service BMW 3 SERIES 1985 E30 Workshop Manual
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Page 1 of 228
BMW 3- & 5-Series
Service and Repair Manual
A K Legg LAE MIMI and Larry Warren
Models covered
3-Series (E30)
316 (83 to 88), 316i (88 to 91), 318i (83 to 91), 320i (87 to 91), 325i (87 to 91).
Also Touring and Convertible versions of these models
5-Series (E28)
518 (81 to 85), 518i (85 to 88), 525i (81 to 88), 528i (81 to 88), 535i (85 to 88), M535i (85 to 88)
5-Series (E34)
518i (90 to 91), 520i (88 to 91), 525i (88 to 91), 530i (88 to 91), 535i (88 to 91)
Engines covered
1596 cc, 1766 cc, 1795 cc, 1990 cc, 2494 cc, 2788 cc, 2986 cc & 3430 cc
Does not cover Diesel, dohc or V8 engines, or four-wheel-drive models
© Haynes Publishing 1997
A book in the Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmitted
in any form or by any means, electronic or mechanical, including
photocopying, recording or by any information storage or retrieval system,
without permission in writing from the copyright holder.
ISBN1 85960 236 3
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,Somerset
BA22 7JJ, England
Haynes Publishing
Sparkford, Nr Yeovil, Somerset BA22 7JJ, England
Haynes North America, Inc
861 Lawrence Drive, Newbury Park, California 91320, USA
Editions Haynes S.A.
147/149, rue Saint Honoré, 75001 PARIS, France
Haynes Publishing Nordiska AB
Box 1504, 751 45 Uppsala, Sweden
(1948-256-11AA3)
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1 2 3
Page 7 of 228
0•7Anti-theft audio system
Anti-theft audio system
General information
Some models are equipped with an audio
system having an anti-theft feature that will
render the stereo inoperative if stolen. If the
power source to the stereo is cut, the stereo
won’t work even if the power source is
immediately re-connected. If your vehicle is
equipped with this anti-theft system, do not
disconnect the battery or remove the stereo
unless you have the individual code number
for the stereo.
Refer to the owner’s handbook suppliedwith the vehicle for more complete
information on this audio system and its anti-
theft feature.
Unlocking procedure
1Turn on the radio. The word “CODE” should
appear on the display.
2Using the station preset selector buttons,
enter the five-digit code. If you make a
mistake when entering the code, continue
the five-digit sequence anyway. If you hear
a “beep,” however, stop immediately andstart the sequence over again. Note: Yo u
have three attempts to enter the correct
code. If the correct code isn’t entered in
three tries, you’ll have to wait one hour, with
the radio on, before you enter the codes
again.
5Once the code has been entered correctly,
the word “CODE” should disappear from the
display, and the radio should play (you’ll have
to tune-in and enter your preset stations,
however).
6If you have lost your code number, contact
a BMW dealer service department.
Instrument panel language display
On some later models, disconnecting the
battery may cause the instrument panel
display to default to the German language
(this does not usually apply to UK models). If
it is necessary to reset the correct language
after the battery is reconnected, proceed as
follows. With all the doors shut and theignition on (engine not running), press the trip
reset button until the panel displays the
desired language. There are eight languages
available. If you wish to bypass a particular
selection, release the reset button and press
again - this will cause the display to advance
to the next language. Once the correctlanguage has been selected, continue holding
the reset button until the display reads “I.O.
Version 2.0”. Continue holding the button until
it reads “H.P. Version 3.4”, then release the
button.
Page 11 of 228
1
Engine
Oil filter
M10 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C121
M20 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C160
M30 engines
3-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C160
5-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion X115
M40 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion X120
Valve clearances (intake and exhaust)
M10 engines
Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm
Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm
M20 engines
Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm
Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm
M30 engines
Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm
Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm
M40 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic adjusters
Cooling system
Antifreeze mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40% antifreeze/60% water
Chapter 1
Routine maintenance and servicing
Air filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Automatic transmission fluid and filter change . . . . . . . . . . . . . . . . . 28
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . 8
Battery check, maintenance and charging . . . . . . . . . . . . . . . . . . . . 13
Brake system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cooling system - draining, flushing and refilling . . . . . . . . . . . . . . . . 29
Cooling system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Differential lubricant change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Differential lubricant level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Driveshaft gaiter check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drivebelt check, adjustment and renewal . . . . . . . . . . . . . . . . . . . . . 11
Engine idle speed and CO level check and adjustment . . . . . . . . . . 12
Engine oil and filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Evaporative Emissions Control (EVAP) system check . . . . . . . . . . . 33
Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuel system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Manual transmission lubricant change . . . . . . . . . . . . . . . . . . . . . . . 31
Manual transmission lubricant level check . . . . . . . . . . . . . . . . . . . . 16
Power steering fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Routine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service light resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Spark plug check and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spark plug HT leads, distributor cap and rotor - check
and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering and suspension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Throttle linkage - check and lubrication . . . . . . . . . . . . . . . . . . . . . . 19
Tyre and tyre pressure checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tyre rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tune-up general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Underbonnet hoses - check and renewal . . . . . . . . . . . . . . . . . . . . . 10
Valve clearances - check and adjustment . . . . . . . . . . . . . . . . . . . . 18
Wiper blades - check and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty
Specifications Contents
Page 14 of 228
Maintenance schedule
The following maintenance intervals are based on the assumption
that the vehicle owner will be doing the maintenance or service work,
as opposed to having a dealer service department do the work.
Although the time/mileage intervals are loosely based on factory rec-
ommendations, most have been shortened to ensure, for example, that
such items as lubricants and fluids are checked/changed at intervals
that promote maximum engine/driveline service life. Also, subject to
the preference of the individual owner interested in keeping his or her
vehicle in peak condition at all times, and with the vehicle’s ultimate
resale in mind, many of the maintenance procedures may be
performed more often than recommended in the following schedule.
We encourage such owner initiative.
When the vehicle is new, it should be serviced initially by a factory-
authorised dealer service department, to protect the factory warranty.
In many cases, the initial maintenance check is done at no cost to the
owner (check with your dealer service department for more
information).
1•4Maintenance and servicing
Every 250 miles or weekly, whichever
comes first
m mCheck the engine oil level (Section 4)
m mCheck the engine coolant level (Section 4)
m mCheck the brake fluid level (Section 4)
m mCheck the clutch fluid level (Section 4)
m mCheck the washer fluid level (Section 4)
m mCheck the tyres and tyre pressures (Section 5)
Every 6000 miles or 6 months,
whichever comes first
All items listed above, plus:
m mChange the engine oil and oil filter (Section 6)
m mCheck the power steering fluid level (Section 7)
m mCheck the tyres, and rotate if necessary (Section 9)
m mCheck the automatic transmission fluid level
(Section 8)
m mCheck the underbonnet hoses (Section 10)
m mCheck/adjust the drivebelts (Section 11)
m mCheck engine idle speed and CO (Section 12)
Every 12 000 miles or 12 months,
whichever comes first
All items listed above, plus:
m mCheck/service the battery (Section 13)
m mCheck the spark plugs (Section 14)
m mCheck/renew the HT leads, distributor cap and
rotor (Section 15)
m mCheck/top-up the manual transmission lubricant
(Section 16)
m mCheck the differential oil level (Section 17)
m mCheck the valve clearances, and adjust if
necessary - does not apply to M40 engines
(Section 18)
m mCheck and lubricate the throttle linkage (Section 19)
m mRenew the air filter (Section 20)
m mCheck the fuel system (Section 21)
m mInspect the cooling system (Section 22)
m mInspect the exhaust system (Section 23)
m mInspect the steering and suspension components
(Section 24)
m mCheck the driveshaft gaiter(s) (Section 25)
m mInspect the brakes (Section 26)
m mInspect/renew the windscreen wiper blades
(Section 27)
Every 24 000 miles or 2 years,
whichever comes first
All items listed above plus:
m mChange the automatic transmission fluid and filter
(Section 28)
m mDrain, flush and refill the cooling system (Section 29)
m mRenew the spark plugs (Section 14)
m mCheck/renew the spark plug HT leads (Section 15)
m mRenew the fuel filter (Section 30)
m mChange the manual transmission lubricant (Section 31)
m mChange the differential oil (Section 32)
m mCheck the evaporative emissions system, where
applicable (Section 33)
m mReset the service indicator lights (Section 34)
m mRenew brake fluid by bleeding (see Chapter 9)
m mCheck the handbrake operation (see Chapter 9)
Every 60 000 miles
m
mRenew the timing belt (Section 35)
Page 15 of 228
1•5
Underbonnet view (left-hand side) of a
UK model 318i (1988)
1 Radiator
2 Intake manifold
3 Idle control valve
4 Accelerator cable
5 Diagnostic/service indicator resetting
socket
6 Fuse/relay box
7 Brake hydraulic fluid reservoir
8 Airflow meter
9 Air cleaner unit
10 Radiator filler cap
11 Radiator top hose
12 Oil filter housing
Underbonnet view (right-hand side) of a
UK model 318i (1988)
1 Oil filler cap
2 Valve cover
3 Engine oil filler dipstick
4 Viscous cooling fan
5 Distributor cap cover
6 Bottom hose
7 Windscreen washer fluid reservoir
8 Ignition coil
9 Clutch hydraulic fluid reservoir
10 Battery
1
Maintenance and Servicing
Page 17 of 228
1 Introduction
This Chapter is designed to help the home
mechanic maintain his or her vehicle with the
goals of maximum performance, economy,
safety and reliability in mind. Included is a
master maintenance schedule, followed by
procedures dealing specifically with each item
on the schedule. Visual checks, adjustments,
component renewal and other helpful items
are included. Refer to the accompanying
illustrations of the engine compartment and
the underside of the vehicle for the locations
of various components. Servicing the vehicle,
in accordance with the mileage/time
maintenance schedule and the step-by-step
procedures, will result in a planned
maintenance programme that should produce
a long and reliable service life. Keep in mind
that it is a comprehensive plan, so maintaining
some items but not others at specified
intervals, will not produce the same results.
2 Routine maintenance
As you service the vehicle, you will discover
that many of the procedures can - and should
- be grouped together, because of the nature
of the particular procedure you’re performing,
or because of the close proximity of two
otherwise-unrelated components to one
another. For example, if the vehicle is raised
for chassis lubrication, you should inspect the
exhaust, suspension, steering and fuelsystems while you’re under the vehicle. When
the wheels are removed for other work, it
makes good sense to check the brakes, since
the wheels are already removed. Finally, let’s
suppose you have to borrow a torque wrench.
Even if you only need it to tighten the spark
plugs, you might as well check the torque of
as many critical nuts and bolts as time allows.
The first step in this maintenance
programme is to prepare yourself before the
actual work begins. Read through all the
procedures you’re planning to do, then gather
up all the parts and tools needed. If it looks
like you might run into problems during a
particular job, seek advice from a mechanic or
an experienced do-it-yourselfer.
3 Engine “tune-up”-
general information
The term “tune-up” is used in this manual to
represent a combination of individual
operations rather than one specific procedure.
If, from the time the vehicle is new, the
routine maintenance schedule is followed
closely, and frequent checks are made of fluid
levels and high-wear items, as suggested
throughout this manual, the engine will be
kept in relatively good running condition, and
the need for additional work will be minimised.
More likely than not, however, there will be
times when the engine is running poorly due
to a lack of regular maintenance. This is even
more likely if a used vehicle, which has not
received regular and frequent maintenance
checks, is purchased. In such cases, an
engine tune-up will be needed outside of the
regular maintenance intervals. The first step in any tune-up or diagnostic
procedure to help correct a poor-running
engine is a cylinder compression check. A
compression check (see Chapter 2B) will help
determine the condition of internal engine
components, and should be used as a guide
for tune-up and repair procedures. If, for
instance, 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 most
often needed to bring a generally poor-
running engine back into a proper state of
tune.
Minor tune-up
Check all engine-related fluids (Section 4)
Check all underbonnet hoses (Section 10)
Check and adjust the drivebelts (Sec-
tion 11)
Clean, inspect and test the battery (Sec-
tion 13)
Renew the spark plugs (Section 14)
Inspect the spark plug HT leads, distributor
cap and rotor (Section 15)
Check the air filter (Section 20)
Check the cooling system (Section 22)
Major tune-up
All items listed under minor tune-up, plus . . .
Check the ignition system (see Chapter 5)
Check the charging system (see Chapter 5)
Check the fuel system (see Chapter 4)
Renew the spark plug HT leads, distributor
cap and rotor (Section 15)
1•7
1
Routine Maintenance
Weekly checks
4 Fluid level checks
1
Note:The following are fluid level checks to
be done on a 250-mile or weekly basis.
Additional fluid level checks can be found in
specific maintenance procedures which
follow. Regardless of intervals, be alert to fluid
leaks under the vehicle, which would indicate
a fault to be corrected immediately.
1Fluids are an essential part of the
lubrication, cooling, brake and windscreen
washer systems. Because the fluids gradually
become depleted and/or contaminated during
normal operation of the vehicle, they must be
periodically replenished. See “Lubricants and
fluids”at the beginning of this Chapter before
adding fluid to any of the following
components. Note:The vehicle must be on
level ground when any fluid levels are
checked.
Engine oil
2Engine oil is checked with a dipstick, which
is located on the side of the engine (refer to
the underbonnet illustrations in this Chapter
for dipstick location). The dipstick extends
through a metal tube down into the sump.
3The engine oil should be checked before
the vehicle has been driven, or at least
15 minutes after the engine has been shut off.
4Pull the dipstick out of the tube, and wipe
all of the oil away from the end with a clean
rag or paper towel. Insert the clean dipstick all
the way back into the tube, and pull it out
again. Note the oil at the end of the dipstick.
At its highest point, the oil should be betweenthe two notches or marks (see illustration).
5It takes one litre of oil to raise the level from
the lower mark to the upper mark on the
dipstick. Do not allow the level to drop below
the lower mark, or oil starvation may cause
4.4 The oil level should be kept between
the two marks, preferably at or near the
upper one - if it isn’t, add enough oil to
bring the level to the upper mark
If the oil is checked
immediately after driving the
vehicle, some of the oil will
remain in the upper part of
the engine, resulting in an inaccurate
reading on the dipstick.
Page 19 of 228
inhibitors wear out, so it must be renewed at
the specified intervals.
Brake and clutch fluid
Warning: Brake fluid can harm
your eyes and damage painted
surfaces, so use extreme caution
when handling or pouring it. Do
not use brake fluid that has been standing
open or is more than one year old. Brake
fluid absorbs moisture from the air, which
can cause a dangerous loss of brake
effectiveness. Use only the specified type
of brake fluid. Mixing different types (such
as DOT 3 or 4 and DOT 5) can cause brake
failure.
14The brake master cylinder is mounted at
the left rear corner of the engine
compartment. The clutch fluid reservoir
(manual transmission models) is mounted on
the right-hand side.
15To check the clutch fluid level, observe
the level through the translucent reservoir.
The level should be at or near the step
moulded into the reservoir. If the level is low,
remove the reservoir cap to add the specified
fluid (see illustration).
16The brake fluid level is checked by looking
through the plastic reservoir mounted on the
master cylinder (see illustration). The fluid
level should be between the MAX and MIN
lines on the reservoir. If the fluid level is low,
first wipe the top of the reservoir and the cap
with a clean rag, to prevent contamination of
the system as the cap is unscrewed. Top-up
with the recommended brake fluid, but do not
overfill.
17While the reservoir cap is off, check the
master cylinder reservoir for contamination. If
rust deposits, dirt particles or water droplets
are present, the system should be drained
and refilled.
18After filling the reservoir to the proper
level, make sure the cap is seated correctly, to
prevent fluid leakage and/or contamination.
19The fluid level in the master cylinder will
drop slightly as the disc brake pads wear.
There is no need to top up to compensate for
this fall provided that the level stays above the
MIN line; the level will rise again when new
pads are fitted. A very low level may indicateworn brake pads. Check for wear (see Sec-
tion 26).
20If the brake fluid level drops consistently,
check the entire system for leaks immediately.
Examine all brake lines, hoses and
connections, along with the calipers, wheel
cylinders and master cylinder (see Sec-
tion 26).
21When checking the fluid level, if you
discover one or both reservoirs empty or
nearly empty, the brake or clutch hydraulic
system should be checked for leaks and bled
(see Chapters 8 and 9).
Windscreen washer fluid
22Fluid for the windscreen washer system is
stored in a plastic reservoir in the engine
compartment (see illustration).
23In milder climates, plain water can be
used in the reservoir, but it should be kept no
more than two-thirds full, to allow for
expansion if the water freezes. In colder
climates, use windscreen washer system
antifreeze, available at any car accessory
shop, to lower the freezing point of the fluid.
This comes in concentrated or pre-mixed
form. If you purchase concentrated antifreeze,
mix the antifreeze with water in accordance
with the manufacturer’s directions on the
container.
Caution: Do not use cooling
system antifreeze - it will damage
the vehicle’s paint.
5 Tyre and tyre pressure
checks
1
1Periodic inspection of the tyres may save
you the inconvenience of being stranded with
a flat tyre. It can also provide you with vital
information regarding possible problems in
the steering and suspension systems before
major damage occurs.
2Tyres are equipped with bands that will
appear when tread depth reaches 1.6 mm, at
which time the tyres can be considered worn
out. This represents the legal minimum tread
depth; most authorities recommend renewing
any tyre on which the tread depth is 2 mm or
less. Tread wear can be monitored with a
simple, inexpensive device known as a tread
depth indicator (see illustration).
3Note any abnormal tyre wear (see
illustration overleaf). Tread pattern irregular-
ities such as cupping, flat spots and more
wear on one side than the other are
indications of front end alignment and/or
wheel balance problems. If any of these
conditions are noted, take the vehicle to a tyre
specialist to correct the problem.
4Look closely for cuts, punctures and
embedded nails or tacks. Sometimes, after a
nail has embedded itself in the tread, a tyre
will hold air pressure for a short time, or may
1•9
4.22 The windscreen washer fluid reservoir
is located in the right front corner of the
engine compartment on most models4.16 The brake fluid level should be kept
above the MIN mark on the translucent
reservoir - unscrew the cap to add fluid4.15 Adding hydraulic fluid to the clutch
fluid reservoir
5.4a If a slow puncture is suspected,
check the valve core first to make sure it’s
tight5.2 Use a tyre tread depth indicator to
monitor tyre wear - they are available at
car accessory shops and service stations,
and cost very little
1
Weekly Checks
Page 20 of 228
leak down very slowly. If a slow puncture
persists, check the valve stem core to make
sure it is tight (see illustration). Examine the
tread for an object that may have embedded
itself in the tyre, or for a previous repair that
may have begun to leak. If a puncture is
suspected, it can be easily verified by
spraying a solution of soapy water onto the
puncture (see illustration). The soapy
solution will bubble if there is a leak. Unless
the puncture is unusually large, a tyre
specialist can usually repair the tyre.
5Carefully inspect the inner sidewall of each
tyre for evidence of brake fluid leakage. If you
see any, inspect the brakes immediately.
6Correct air pressure adds miles to the life
span of the tyres, improves fuel economy, and
enhances overall ride quality. A tyre pressure
gauge is essential.
7Always check the tyre pressures when the
tyres are cold (ie before driving the vehicle).Checking the pressures when the tyres are
warm, or hot, will result in higher readings,
due to heat expansion. On no account should
air be let out of the tyres in this case, or the
tyres will effectively be under-inflated when
cold.
8Unscrew the valve cap protruding from the
wheel or hubcap, and push the gauge firmly
onto the valve stem (see illustration). Note
the reading on the gauge, and compare thefigure to the recommended tyre pressures
shown in the Specifications listed at the
beginning of this Chapter. Be sure to refit the
valve cap to keep dirt and moisture out of the
valve stem mechanism. Check all four tyres
and, if necessary, add enough air to bring
them to the recommended pressure.
9Don’t forget to keep the spare tyre inflated
to the specified pressure.
1•10
5.8 To extend the life of the tyres, check
the air pressure at least once a week with
an accurate gauge (don’t forget the spare!)5.4b If the valve core is tight, raise the
vehicle, and spray a soapy water solution
onto the tread as the tyre is turned slowly -
leaks will cause small bubbles to appear
Tyre tread wear patterns
Shoulder Wear
Underinflation (wear on both sides)
Under-inflation will cause overheating of the
tyre, because the tyre will flex too much, and
the tread will not sit correctly on the road
surface. This will cause a loss of grip and
excessive wear, not to mention the danger of
sudden tyre failure due to heat build-up.
Check and adjust pressures
Incorrect wheel camber (wear on one side)
Repair or renew suspension parts
Hard cornering
Reduce speed!
Centre Wear
Overinflation
Over-inflation will cause rapid wear of the
centre part of the tyre tread, coupled with
reduced grip, harsher ride, and the danger of
shock damage occurring in the tyre casing.
Check and adjust pressures
If you sometimes have to inflate your car’s
tyres to the higher pressures specified for
maximum load or sustained high speed, don’t
forget to reduce the pressures to normal
afterwards.
Uneven Wear
Front tyres may wear unevenly as a result of
wheel misalignment. Most tyre dealers and
garages can check and adjust the wheel
alignment (or "tracking") for a modest charge.
Incorrect camber or castor
Repair or renew suspension parts
Malfunctioning suspension
Repair or renew suspension parts
Unbalanced wheel
Balance tyres
Incorrect toe setting
Adjust front wheel alignment
Note: The feathered edge of the tread which
typifies toe wear is best checked by feel.
Weekly Checks
Keep an accurate gauge in
the glove compartment. The
pressure gauges attached to
the nozzles of air hoses at
service stations are often
inaccurate.
Page 22 of 228
Cartridge-type oil filter
17Some models are equipped with a
cartridge-type oil filter. Unscrew the bolt,
remove the cover, and lift the filter out (see
illustrations).
18Compare the new cartridge with the old
one, to make sure they are the same type,
then lower it into the housing.
19Using a clean rag, wipe off the mounting
surface of the housing and cover. If necessary,
renew the rubber O-ring (see illustration).
Smear some clean oil on the O-ring and refit
the cover and bolt. Tighten the bolt securely.
All models
20Remove all tools and materials from under
the vehicle, being careful not to spill the oil
from the drain pan, then lower the vehicle.
21Add new oil to the engine through the oil
filler cap in the valve cover. Use a funnel to
prevent oil from spilling onto the top of the
engine. Pour the specified quantity of fresh oil
into the engine. Wait a few minutes to allow the
oil to drain into the sump, then check the level
on the dipstick (see Section 4 if necessary). If
the oil level is correct, refit the filler cap.
22Start the engine and run it for about a
minute. The oil pressure warning light may
take a few seconds to go out while the new
filter fills with oil; don’t rev the engine while
the light is on. While the engine is running,
look under the vehicle, and check for leaks at
the sump drain plug and around the oil filter. Ifeither one is leaking, stop the engine and
tighten the plug or filter slightly.
23Wait a few minutes, then recheck the level
on the dipstick. Add oil as necessary.
24During the first few days after an oil
change, make it a point to check frequently
for leaks and proper oil level.
25The old oil drained from the engine cannot
be re-used in its present state, and should be
discarded. Oil reclamation centres and some
service stations will accept the oil, which can
be recycled. After the oil has cooled, it can be
transferred into a container for transport to a
disposal site.
7 Power steering fluid level
check
1
1Check the power steering fluid level
periodically to avoid steering system
problems, such as damage to the pump.
Proceed as follows.Caution: Do not hold the steering
wheel against either stop (full-left
or full-right lock) for more than
five seconds. If you do, the power
steering pump could be damaged.
2On some models, the power steering fluid
reservoir is located on the left side of the
engine compartment, and has a twist-off cap
with an integral fluid level dipstick (see
illustration). Other models use a hydraulic
power steering and brake servo system which
combines the fluid in one reservoir, located at
the right rear corner of the engine
compartment.
3Park the vehicle on level ground, and apply
the handbrake.
4On models with a fluid dipstick, run the
engine until it has reached normal operating
temperature. With the engine at idle, turn the
steering wheel back and forth several times to
get any air out of the steering system. Switch
off the engine, remove the cap by turning it
anti-clockwise, wipe the dipstick clean, and
refit the cap. Remove the cap again, and note
the fluid level. It must be between the two
lines (see illustration).
5On hydraulic servo models, pump the brake
pedal about ten times or until the pedal is firm.
Remove the nut, lift the cap off, and make
sure the fluid is within 6.0 mm of the top of the
reservoir.
6Add small amounts of fluid until the level is
correct (see illustration).
1•12
7.6 Adding fluid to the power steering
reservoir7.4 The power steering fluid level should
be kept between the two arrows near the
upper step on the dipstick7.2 The power steering fluid reservoir
(arrowed) is located on the left side of the
engine compartment
6.19 Renewing the rubber O-ring in the
cover6.17c . . . and lift out the cartridge
Every 6000 miles
6.17b . . . remove the cover . . .
Note: It is
antisocial and
illegal to dump
oil down the
drain. To find
the location of
your local oil
recycling
bank, call this
number free.
Page 23 of 228
Caution: Do not overfill the
reservoir. If too much fluid is
added, remove the excess with a
clean syringe. Refit the cap.
7If frequent topping-up is needed, check the
power steering hoses and connections for
leaks and wear (see Section 10).
8Check the condition and tension of the
drivebelt (see Section 11).
8 Automatic transmission fluid
level check
1
Caution: The use of transmission
fluid other than the type listed in
this Chapter’s Specifications
could result in transmission
malfunctions or failure.
1The automatic transmission fluid should be
carefully maintained. Low fluid level can lead
to slipping or loss of drive, while overfilling
can cause foaming and loss of fluid. Either
condition can cause transmission damage.
2Since transmission fluid expands as it heats
up, the fluid level should only be checked
when the transmission is warm (at normal
operating temperature). If the vehicle has just
been driven over 20 miles (32 km), the
transmission can be considered warm. You
can also check the fluid level when the
transmission is cold. If the vehicle has not
been driven for over five hours and the fluid is
about room temperature (20°C), the
transmission is cold. However, the fluid level
is normally checked with the transmission
warm, to ensure accurate results.
Caution: If the vehicle has just
been driven for a long time at
high speed or in city traffic, in hot
weather, or if it has been pulling
a trailer, an accurate fluid level reading
cannot be obtained. Allow the trans-
mission to cool down for about 30 minutes.
3Immediately after driving the vehicle, park it
on a level surface, apply the handbrake and
start the engine. While the engine is idling,
depress the brake pedal and move theselector lever through all the gear ranges,
beginning and ending in Park.
4The automatic transmission dipstick tube is
located in the left rear corner of the engine
compartment.
5With the engine still idling, pull the dipstick
out of the tube (see illustration), wipe it off
with a clean rag, push it all the way back into
the tube and withdraw it again, then note the
fluid level.
6The level should be between the two marks
(see illustration). If the level is low, add the
specified automatic transmission fluid through
the dipstick tube - use a clean funnel,
preferably equipped with a fine mesh filter, to
prevent spills.
Caution: Be careful not to
introduce dirt into the
transmission when topping up.
7Add just enough of the recommended fluid
to fill the transmission to the proper level. It
takes about half a litre to raise the level from
the low mark to the high mark when the fluid
is hot, so add the fluid a little at a time, and
keep checking the level until it’s correct.
8The condition of the fluid should also be
checked along with the level. If the fluid is
black or a dark reddish-brown colour, or if it
smells burned, it should be changed (see
Section 28). If you are in doubt about its
condition, purchase some new fluid, and
compare the two for colour and smell.
9 Tyre rotation
1
1The tyres can be rotated at the specified
intervals, or whenever uneven wear is noticed.
However, bear in mind that if rotation
succeeds in making all the tyres wear evenly,
you will eventually have to renew all four at
once. Since the vehicle will be raised and the
wheels removed anyway, check the brakes
also (see Section 26). Note: Even if you don’t
rotate the tyres, at least check the wheel bolt
tightness.
2It is recommended that the tyres be rotatedin a specific pattern (see illustration)so that
their direction of rotation remains the same.
3Refer to the information in “Jacking and
towing”at the front of this manual for the
proper procedure to follow when raising the
vehicle and changing a tyre.
4The vehicle must be raised on a hoist or
supported on axle stands to get all four tyres
off the ground. Make sure the vehicle is safely
supported!
5After the rotation procedure is finished,
check and adjust the tyre pressures as
necessary, and be sure to check the wheel
bolt tightness.
10 Underbonnet hose check
and renewal
3
Warning: Renewal of air
conditioning hoses must be left
to a dealer service department or
air conditioning specialist having
the equipment to depressurise the system
safely. Never disconnect air conditioning
hoses or components until the system has
been depressurised.
General
1High temperatures under the bonnet can
cause deterioration of the rubber and plastic
hoses used for various systems. Periodic
inspection should be made for cracks, loose
clamps, material hardening, and leaks.
2Information specific to the cooling system
can be found in Section 22, while the braking
system is covered in Section 26.
3Most (but not all) hoses are secured with
clamps. Where clamps are used, check to be
sure they haven’t lost their tension, allowing
the hose to leak. If clamps aren’t used, make
sure the hose has not expanded and/or
hardened where it slips over the fitting,
allowing it to leak.
Vacuum hoses
4It’s quite common for vacuum hoses,
especially those in the emissions system, to
be colour-coded or identified by coloured
1•13
9.2 The tyre rotation pattern for these
models8.6 With the fluid hot, the level should be
kept between the two dipstick notches,
preferably near the upper one8.5 The automatic transmission fluid
dipstick (arrowed) is located near the
bulkhead on the left side of the engine
compartment
1
Every 6000 miles