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Inspection & Maintenance

INTRODUCTION

SAGA
00 GENERAL

Model YR 2008
English Edition RDPE-08MA050
Destination: MHR
January 2008 Printed in Malaysia

Copyright

Perusahaan Otomobil
Nasional Sdn Bhd
(Company No.: 100995-U)
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Printed in Malaysia 3 January 2008 Eng

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INTRODUCTION P M 0 1
Content /I

00 GENERAL

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1

EXPLANATION OF MANUAL CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2

PRECAUTIONS BEFORE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/3

PROTECTING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/3
DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS . . . 00/3
REMOVAL AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/4
PARTS TO BE REPLACED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/4
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/4
TUBES AND OTHER RUBBER PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
SERVICING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ....................................... 00/6
IN ORDER TO PREVENT VEHICLES FROM FIRE . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
Health Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
Recommended Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7

SUPPORT LOCATIONS FOR LIFTING AND JACKING . . . . . . . . . . . . . . . . . . . . . . 00/7

H-BAR LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/8
MAKING WOODEN ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/9

All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

Copyright

Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)

Printed in Malaysia 3 January 2008 Eng

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00 GENERAL
/1 FOREWORD / HOW TO USE THIS MANUAL

FOREWORD PDI000FWORD000

This Inspection and Maintenance Manual explains the main points necessary for inspection and
maintenance of Proton vehicles, combining Pre-Delivery Inspection and Periodic Inspection in one
volume. It is intended to contain enough information to allow the user to conduct work quickly and
with precision .
For checking procedures, specifications, tightening torques, etc., there may be instances in which
reference to the Workshop Manual is necessary. If so, refer to the Workshop Manual applicable to
that model.
All information, illustrations and product descriptions contained in this manual are current as of time
of publication. We, however, reserve the right to make changes at any time without prior notice for
obligation.

HOW TO USE THIS MANUAL PDI000GINFO037

EXPLANATION OF MANUAL CONTENTS

DOIIP000R9001

Symbol Description
A Indicates the group title
B Indicates the section title
C Indicates the group number
D Indicates the page number

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HOW TO USE THIS MANUAL /2

Symbol Description
Indicates the inspection to be made. The number preceding the indication of the
E inspection to be made is the same number as that used preceding in the periodic
inspection and maintenance schedule.
F Indicates the Maintenance interval
Indicates the maintenance operation code.
I : Inspection
G R : Replace or change
L : Lubrication
none : Not applicable

ABBREVIATIONS

A / T : Automatic Transmission
CO : Carbon Monoxide
EGR : Exhaust Gas Recirculation
M.P.I : Multi Point Injection
P.A.D.T : Proton Advance Diagnostic Tool
SOHC : Single Overhead Camshaft
DOHC : Double Overhead Camshaft
FWD : Front Wheel Drive Vehicles
M / T : Manual Transmission
ISC : Idling Speed Control
SRS : Supplemental Restraint System
A.B.S : Anti-skid Brake System
TC : Traction Control

MODEL
Hatchback

Fuel Supply
Model Code Engine Model Transmission Model
System
SNBFRMA
SNSFRMA MFA30A
BT3 SNJFRMA MPI
S4PE
SRSFRMA (D4) F4A41
SRJFRMA
MPI
BT6 SNSWRMA F5M41
(NGV)

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00 GENERAL
/3 PRECAUTIONS BEFORE SERVICE

PRECAUTIONS BEFORE SERVICE

PDI000BSERV008

PROTECTING THE VEHICLE

If there is a likelihood of damaging interior or
exterior parts during service operations, protect
them with suitable covers (such as Seat covers,
Fender covers, etc.).

DOIIP000R9015

DOING SERVICE WORK IN GROUPS OF

TWO OR MORE MECHANICS
If the service work is to be done by two or more
mechanics working together, all the mechanics
involved should take safety into consideration
while they work.

DOIIP000R9016

REMOVAL AND DISASSEMBLY

When checking a malfunction, find the cause of
the problem. If it is determined that removal
and/or disassembly is necessary, perform the
work by following the procedures contained in
this Manual.

DOIIP000R9017

If punch marks or marks or mating marks are

made to avoid error in assembly and facilitate
the assembly work, be sure to make them in
locations which will have no detrimental effect
on performance and/or appearances.
If an area having many parts, similar parts, and/
or parts which are symmetrical right and left is
disassembled, be sure to arrange the parts so
that they do not become mixed during the
assembly process.
1. Arrange the parts removed in the proper
order.
DOIIP000R9018
2. Determine which parts are to be reused and
which are to be replaced.

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GENERAL 00
PRECAUTIONS BEFORE SERVICE /4

3. If bolts, nuts, etc., are to be replaced, be

sure to use only the exact size specified.

SPECIAL TOOLS
If other tools are substituted for the special
tools to do service or repair work, there is the
danger that vehicle parts might be damaged, or
the technician might be injured; therefore, be
sure to use the special tool whenever doing any
work for which the use of one is specified.

DOIIP000R9019

PARTS TO BE REPLACED
If any of the following parts are removed, they
must be replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packing
4. O-ring
5. Lock washers
6. Split pins
7. Self-locking nuts
PARTS
DOIIP000R9020 When replacing parts, use PROTON genuine
parts.

DOIIP000R01026

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00 GENERAL
/5 PRECAUTIONS BEFORE SERVICE

TUBES AND OTHER RUBBER PARTS

Be careful to avoid spilling any petrol, oil, etc.,
because if it adheres to any tubes or rubber
parts, they might be adversely affected.

DOIIP000R9022

LUBRICANTS
In accordance with the instruction in this
Manual, apply the specified lubricants in the
specified locations during assembly and instal-
lation.

DOIIP000R9023

BRAKE FLUID
Be careful to avoid spilling any brake fluid,
because if it adheres to the vehicle body, the
paint coat might be discolored.

DOIIP000R9024

SERVICING THE ELECTRICAL SYSTEM

1. When working on the electrical system, be
sure to avoid arbitrary changes to the
electrical devices or wiring as such can
cause electrical overloading and shorts,
and fire.
2. When servicing the electrical system, dis-
connect the negative cable terminal from
the battery.
CAUTION
Before connecting or disconnecting the
DOIIP000R9025
negative cable, be sure to turn off the
ignition switch and the lighting switch.

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PRECAUTIONS BEFORE SERVICE /6

(If this is not done, there is the possibility

of semiconductor parts being damaged.)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Refer to Workshop Manual Chassis – Group 52B.

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00 GENERAL
/7 SUPPORT LOCATIONS FOR LIFTING AND JACKING

IN ORDER TO PREVENT VEHICLES FROM FIRE

‘‘Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high
quality and safety of the vehicle, it is important that any accessories that may be fitted or
modifications/repairs that may be carried out which involve the electrical or fuel systems, MUST be
carried out in accordance with PROTON’S Information/Instructions’’.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine
oil and by degreasing components, where practicable, before handling them.
Other precautions:
. Avoid prolonged and repeated contact with oils, particularly used engine oils.
. Wear protective clothing, including impervious gloves where practicable.
. Avoid contaminating clothes, particularly underpants, with oil.
. Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
. Do not wear heavily soiled clothing and oil-impregnated footwear. Overalls must be cleaned
regularly and kept separate from personal clothing.
. Where there is a risk of eye contact, eye protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash facility should be provided.
. Obtain First Aid treatment immediately for open cuts and wounds.
. Wash regularly with soap and water to ensure all oil is removed especially before meals (skin
cleansers and nail brushes will help). After cleaning, the application of preparations containing
lanolin to replace the natural skin oils is advised.
. Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.
. Use barrier creams, applying them before each work period, to help the removal of oil from the
skin after work.
. If skin disorders develop, obtain medical advice without delay.

SUPPORT LOCATIONS FOR LIFTING AND JACKING PDI000SLIFT009

DOIJP000R04001 DOIJP000R04002 DOIJP000R04003

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SUPPORT LOCATIONS FOR LIFTING AND JACKING /8

DOIIP000R9005
DOIIP000R9006 DOIIP000R9007

DOIIP000R9008 DOIIP000R9010

DOIIP000R9009

Label Description
A Garage jack
B Axle stand
C Single-post lift
D Double-post lift
E H-bar lift
F Notch

H-BAR LIFT
If, when an H-bar lift (E) is used for lifting the
vehicle, the metal attachment (G) included with
the H-bar lift (E) is used, there is the possibility
of damage to the suspension arms, etc, thus, the
following procedures should be followed for
lifting.
1. The vehicle should be placed on the H-bar
lift (E) in the same direction.

DOIIP000R9011

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00 GENERAL
/9 SUPPORT LOCATIONS FOR LIFTING AND JACKING

2. Place the attachments (G) on the H-bar lift

(E) so that there is contact at designated
chassis location. Note that attachments (G)
are made according to the procedure
described afterward.
3. Refer to the respective model page for the
chassis support locations.

DOIIP000R9012

MAKING WOODEN ATTACHMENTS

1. Prepare wooden blocks and nails (D) as
shown in the illustration

Item Size Quantity

Block (A) 90x95 mm 2
(3.543x3.74
in)
Block (B) 60x100 mm 4
(2.362x3.9-
37 in)
Block (C) 140x40 mm 8
(5.511x1.5-
74 in)
Nails (D) 70 mm as needed
(2.755 in) or
longer

CAUTION
The material used for the blocks must be
hard wood.
2. Make grooves of the dimensions shown in
the illustration in blocks (B) and (C) by using
a saw and chisel.
3. Use the nails to the nail blocks (B) and (C)
DOIIP000R9013
together so that block (B) sandwiched in
between; make four attachments such as
shown in the illustration.

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GENERAL 00
SUPPORT LOCATIONS FOR LIFTING AND JACKING /10

4. Finished wooden attachment.

Symbol Description
(A) Movable according to chassis
width

DOIIP000R9014

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00 GENERAL
/11 SUPPORT LOCATIONS FOR LIFTING AND JACKING

NOTE

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INTRODUCTION P M 0 1
INDEX /1

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 3
Content

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SAGA Model YR 2008 English Edition RDPE-08MA050 January 2008 Printed in Malaysia