|
Manual Coverage
|
|
Systems Covered
|
|
Engine Mechanical:
|
Detailed overhaul procedures, component testing, timing belt/chain replacement, lubrication system.
|
|
Engine Performance:
|
Fuel delivery, ignition system, emission control systems (catalytic converter, EGR), engine management (ECU diagnostics).
|
|
Transmission Manual:
|
Clutch system, gearbox overhaul, shift mechanism, lubrication.
|
|
Transmission Automatic:
|
ATF specifications, valve body operation, torque converter, shift control, overhaul procedures.
|
|
Drivetrain:
|
Front-wheel drive axle shafts, differentials, propeller shafts (if applicable to AWD variants).
|
|
Suspension:
|
Front MacPherson struts, rear multi-link or independent suspension, springs, shock absorbers, bushings, alignment specifications.
|
|
Steering:
|
Power steering system, steering rack/gearbox, tie rods, wheel alignment.
|
|
Brakes:
|
Front disc brakes, rear drum or disc brakes, ABS (Anti-lock Braking System) operation and diagnostics, brake fluid specifications, bleeding procedures.
|
|
Electrical System:
|
Battery, charging system (alternator, regulator), starting system (starter motor), fuses, relays, wiring diagrams, lighting.
|
|
Body And Chassis:
|
Body panel removal/installation, interior trim, doors, windows, sunroof, chassis diagnostics.
|
|
HVAC:
|
Air conditioning system, heater core, blower motor, refrigerant R-134a, diagnostics.
|
|
Safety Systems:
|
Airbag system diagnostics and replacement procedures (if equipped).
|
|
Procedures Included
|
|
Routine Maintenance:
|
Oil change intervals, filter replacements, spark plug replacement, air filter inspection/replacement, fluid checks and top-offs.
|
|
Diagnostics Troubleshooting:
|
Step-by-step diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems.
|
|
Engine Rebuild:
|
Complete engine disassembly, inspection, measurement, and reassembly procedures, including torque specifications.
|
|
Transmission Repair:
|
Complete overhaul of both manual and automatic transmissions, including internal component replacement.
|
|
Brake System Repair:
|
Brake pad/shoe replacement, rotor/drum resurfacing/replacement, caliper/wheel cylinder overhaul, ABS component testing.
|
|
Electrical Component Replacement:
|
Alternator, starter motor, ignition coils, sensors, actuators, power windows, locks, and audio systems.
|
|
Suspension And Steering Repair:
|
Ball joint replacement, strut/shock replacement, power steering pump replacement, rack and pinion service.
|
|
Bodywork And Trim Repair:
|
Removal and installation of bumpers, fenders, doors, hood, trunk lid, interior panels.
|
|
Technical Depth
|
|
Depth Level:
|
Comprehensive; covers everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostics.
|
|
Diagnostic Tools:
|
Information on using OBD-I (On-Board Diagnostics) systems prevalent in these years, including diagnostic trouble codes (DTCs) and their meanings.
|
|
Wiring Diagrams:
|
Detailed, system-specific electrical wiring diagrams for easy troubleshooting of electrical issues.
|
|
Torque Specifications:
|
Precise torque values for all critical fasteners, essential for proper assembly and preventing component damage.
|
|
Special Tools:
|
Identification and usage of specialized tools required for specific repair procedures.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Displacement 1.5L:
|
1.5L (1498cc) 4-cylinder, SOHC, 16-valve (Z5-DE). Estimated horsepower: 90-95 HP. Estimated torque: 90-95 lb-ft.
|
|
Engine Displacement 1.8L:
|
1.8L (1839cc) 4-cylinder, DOHC, 16-valve (BP-ZE for GT/Sport trims). Estimated horsepower: 120-130 HP. Estimated torque: 110-120 lb-ft.
|
|
Engine Displacement 2.0L:
|
2.0L (1998cc) 4-cylinder, DOHC, 16-valve (FS-DE). Found in later models. Estimated horsepower: 115-125 HP. Estimated torque: 125-130 lb-ft.
|
|
Performance
|
|
Fuel Injection:
|
Electronic Fuel Injection (EFI) or Multi-Point Fuel Injection (MPFI).
|
|
Compression Ratio:
|
Varies by engine; typically around 9.0:1 to 10.0:1.
|
|
Redline Rpm:
|
Approximately 6,500 - 7,000 RPM, depending on engine and trim.
|
|
Fuel System
|
|
Fuel Type:
|
Unleaded gasoline (Octane rating typically 87 minimum).
|
|
Fuel Tank Capacity:
|
Approx. 13.2 gallons (50 Liters).
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change Interval:
|
Every 5,000-7,500 miles or 6-12 months, whichever comes first (refer to manual for specific recommendations based on driving conditions).
|
|
Engine Oil Filter Replacement:
|
At every oil change.
|
|
Timing Belt Replacement:
|
Typically every 60,000-90,000 miles or 5-7 years for engines equipped with a belt (e.g., BP-ZE, Z5-DE). Critical maintenance item.
|
|
Spark Plug Replacement:
|
Every 30,000-60,000 miles, depending on spark plug type (e.g., copper vs. platinum).
|
|
Fluid Specifications
|
|
Engine Oil Viscosity:
|
Refer to manual; commonly 5W-30 or 10W-30.
|
|
Coolant Type:
|
Ethylene glycol based antifreeze/coolant. Capacity approx. 5.5-6.5 liters.
|
|
Brake Fluid Type:
|
DOT 3 or DOT 4 brake fluid.
|
|
Power Steering Fluid:
|
ATF or specific power steering fluid (check manual).
|
|
Known Issues
|
|
Engine Oil Consumption:
|
Some engines, particularly the BP series, could experience higher oil consumption as they aged; regular checks are vital.
|
|
Timing Belt Tensioner:
|
Failure of the timing belt tensioner on certain BP engines could lead to catastrophic engine damage.
|
|
Oxygen Sensor:
|
Oxygen sensors can degrade over time, affecting fuel economy and emissions.
|
|
Catalytic Converter:
|
Can become clogged or fail due to age or engine issues.
|
|
Rust Corrosion:
|
Common in older vehicles, particularly in areas with road salt. Check body panels, wheel wells, and undercarriage.
|
|
Automatic Transmission Shifts:
|
Rough shifting or slipping in older automatic transmissions can indicate wear or low fluid.
|
