02 - lubrication and maintenance

8/3/2019 02 - Lubrication and Maintenance

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For later modelsrefer to supplement. LUBRICATION AND MAINTENANCE I I

SPECIFICATIONSCAPACITY AND GRADEEngine:

Lubricant SF 20W/50Sump capacity -1979-1981 1600 cc models 3.5 litres1979-1987 1800 cc models 4.0 litresCooling system capacity:1979-1981 1600 cc models 5.3litres1979-1987 1800 cc models 5.51itresManual transaxle two wheel drive models:Lubricant SAE 80W-90Capacity-1979-1984 models 2.7 litres1985-1987 Sedan andStation Wagon models 2.61itresManual transaxle four wheel drive models:Lubricant SAE 80W-90Capacity -1979-1984 and Utility models 3.0 litres1985-1987 Sedan andStation Wagon models 3.31itresAutomatic transaxle two wheel drive models,transmission:Lubricant. . . . . . . . . . . . . . . . . . . . . . . . Dexron IICapacity 1983-1984 models -Dry refill. . . . . . . . . . . . . . . . . . . . . . 5.6-6.0 litresCapacity 1985-1987 models -Dry refill. . . . . . . . . . . . . . . . . . . . . . 6.0-6.4 litresAutomatic transaxle four wheel drive models,transmission:Lubricant Dexron IICapacity 1983-1984 models-Dry refill. . . . . . . . . . . . . . . . . . . . . . 6.0-6.4 litresCapacity 1985-1987 models -Dry refill. . . . . . . . . . . . . . . . . . . . . . 6.8-7.2 litresAutomatic transaxle, differential:Lubricant SAE 80W-90Capacity. . . . . . . . . . . . . . . . . . . . . . 1.1-1.31itresRear axle four wheel drive models:Lubricant SAE 80W-90Capacity 0.8 litresSteering gear:Lubricant -Manual steering. . . . . . . . Subaru steering greasePower steering. . . . . . . . . . . . . . . . . . . . Dexron IIBrake fluid type Dot 3 or 4Fuel tank capacity:1979-1982 Sedan. . . . . . . . . . . . . . . . . . 50 litres1979-1982 Station Wagonand Utility. . . . . . . . . . . . . . . . . . . . . . . . 45 litres1983-1984 Sedan and Coupe " 601itres1983-1984 Station Wagonand Utility. . . . . . . . . . . . . . . . . . . . . . .. 55 litres1985-1987 Sedan andStation Wagon. . . . . . . . . . . . . . . . . . . . . 60 litres1985-1987 Utility 551itres

NOTE: Lubricant capacities shown areapproximate only. The correct lubricant levelshould be checked at the/iller plug or dipstick.

1. HOW TO GREASE AND OIL CHANGETOOLS, STORES AND EQUIPMENTREQUIRED

I Set of ring spanners.1 Adjustable spanner.1 Hydraulic jack.1 Set of car ramps.1 Set of chassis stands.1 Oil can.1 Oil gun.1 Filter removal tool.1 Oil drain tin.1 Parts washing tin.1 Funnel.1 Wire brush.1 Parts washing brush.1Tin of brake fluid.1Tin of engine oil.1 Tin of transmission oil.I Tin offront differential oil (automatic transaxlevehicles only).1Tin of rear differential oi l (four wheel drivevehicles only).NOTE: All lubricant capacities and grades forthe various assemhlies can be obtained byreferring to the Specifications in this section.

TO DO THE JOB(1) Remove the spare tyre from the enginecompartment to allow access to the transaxle dipstick(s).(2) Run the front of the vehicle onto the carramps, stop the engine, apply the handbrake andchock the front wheels.

location of th e engine sump drain plug, sump guardremoved, 1986 model shown.


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12 Lubrication and Alaintenance(3) Ralse t he r ear o f th e vehicle with t he j ac k

an d place chassis stands under t h e r ear j ack in g points.NOTE: It is best i fthe vehicle is kept as level aspossible to avoid false readings when checkingthe lubricant levels.(4) Using a wire brush an d a cloth, clean aroundthe engine s um p d ra in plug, transmission dipstick(s)

and the rear axle filler plug on four wheel drivevehicles.(5) Place a drain ti n u nd er th e engine sump,r emo ve t h e sump drain plug with the appropriate sizering spanner an d allow t he s um p to completely drain.

NOTE: It is best to drain the engine sump withthe oil at operating temperature. However i fthe oil is hot take care to avoid scalding.When the sump has completely drained, instalan d securely tighten the sump drain plug. Wipe

around the plug after installing.NOTE: Before installing the sump drain plugcheck the plug sealing gasket to ensure that it isserviceable.

M e th o d o f removing th e engine oi l filter, 1 9 8 6 modelshown.

(6) R em ov e t he oil filter with th e removal toolan d allow th e residual engine oil to dra in into thedrain tin. Smear oil o n to t he sealing gasket of th e newfilter an d tighten th e filter by hand as per thetightening instructions supplied with th e new filter.IMPORTANT: Before installing the new filterensure that the sealing gasket from the oldfilter has not come away from the oldfilter andadhered itself to the filter sealing seat on theengzne.

(7) On manual t ransaxle models, remove thedipstick an d check that th e oil level is between theupper an d lower marks on th e dipstick.If th e oil level is low use th e oil gun or a funnel tofill th e transaxle to t he correct level with th e specifiedoil. Recheck th e oil level an d replace th e dipstick.

Check th e manual transaxle o il le vel using th e dip-stick, 1 9 8 6 model shown.(8) On automatic transaxle models, r em ov e t hedifferential dipstick an d check that th e oil level isbetween th e upper and lower m ar ks o n th e dipstick. Ifth e oil level is low use th e oil gun or a funnel to fill th edifferential to the correct level with th e specified oil,recheck th e oil level an d replace th e dipstick.Refer t o t he A ut om a ti c T ra ns ax le section for th ecorrect p r ocedu re t o check an d to p up t h e au to mat i c

transmission fluid level.(9) R em ov e t he level plug from t he r ea r axle onfour wheel drive models. Use a finger or a bent pieceof wire to check th e oil level. Th e correct level is whenth e oil is level with th e bottom of the plug hole.If th e oil level is low use the oil gun to fill t he r ea raxle to the correct level with th e specified oil. Whensatisfied that th e level is correct instal an d firmlytighten th e plugs. W ip e a ro un d t he plugs with a clothafter installing them.(10) Using th e funnel, fill th e engine with th especified amount an d grade of engine oil an d st ar t an dr un the engine for a few minutes. Ensure t ha t t he oilpressure warning lamp goes out. Sto p t h e engine, waitfor a few minutes an d check the oil level on thedipstick. If necessary ad d oil to b r in g t h e level to thefull mark on th e dipstick.

Location of th e manual transaxle d ra in p lu g, 1 9 8 6model shown.


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l ~ u b r i c a t i o n and Alaintena nee

View of t he a ut om at ic transaxle d ip st ic k a nd f ro ntdifferential dipstick. S pa r e t y re removed, 1 9 8 6 modelshown.

NOT E: To prevent overfilling initially, it isgood policy not to pour all of the specifiedamount of the o il in to th e en gin e in on e go assometimes the amou nts specified are onlyapproximate. It is best to hold back at leastha((a litre and top up to the fu ll mark on thedipstick G;/ier t he e ngine has been run for a f ewminutes.

Location of t he r ea r a xl e oil level c he ck in g a nd drainplugs, four wheel drive models.(11) Check thoroughly for oil leaks at the engine

sump plug and engine oil filter if a new filter wasfitted.(12) Referring to the Service Schedule, lubricateand check all other items which coincide with thegrease and oil change intervals.(13) Lower the vehicle to the ground, instal thespare wheel. road test and check for oil leaks.


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14 Lubrication and ~ M a i n t e n a n c e

2. SERVICE SCHEDULE

daily THOUSAND KILOMETRESJOB or1,000 km 10 20 25 30 40 50 60 70 75 80 90 100ENGINE

(1) Check the oil level on the dipstick each time the fuel tank is topped up or every 1,000 km. Top upas necessary with the correct grade of engine oil.(2) Drain and refill the engine sump and renew the oil filter every 10,000 km or six months.NOTE: When driving under severe or dustyconditions it is recommended that the engineoil and/ilter are changed more frequently.(3) Check and if necessary adjust the valve clearance on OHV engines every 20,000 km or 12months.(4) Check and if necessary adjust the camshaft drive belt tension on OHC engines every 25,000 km or

12 months.(5) Renew the camshaft drive belts on OHC engines every 100,000 km or 48 months.COOLING SYSTEM

(1) Check the coolant level in the radiator or coolant reservoir daily or every 1,000 km.NOTE: If the engine is at normal operatingtemperature use care when removing the radia-tor cap to avoid scalding.(2) Drain, flush and refill the cooling systemevery:(a) 40,000 km or 24 months on 1979-1984 and Utility models.(b) 50,000 km or 24 months on 1985-1987 models.(3) Check the radiator hoses, heater hoses and drive belts every 20,000 km or 12 months.

FUEL SYSTEM( I ) Inspect the air cleaner element and the PCVfilter, if applicable, every:(a) 20,000 km or 12 months on 1979-1984 and Utility models.(b) 25,000 km or 12 months on 1985-1987 models.(2) Renew the air cleaner element and the PCVfilter, if applicable, every:(a) 40,000 km or 24 months on 1979-1984 and Utility models.


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Lubrication and Maintenance 15daily THOUSAND KILOMETRESJOB or1,000 km 10 20 25 30 40 50 60 70 75 80 90 100

(b) 50,000 km or 24 months on 1985-1987 models.NOTE: Do not wash the viscous paper typeelement in solvent or blow it out withcompressed air.(3) Renew the fuel filter and inspect all hoses

and connections every:(a) 20,000 km or 12 months on 1979-1984 and Utility models.(b) 50.000 km or 24 months on 1985-1987 models.(4) Adjust the engine idle speed and mixture, ifapplicable, every:(a) 20,000 km or 12 months on 1979-1984 and Utility models.(b) 25,000 km or 12 months on 1985-1987 models.(5) Check the operation of the manual or auto-matic choke and adjust or lubricate as necessaryevery:(a) 20,000 km or 12 months on 1979-1984 and Utility models.(b) 25,000 km or 12 months on 1985-1987 models.

MANUAL TRANSAXLE AND CLUTCH(I ) Check the oil level every 20,000 km or 12 months and top up as necessary.(2) Drain and refill the transaxle oil every:(a) 40,000 km or 24 months on 1979-1984 and Utility models.(b) 50,000 km or 24 months on 1985-1987 models.(3) Check the clutch cable and, if applicable the hill holder adjustment every 25,000 km or 12 months.(4) Inspect the Constant Velocity (CV) joint boots for damage and security every 10,000 km or 6months. Renew the boots or joints as necessary.

AUTOMATIC TRANSAXLE(I ) Check the oil level in both the transmission and the front differential every 10,000 km or 6months. The transmission check should be performedafte r a run with the t ransmission at operating tem-perature and the selector lever in the Park or Neutralposition and the engine running.(2) Drain and refill both the transmission anddifferential oil every:(a) 40,000 km or 24 months on 1979-1984 and Utility models.


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,If) Lubrication and j\l1aintenance

daily THOUSAND KILOMETRESJOB or1,000 km 10 20 25 30 40 50 60 70 75 80 90 100(b) 50,000 km or 24 months on 1985-1987 models.NOTE: When the vehicle is subjected toextreme or severe conditions. it is advisable tochange the automatic transaxle oils morefrequently.

REAR AXLE(I ) On four wheel drive vehicles check the rear axle oil level every 20,000 km or 12 months and topup as necessary.(2) On four wheel drive vehicles renew the rearaxle oil every:(a) 40,000 km or 24 months 1979-1984 and Utility models.(b) 50,000 km or 24 months 1985-1987models. (3) On four wheel drive vehicles inspect the CV joint boots for damage every 10,000 km or 6 months.Renew the boots or joints as necessary.(4) Dismantle, inspect and repack the rear hubbearings every:(a) 40,000 km or 24 months on 1979-1984 and Utility models.(b) 100,000 km or 48 months 1985-1987 mod- cis.NOTE: Inspect the rear hub bearings and CVjoint hoots more often in vehicles that aredriven through mud or water.

STEERING GEAR(I ) Check the level of the fluid in the power steering reservoir every 1,000 km or when the engineoil is checked.(2) Inspect the steering gear and linkages for security, damage, wear or leaks every 10,000 km or 6months.(3) Check and adjust the s teering gear every 25,000 km or 12 months.

FRONT SUSPENSION( 1) Dismantle and grease the front hub bearings

every:(a) 40,000 km or 24 months on 1979-1984 and Utility models.(b) 100,000 km or 48 months on 1985-1987 models.(2) Inspect the suspension ball joints boots for damage every 10,000 km or 6 months.NOTE: Inspect thefront hub hearings and balljoints more ojien in vehicles that are driventhrough mud or water.(3) Check the wheel alignment every 20,000 km or 12 months.


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daily THOUSAND KILOMETRESJOB or1,000 km 10 20 25 30 40 50 60 70 75 80 90 100BRAKE SYSTEM

( I) Check the level of fluid in the master cylin- der visually each time the fuel tank is topped up orevery 1,000 km. Top up as necessary using the correctbrake fluid.NOTE: If constant topping up of the mastercylinder is required the entire braking systemshould be checked for leaks.(2) Renew the brake fluid in the ent ir e systemevery:(a) 20,000 km or 12 months on 1979-1984 and Utility models.(b) 50,000 km or 24 months on 1985-1987 models.(3) Inspect the disc pads for wear every 10,000 km or six months. Inspect the calipers for leakage.(4) Inspect the rear brake shoe linings and drums for wear every 40,000 km or 24 months.Inspect the rear wheel cylinders for leakage.(5) Inspect the servo hose and check valve and all hydraulic brake lines for damage and chafing,paying particular attention to the flexible hoses every20,000 km or 12 months.NOTE: The servo unit check valve is incorpo-rated in the hose on some models.(6) Overhaul the calipers and wheel cylinders on 1979-1984 and Utility models every 40,000 km or 24months.(7) Check and adjust the operation of the foot- brake and handbrake every 20,000 km or 12 months.

ELECTRICAL SYSTEM II(I) Check and top up the battery electrolyte, ifapplicable, with distilled water as required or at leastmonthly, never allow the electrolyte level to fall belowthe p l a t c ~ .NOTE: On some models, the batterv is main-tenancefree. requiring only the term"inals to bekept corrosion free.(2) Renew the spark plugs every:(a) 20,000 km or 12 months on 1979-1984 and Utility models.(b) 25,000 km or 12 mon ths on 1985-1987 models.(3) Inspect the distributor points, if applicable, for burning or pitting and lubricate the distributorcam every 10,000 km or 6 months. If the points a reburned or pitted, the condenser and points should berenewed.(4) Inspect the distributor cap, the rotor and the high tensIon leads for signs of deterioration or cracksevery 20,000 km or 12 months.

Lubrication and Maintenance I i


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18 Lubrication and lHaintenanre

daily THOUSAND KILOMETRESJOB or1,000 km 10 20 25 30 40 50 60 70 75 80 90 100

(5) Renew the distributor points an d condenser, if applicable, every 20,000 km or 12 months.(6) Check an d adjust th e ignition timing every:(a) 20,000 km or 12 months on 1979-1984 and Utility models.(b) 25,000 or 12 months on 1985-1987 models. (7) Check all e lectrical equipment including lamps, headlamp aim, horn and windscreen wipersevery 20,000 km or 12 months.BODY

(I ) Check an d lubricate the following compo- nents every 20,000 km or 12 months with dry lubri-cant: Door locks an d strikers, bonnet catch, luggagecompartment lid or tailgate lock an d striker. Lubri-cate with a few drops of engine oil: Door hinges,throttle cable a nd ha ndbra ke cable.(2) Check all body an d chassis nuts an d bolts for security every 20,000 km or 12 months.EMISSION CONTROL

(1) Renew the rcv valve every:(a) 40,000 km or 24 months on 1979-1984 and Utility models.(b) 50,000 km or 24 months on 1985-1987 models.(2) Inspect the opera tion of the EGR system, if applicable, every 20,000 km or 12 months.(3) Check the charcoal canister, if applicable, and all emission control lines an d hoses for signs ofdeterioration every 40,000 km or 24 months.(4) Renew the charcoal canister every 100,000 km on 1987 models.WHEELS AND TYRES

( I ) At least once a fortnight check an d adjust thetyre pressures when the tyres are cold. Frequent loss ofpressure should be investigated an d leakage rectified.

NOTE: The recommended tyre pressures andthe sizes oftyres which may be installed to thevehicle arc printed on a decal positionedon thedrivers door jam.(2) Inspect the tyres regularly for damage an dabnormal wear. Any abnormal wear may be du e toone or more of the faults shown in the illustrations inTyre Wear Trouble Shooting in th e Wheels an d Tyressection.


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Lubrication ([nd A]aintenrUlce

3. LUBRICATON CHART

12

905 74


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Lubrication and Alaintenance

4. MAINTENANCE CHART

GJ 04--4 7

-4 4-6

..~ - - - 4..

236- Me

MAINTENANCE KEY1. Radiator 7. Ca rburettor and2. Battery ai r cleaner

1979-1984 and assembly11 12 Util ity models 8. C.V. joint an d

3. Battery steering boot1985-1987 checking pointsmodels 9. Front brakes and

4. Spark plugs and hu b bearingsp lug gap 10 . R ear b rakes andmeasuring point hub bearings

I I ~ : : : J I I Ii' ill 5. Distributor 11 . Fuel f i l tercontact breaker 1979-1984 an d8 8 8 8 gap 1979-1984 and Util ity modelsUtil ity models 12 . Fuel f i l ter6. Distributor 1985-19871985-1987 modelsmodels

02 - lubrication and maintenance

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