANCE INTERVALS
OPERATION CONDITION

EVERY 3,000 MILES

ENGINE OIL AND FILTER R A,B,C,F,H
(4,800 KM) OR 3 MONTHS

AIR CLEANER FILTER R MORE FREQUENTLY C,E

EVERY 24,000 MILES

SPARK PLUGS R B,H
(40,000 KM) OR 18 MONTHS

BRAKE PADS, CALIPERS, ROTORS I MORE FREQUENTLY C,D,G,H

REAR BRAKE DRUMS/LININGS I MORE FREQUENTLY C,D,G,H
EVERY 7,500 MILES
STEERING GEAR RACK LINKAGE & BOOTS I C,D,E,F
(12,000 KM) OR 6 MONTHS

EVERY 7,500 MILES

DRIVESHAFTS & BOOTS I C,E,F
(12,000 KM) OR 6 MONTHS

SEVERE DRIVING CONDITIONS

A- Repeated short distance driving
B- Extensive idling
C- Driving in dusty conditions
D- Driving in areas using salt or other corrosive materials or in very cold weather
E- Driving in sandy areas
F- More than 50% driving in heavy city traffic during hot weather above 90oF (32oC)
G- Driving in mountainous areas
H- Towing a trailer
10-4 RECOMMENDED LUBRICANTS AND CAPACITIES

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 API classification GL-4 or GL-5 SAE grade number:

SAE 75W-85W or SAE 75W-90W

Automatic transaxle GENUINE HYUNDAI AUTOMATIC MOPAR ATF PLUS TYPE 7176
TRANSMISSION FLUID, MOPAR ATF is recommended lubricant
PLUS TYPE 7176 OR DIAMOND ATF
SP.

Brake Conforming to DOT 3 or equivalent

Rear wheel bearing Multi-purpose grease NLGI

Grade #2, EP

Cooling system High quality ethylene glycol Concentration level 50%

Transaxle linkage, parking Multipurpose grease NLGI

brake cable mechanism, hood Grade #2
lock and hook, door latch, seat
adjuster, trunk latch, door hinges,
trunk hinges

Power steering DEXRON or DEXRON®ll type

LUBRICANTS CAPACITIES

Description Capacities Remarks

Engine oil
Oil pan 4.0 lit (4.2 U.S. qts., 3.5 Imp.qts.)
Oil filter 0.4 lit (0.42 U.S. qts., 0.35 Imp.qts.)
TotaI 4.4 lit (4.62 U.S. qts., 3.85 Imp.qts.)
Cooling system 5.0 lit (5.4 U.S. qts., 4.8 Imp.qts.)
Manual transaxle 1.8 lit (1.9 U.S. qts., 1.6 Imp.qts.)
Automatic transaxle 6.1 lit (6.4 U.S. qts., 5.4 Imp.qts.)
Power steering 0.9 lit (0.95 U.S. qts., 0.79 Imp.qts.)
 MAINTENANCE SERVICE 10-5

MAINTENANCE SERVICE
CHECKING ENGINE OIL
1. Position the vehicle on a level surface.
2. Warm up the engine.

NOTE
If a vehicle that has been out of service for a prolonged
period of time, warm up the engine for approximately 20
minutes.

3. Stop the engine, and wait 2 or 3 minutes, then check the

oil level after engine oil drains to the oil pan.
4. Check that the engine oil level is within the level range
indicated on the oil dipstick. If the oil level is found to have
fallen to the lower limit (the MIN mark), refill to the “MAX”
mark.

NOTE
When refilling, use the same type of engine oil as the one
currently being used.

5. Check that the oil is not dirty or contaminated with coolant

or gasoline, and that it has the proper viscosity.

CHANGING THE ENGINE OIL

1. Warm up the engine.
2. With the engine off remove engine oil drain plug and drain
oil.
3. Replace the drain plug and tighten.

Tightening torque
Drain plug .... 34-44 Nm (350-450 kg.cm, 25-33 Ib.ft)

4. Fill the crankcase with fresh oil through the filler port.

Dry fill . . . . . . . . . . . . . . . 4.4 lit. (4.62 U.S.qts., 3.85 Imp.qts.)

Drain and refill
Without oil filter: 2.9 lit (3.06 U.S.qts., 2.55 Imp.qts.)
With oil filter: 3.3 lit (3.49 U.S.qts., 2.90 Imp.qts.)

5. Check the oil level.

6. Install the filler cap.
7. After a road test recheck the level of the engine oil.

Recommended engine oil

API SG or SGKD
SAE 20W-20, 20W-40, 20W-50 (ABOVE 32 o F OR 0 o C)
10W-30, 10W-40, 10w-50 (ABOVE -10 o F OR -23 o C)
5W-20, 5W-30, 5W-40 (BELOW 60°F OR 16 o C)
10-6 MAINTENANCE SERVICE

REPLACEMENT OF THE ENGINE OIL

FILTER
1. Replace the oil filter at of every oil change.
2. Use a filter wrench 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 turning it by hand.

CHECKING AND ADJUSTMENT OF V-BELT

TENSION
Measure the deflection of the V-belt at the point shown in the
illustration.

V-belt deflection [under a tension of 10 kg (22 lb)]. . . . . . . . . .

9.0-11.5 mm (0.35-0.45 in.)

REPLACEMENT OF THE AIR FILTER

The air filter will become dirty and loaded with dust during use
and the filtering effect will be substantially reduced. Replace
with a new one.
1. Remove the air intake hose and air duct.
2. Disconnect the connector for the air-flow sensor from the
air filter cover.
3. Disconnect the air filter cover clip.
4. Remove the air filter cover.

CAUTION
The air filter cover should be removed carefully because
it includes the air-flow sensor.

5. Remove the air filter element.

6. Insert a new air filter element and clamp the air filter cover
closed.
 MAINTENANCE SERVICE 10-7

COOLING SYSTEM
Check the cooling system for damaged hoses, loose or leaking
connections.

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.

CAUTION
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%.

Replacement the Coolant

1. Set the temperature control level to the hot position.

2. Remove the radiator cap.

CAUTION
Remove cap slowly as the system is pressurized and the
coolant may be hot.

3. Loosen the drain plug to drain the coolant.

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. Fill into the reserve tank with coolant.
8. After warming the engine until the thermostat opens,
remove the radiator cap and check the coolant level.
9. Fill the radiator with coolant up to the filler neck, and install
the radiator cap securely.
10. Fill the reserve tank with coolant up to the “FULL” line.
10-8 MAINTENANCE SERVICE

REPLACEMENT OF IGNITION CABLES

The ignition cables should be replaced periodically with new
ones. After replacing, make sure that the ignition cables and
terminals are properly connected and fully seated.

NOTE
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

The oxygen sensor is a device which controls the fuel mixture.
If the oxygen sensor is damaged, the exhaust-gas cleaning effect
as well as driveability deteriorates. Therefore, it should be
replaced periodically with a new one.

FUEL SYSTEM
Tank, Lines And Connections

1. Check for damage or leakage in the fuel lines and

connections.
2. Inspect the surface of 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.

Fuel Filter
The fuel filter should be replaced regularly because its
performance is reduced by dirt and water collected over an
extended period of use. Replace as required.
 MAINTENANCE SERVICE 10-9

CRANKCASE EMISSION CONTROL SYSTEM

(PCV valve)
The crankcase ventilation system must be kept clean to maintain
good engine performance.
Periodic servicing is required to remove combustion Br-products
from the PCV valve.

1. Disconnect the ventilation hose from the positive crankcase

ventilation (PCV) valve. Then, remove PCV valve from the
rocker cover and reconnect it to the ventilation hose.
2. Idle the engine and put a finger to the open end of PCV valve
to make sure that intake manifold vacuum is felt on the
finger.

NOTE
At this time, the plunger inside the PCV valve moves back
and forth.

3. If vacuum is not felt on finger, clean the PCV valve and

ventilation hose in cleaning solvent or replace if necessary.
10-10 MAINTENANCE SERVICE

EVAPORATIVE EMISSION CONTROL SYSTEM

1. If the fuel-vapor vent line is clogged or damaged, a fuel-vapor
mixture excapes into the atmosphere causing excessive
emissions. Disconnect the line at both ends, and blow it
clean with compressed air. Remove the filler cap from the
filler pipe and check to see if there is evidence that the
packing makes improper contact to the filler pipe.
2. The overfill limiter (2-way valve) installed on the vapor line
between the canister inlet and fuel tank outlet should be
checked for correct operation.

CANISTER (Replacement)
If the canister filter becomes clogged, the purge air volume will
decrease and the canister should be replaced.
 MAINTENANCE SERVICE 10-11

MANUAL TRANSMISSION (Inspect oil level)

Inspect each component for evidence of leakage, and check the
oil level by removing the filler plug. If the oil is contaminated,
it is necessary to replace it with new oil.
1. With the vehicle parked at a level place, remove the filler
plug and make sure that oil level is at the same level as the
plug hole.
2. Check to be sure that the transmission oil is not dirty.

TRANSMISSION OIL (Replacement)

1. With the vehicle parked at a level place, remove the
magnetic drain plug to drain transmission oil.
2. Replace washer with a new one and install the magnetic
plug.
3. Pump transmission oil (through the filler plug hole) until the
oil level is at the same level as the plug hole.

Transmission oil capacity :

1.8 liters (1.9 U.S. qts., 1.6 Imp. qts.)

AUTOMATIC TRANSMISSION (Change fluid)

Drain the fluid and check whether there is any evidence of
contamination.
Replenish with new fluid after the cause of any contamination
has been corrected.
1. Remove drain plug at differential bottom to let fluid drain.
2. Place a drain container with large opening under the
transmission oil pan.
3. Loosen oil pan bolts and tap pan at one corner to break it
loose allowing fluid to drain, then remove oil pan.
4. Check the oil filter for clogging and damage and replace if
necessary.
5. Clean drain plug and tighten drain plug with gasket to
30-35 Nm (300-350 kg.cm, 22-25 Ib.ft).
6. Clean both gasket surfaces of transmission case and oil pan.
7. Install oil pan with new gasket and tighten oil pan bolts to
10-12 Nm (100-120 kg.cm, 7.5-8.5 lb.ft).
8. Pour 4 liters (4.2 U.S.qts., 3.5 Imp.qts.) of ATF into case
through dipstick hole. [Total quantity of ATF required is
approx. 6.1 liters (6.4 U.S.qts., 5.4 Imp.qts.). However,
approx. 4.5 liters (4.8 U.S.qts., 4.0 Imp.qts.) of fluid can be
replaced, the ballance of the fluid remains in the torque
converter.]
10-12 MAINTENANCE SERVICE

9. Start engine and allow to idle for at least two minutes. Then,
with parking brake on, move selector lever momentarily to
each position., ending in “N” Neutral position.
10. Add sufficient ATF to bring fluid level to lower mark.
Recheck fluid level after transmission is at normal operating
temperature.
Fluid level should be between upper and lower marks of
“HOT” range. Insert dipstick fully to prevent dirt from
entering transmission.

INSPECT STEERING LINKAGE

1. Check steering wheel freeplay.

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

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 OIL PUMP BELT

(Check and service as required)
1. Inspect the belt for evidence of cuts and cracks. Replace, if
necessary.
2. Check belt for proper tension. If necessary, adjust the belt
tension as follows.
1) Push the belt with a force of 98 N (22 lb) at a point
halfway between the power steering oil pump pulley and
water pump pulley. The belt deflection should be 6 to 9
mm (0.24-0.35 in.)
2) If belt deflection is not within specified limits, loosen oil
pump mounting bolt, and move the oil pump to obtain
proper belt deflection at 98 N (22 lb) force.

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 (122oF).
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 add fluid in the oil reservoir through the oil
filler if necessary.
 MAINTENANCE SERVICE 10-13

POWER STEERlNG 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,

STEERlNG 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 leakage and damage.
Replace them if defective.

REAR WHEEL BEARINGS

(Inspect for grease leaks)
Inspect for evidence of grease leakage around the hub cap and
the back of the hub. If there is leakage of grease, remove the
hub and inspect its oil seal for damage. Clean the grease off the
hub and bearing and repack with specified new grease.

Specified grease :
Multipurpose grease SAE J310a. NLGI No.2

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.

CHANGING OF THE BRAKE FLUID

1. Refer to page 58-5 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 in a vessel for
receiving the brake fluid.
10-14 MAINTENANCE SERVICE

3. 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.
4. Repeat the above operation until no air bubbles are in the
brake fluid.
5. Repeat these steps for the other cylinders.
6. Add fresh brake fluid up to the “MAX” level in the reserve
tank.

Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . DOT 3 or equivalent

CHECKING TIRE INFLATION PRESSURE

Check the Tire inflation Pressures as Follows.

TIRE INFLATION PRESSURE (Check with Tires Cool)

Tire size Front Rear

P175/65 TR 14
200 kPa (29 psi) 200 kPa (29 psi)
P/85/60 HR 14

T125/70 D 15 (Temporary) 414 kPa (60 psi) 414 kPa (60 psi)

ROAD TEST
Drive the vehicle and check for abnormal conditions.
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.
 MAINTENANCE SERVICE 10-15

FRONT DISC BRAKE PADS

Check for fluid contamination and wear. Replace complete set
of pads if defective.

NOTE:
If a squealing or scraping noise occurs from the brake during
driving, check for pad wear indicator contacting the disc, the
brake pad should be replaced.

CAUTION
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.)

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) Check the brake shoes for wear.

Thickness of lining “B” [Limit] . . . . . . . . 1.5 mm (0.059 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.