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MARUTI SUZUKI 800, Service Manual

The Yamaha 800 Owner's Manual is a comprehensive guide to operating and maintaining your Yamaha 800. With detailed instructions and illustrations, this manual is essential for maximizing the performance and longevity of your vehicle. Download it for free from manualshive.com and unleash the full potential of your Yamaha 800.

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6A1

ENGINE MECHANICAL (F8D ENGINE)

6A1-1

SECTION 6A1

ENGINE MECHANICAL

(F8D ENGINE)

CONTENTS

GENERAL DESCRIPTION

6A1- 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Engine

6A1- 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Engine Lubrication

6A1- 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

ON-VEHICLE SERVICE

6A1- 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Compression Check

6A1- 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Engine Vacuum Check

6A1- 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Oil Pressure Check

6A1- 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Valve Lash (Clearance)

6A1- 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Air Cleaner Filter

6A1- 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Head Cover

6A1-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Throttle Body and Intake Manifold

6A1-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Exhaust Manifold

6A1-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Timing Belt and Belt Tensioner

6A1-15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Oil Pan and Oil Pump Strainer

6A1-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Oil Pump

6A1-23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Rocker Arms, Rocker Arm Shaft and Camshaft

6A1-26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Valves and Cylinder Head

6A1-32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Piston, Piston Rings, Connecting Rods and Cylinders

6A1-42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

UNIT REPAIR OVERHAUL

6A1-51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Engine Assembly

6A1-51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Main Bearings, Crankshaft and Cylinder Block

6A1-52

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

REQUIRED SERVICE MATERIALS

6A1-64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

SPECIAL TOOLS

6A1-64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

NOTE:
For what each abbreviation stands for (i.e., full term), refer to SECTION 0A.

Summary of Contents for 800

Page 1: ...UTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make mainte nance easier or instructions clearer WARNING This service manual is intended for autho rized Maruti dealers and qualified service mechanics only Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly per form the services describe...

Page 2: ... items will enable one to obtain the full performance of the vehicle When replacing parts or servicing by disassembling it is recommended to use MARUTI genuine parts tools and service materials lubricant sealants etc as specified in each description All information illustrations and specifications contained in this literature are based on the latest product information available at the time of pub...

Page 3: ...d Pinion Steering Wheel and Column Front Suspension Rear Suspension Leaf Spring Type Rear Suspension Coil Spring Type Wheels and Tires DRIVE SHAFT AND PROPEL LER SHAFT Front Drive Shaft BRAKE SYSTEM Brakes 1A 0B SECTION 0A 1B 3A 3 3B 3C 3D 3E 3E1 3F 4 5 TABLE OF CONTENTS ENGINE Engine Diagnosis Engine Mechanical F8B Engine Engine Mechanical F8D Engine Engine Cooling Engine Fuel Engine and Emission...

Page 4: ...Procedure 0A 7 Intermittent and Poor Connection 0A 10 Precaution for Installing Mobile Communication Equipment 0A 11 IDENTIFICATION INFORMATION 0A 11 Vehicle Identification Number 0A 11 Engine Identification Number 0A 11 Transmission Identification Number 0A 11 VEHICLE LIFTING POINTS 0A 12 ABBREVIATIONS MAY BE USED IN THIS MANUAL 0A 14 METRIC INFORMATION 0A 16 Metric Fasteners 0A 16 Fasteners Stre...

Page 5: ...le or drive plate for A T vehicle Using special tool lock flywheel or drive plate and tighten flywheel or drive plate bolts to specified torque Special Tool A 09924 17810 Tightening Torque c 78 N m 7 8 kg m 56 0 lb ft 1 Flywheel bolts or drive plate bolts for A T vehicle 4 A number of abbreviations are used in the text For their full explanations refer to ABBREVIATIONS MAY BE USED IN THIS MANUAL o...

Page 6: ...void getting burned keep away from hot metal parts such as the radiator exhaust manifold tailpipe muffler etc New and used engine oil can be hazardous Children and pets may be harmed by swallowing new or used oil Keep new and used oil and used engine oil filters away from children and pets Continuous contact with used engine oil has been found to cause skin cancer in laboratory ani mals Brief cont...

Page 7: ...osition Whenever you use oil seals gaskets packing O rings locking washers split pins self locking nuts and certain other parts as specified be sure to use new ones Also be fore installing new gaskets packing etc be sure to remove any residual material from the mating surfaces Make sure that all parts used in reassembly are perfectly clean When use of a certain type of lubricant bond or sealant is...

Page 8: ...sing the fuel pressure or fuel can be sprayed out under pressure PRECAUTIONS FOR CATALYTIC CONVERT ER For vehicles equipped with a catalytic converter use only un leaded gasoline and be careful not to let a large amount of un burned gasoline enter the converter or it can be damaged Conduct a spark jump test only when necessary make it as short as possible and do not open the throttle Conduct engin...

Page 9: ... it may cause dam age to electronic control unit and sensors Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained or personal injury may result If not specified use a voltmeter with high impedance M V minimum or a digital type voltmeter When taking measurements at electrical connectors using a tester probe 2 be sure to insert the probe from the wire har...

Page 10: ...CK Possible causes for the open circuit are as follows As the cause is in the connector or terminal in many cases they need to be checked particularly carefully Loose connection of connector Poor contact of terminal due to dirt corrosion or rust on it poor contact tension entry of foreign object etc Wire harness being open When checking system circuits including an electronic control unit such as ...

Page 11: ... 1 Measure resistance between connector terminals at both ends of the circuit being checked between A 1 and C 1 in the figure If no continuity is indicated infinity or over limit that means that the circuit is open between terminals A 1 and C 1 2 Disconnect the connector included in the circuit connector B in the figure and measure resistance between terminals A 1 and B 1 If no continuity is indic...

Page 12: ...SHORT CIRCUIT CHECK wire harness to ground 1 Disconnect negative cable from battery 2 Disconnect connectors at both ends of the circuit to be checked NOTE If the circuit to be checked is connected to other parts dis connect all connectors of those parts Otherwise diagnosis will be misled 3 Measure resistance between terminal at one end of circuit A 1 terminal in figure and body ground If continuit...

Page 13: ...rmed or damaged terminals Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal If contact tension is not enough reform it to increase contact ten sion or replace 1 Check contact tension by inserting and removing just once 2 Check each terminal for bend and proper alignment Poor terminal to wire connection Check each w...

Page 14: ...way from electronic control unit and its wire harnesses Do not run the antenna feeder parallel with other wire har nesses Confirm that the antenna and feeder are correctly adjusted IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The number is punched on the front dash panel in the engine room ENGINE IDENTIFICATION NUMBER The number is punched on the cylinder block TRANSMISSION IDENTIFICAT...

Page 15: ...r part When using frame contact hoist apply hoist as shown right and left at the same position Lift up the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to move vehicle body in both ways Work can be started only after this confirmation Make absolutely sure to lock hoist after vehicle is hoisted up When using frame contact hoist 1 Front ...

Page 16: ...e sure to block the wheels on ground in order to ensure safety After the vehicle is jacked up be sure to support it on stands It is extremely dangerous to do any work on the vehicle raised on jack alone When using floor jack 2 To perform service with either front or rear vehicle end jacked up be sure to place safety stands 1 under body so that body is se curely supported And then check to ensure t...

Page 17: ...ad Camshaft DOJ Double Offset Joint DRL Daytime Running Light DTC Diagnostic Trouble Code Diagnostic Code E EBCM Electronic Brake Control Module ABS Control Module ECM Engine Control Module ECT Sensor Engine Coolant Temperature Sensor Water Temp Sensor WTS EGR Exhaust Gas Recirculation EGRT Sensor EGR Temperature Sensor Recirculated Exhaust Gas Temp Sensor REGTS EFE Heater Early Fuel Evaporation H...

Page 18: ...M Powertrain Control Module PCV Positive Crankcase Ventilation R RH Right Hand S SAE Society of Automotive Engineers SDM Sensing and Diagnostic Module Air bag controller Air bag control module SFI Sequential Multiport Fuel Injection SOHC Single Over Head Camshaft T TBI Throttle Body Fuel Injection Single Point Fuel Injection SPI TCC Torque Converter Clutch TCM Transmission Control Module A T Contr...

Page 19: ...C BOLTS IDENTIFICATION CLASS NUMBERS OR MARKS CORRESPOND TO BOLT STRENGTH INCREAS ING NUMBERS REPRESENT INCREASING STRENGTH STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual If no description or specifi cation is provided refer to the following tightening torque chart for the applicable torque for each fastener When a fastener of gr...

Page 20: ...D LUBRICATION CONTENTS PERIODIC MAINTENANCE SCHEDULE 0B 2 MAINTENANCE SERVICE 0B 5 Engine 0B 5 Ignition System 0B 10 Fuel System 0B 11 Emission Control System 0B 12 Brake 0B 13 Chassis and Body 0B 14 Final Inspection 0B 19 RECOMMENDED FLUIDS AND LUBRICANTS 0B 20 ...

Page 21: ...ystem noise leakage or otherwise defective I I I I I 10 Positive crankcase ventilation System Hoses connections and valve I I I I I IGNITION 1 Ignition wiring damage deterioration I I I I 2 Distributor cap and rotor wear deterioration I I I I 3 Spark plugs clean and adjust the gap I R I R I R I R FUEL 1 Air cleaner Paved road Clean every 5 000 km Replace every 40 000 km Dusty condition Clean every...

Page 22: ...I I I I 6 Master cylinder and wheel cylinder oil leakage boot kit I I I I I R I I I R 7 Brake hoses and pipes leakage damage I I I I I I I I I I WHEEL 1 Tyres air pressure abnormal wear crack ROTATION Rotate and inspect every 5 000 km 2 Wheels damage I I I I I I I I I I 3 Front wheel bearings loose damage I I I I I I I I I 4 Rear wheel bearings loose damage I I I I I I I I I FRONT AND REAR SUSPENS...

Page 23: ...operation I I I I I I I I I I 5 System voltage I I I I I I I I I BODY 1 All chassis bolts and nuts tighten I T T T T T T T T 2 All Latches Hinges Locks function I I L I L I L I L I L I L I L I L I L ROAD TEST 1 Operation of Brakes Gear shifting speedometer I I I I I I I I I I 2 Body and Chassis noise I I I I I I I I I I AIR CONDITIONER if equipped 1 Check belt tension I I I I I I I I I I 2 Check r...

Page 24: ...and Installation in Section 6B WARNING Disconnect negative cable at battery before checking and replacing belt tension A C compressor drive belt inspection If equipped 1 Disconnect negative cable from battery 2 Inspect belt for cracks cuts wear and deterioration Replace if any defect exists 3 Check belt for tension A C compressor drive belt tension b 7 9 mm 0 28 0 35 in deflection under 100N 10 kg...

Page 25: ...D Engine F8D Engine F8B Engine 3 Install cylinder head cover and tighten bolts to specification F8B Engine 0B 6 MAINTENANCE AND LUBRICATION Valve lash clearance When cold Coolant temp is 15 25 C or 59 77 F When hot Coolant temp is 60 68 C or 140 154 F specifica tion Intake 0 13 0 17 mm 0 15 0 19 mm 0 006 0 007 in Exhaust 0 005 0 007 in 0 14 0 18 mm 0 006 0 007 in Valve lash gap a When cold Coolant...

Page 26: ...ining oil wipe drain plug clean Reinstall drain plug and tighten it securely as specified below Tightening Torque a 50 N m 5 0 kg m 36 0 lb ft 1 a 3 Loosen oil filter 1 by using oil filter wrench Special tool Special Tool A 09915 47310 4 Apply engine oil to new oil filter O ring 5 Screw new filter on oil filter stand by hand until filter O ring con tacts mounting surface CAUTION To tighten oil fil...

Page 27: ...RNING To help avoid danger of being burned do not remove ra diator cap while engine and radiator are still hot Scald ing fluid and steam can be blown out under pressure if cap is taken off too soon CAUTION When changing engine coolant use mixture of 50 wa ter and 50 ethylene glycol base coolant Anti Freeze Anti corrosion coolant for the market where ambient temperature falls lower than 16 C 3 F in...

Page 28: ... connect outlet hose to radiator Also install reservoir 5 Slowly pour specified amount of coolant to the base of radiator filler neck and run engine with radiator cap removed until ra diator upper hose is hot This drives out any air which may still be trapped within cooling system Add coolant as necessary un til coolant level reaches filler throat of radiator Reinstall radiator cap 6 Add coolant t...

Page 29: ...or damaged missing or misposi tioned parts open seams holes loose connections or other de fects which could permit exhaust fumes to seep into vehicle Make sure that exhaust system components have enough clear ance from underbody to avoid overheating and possible dam age to floor carpet Any defects should be fixed at once IGNITION SYSTEM Spark Plugs Replacement Replace spark plugs with new ones ref...

Page 30: ...ording to procedure de scribed in Section 6A or 6A1 Fuel Lines Inspection Check fuel lines for loose connection deterioration or damage which could cause leakage Make sure all clamps are secure Replace any damaged or deteriorated parts There should be no sign of fuel leakage or moisture at any fuel con nection Fuel Filter Replacement Fuel filter 1 is installed in front of fuel tank 2 inside the le...

Page 31: ...terioration and damage Replace if faulty EMISSION CONTROL SYSTEM PCV Positive Crankcase Ventilation Valve Inspec tion Check crankcase ventilation hoses and PCV hoses for leaks cracks or clog and PCV valve 1 for stick or clog Refer to Section 6E1 for PCV valve checking procedure Fuel Evaporative Emission Control System if equipped Check EVAP Evaporative Emission canister for damage clog and operati...

Page 32: ...e same time check wheel cylinders for leakage Replace as necessary For the details refer to Section 5 3 Install brake drum and wheel Brake Hoses and Pipes Inspection Perform this inspection where there is enough light and use a mir ror as necessary Check brake hoses and pipes for proper hook up leaks cracks chafing wear corrosion bends twists and other damage Replace any of these parts as necessar...

Page 33: ...r Brake Lever and Cable Inspection Parking brake lever Check tooth tip of each notch for damage or wear If any damage or wear is found replace parking lever Check parking brake lever for proper operation and stroke and adjust it if necessary For checking and adjusting procedures refer to Section 5 a Parking brake lever stroke 3 6 notches With 20 kg or 44 lbs of pull pressure Parking brake cable In...

Page 34: ... Wheel disc inspection Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced Tire rotation Rotate tires referring to Section 3F Wheel Bearing Inspection 1 Check front wheel bearing for wear damage abnormal noise or rattles For details refer to Section 3D 2 Check rear wheel bearing for wear damage abnormal noise or rattle For details refer to Sec...

Page 35: ...ss and retighten them as neces sary Repair or replace defective parts if any a 3 Check steering linkage for looseness and damage Repair or replace defective parts if any 4 Check boots 1 and 2 of steering linkage and steering gear case for damage leaks detachment tear etc If damage is found replace it with new one 5 Check universal joints 3 of steering shaft for rattle and dam age If rattle or dama...

Page 36: ...specified torque Oil change for 5 speed M T 1 Place vehicle level and drain oil by removing drain plug 2 2 Apply sealant to drain plug after cleaning it and tighten drain plug to specified torque 3 Pour specified oil up to level hole 4 Tighten filler plug to specified torque For recommended oil its amount and tightening torque data re fer to On Vehicle Service of Section 7A1 5 Speed M T Oil inspec...

Page 37: ...ection Doors Check that each door of front rear and back doors opens and closes smoothly and locks securely when closed If any malfunction is found lubricate hinge and latch or repair door lock system Engine hood Check that secondary latch operates properly check that second ary latch keeps hood from opening all the way even when pulling hood release handle inside vehicle Also check that hood open...

Page 38: ...om any abnormal condition Gearshift or Select Lever Transmission Check gear shift or select lever for smooth shifting to all positions and for good performance of transmis sion in any position Brake Foot brake Check the following that brake pedal has proper travel that brake works properly that it is free from noise that vehicle does not pull to one side when brake is applied and that brake do not...

Page 39: ...ometer fuel meter tem perature gauge etc are operating accurately Lights Check that all lights operate properly Windshield Defroster Periodically check that air comes out from defroster outlet when operating heater or air conditioning Set fan switch lever to HI position for this check RECOMMENDED FLUIDS AND LUBRICANTS Engine oil SE SF SG SH or SJ Refer to engine oil viscosity chart in item 1 4 Eng...

Page 40: ...er varies depending on the specifications CONTENTS GENERAL DESCRIPTION 1A 2 DIAGNOSIS 1A 3 Diagnosis Table 1A 3 Wiring Circuit 1A 4 ON VEHICLE SERVICE 1A 5 Heater Unit 1A 5 Blower Fan Motor 1A 7 Blower Fan Motor Resistor 1A 8 Heater Control Lever Assembly 1A 9 Blower Fan Motor Switch 1A 11 Air Inlet Box 1A 12 ...

Page 41: ...ventilation consist of the following parts 1 Heater unit 2 Air inlet box or cooling unit 3 Ventilator duct 4 Defroster nozzle 5 Ventilation louver 6 Ventilation air 7 Foot air 8 Defroster air 9 Demister air 10 Fresh air 11 Recirculation air 12 Engine 13 Water valve ...

Page 42: ... faulty Position of control cable clamp is faulty Air damper broken Air ducts clogged Water valve faulty Heater core leaking or clogged Heater hoses leaking or clogged Thermostat faulty Check cables Check control lever Check and adjust clamp position Repair damper Repair air ducts Replace water valve Replace core Replace hoses Check thermostat When mode control lever is changed air outlet port is ...

Page 43: ...1 Blower fan motor 2 Blower fan motor resistor 3 Blower fan motor switch 4 Ignition switch 5 To A C switch if equipped 6 To ECM Idle up signal 1A 4 HEATER AND VENTILATION WIRING CIRCUIT ...

Page 44: ...ter core 2 Blower fan motor assembly 3 Blower fan motor resistor 4 Temperature door assembly 5 Air outlet control door assembly 6 Air outlet control lever 7 Temperature control lever 8 Heater case 9 Water valve HEATER AND VENTILATION 1A 5 ...

Page 45: ...crews 4 if vehicle equipped with A C as shown 6 Remove heater unit 5 from vehicle INSTALLATION Install heater unit by reversing removal procedure noting the fol lowing items When installing each part be careful not to catch any cable or wiring harness Adjust heater control cable refer to heater control lever assem bly in this section Fill engine coolant to radiator refer to ENGINE COOLANT CHARGE i...

Page 46: ...n motor 2 by removing it attaching screws 3 INSPECTION Check continuity between two terminal as shown in figure If check results are continuity proceed to next operation check if not replace Connect battery to blower fan motor as shown then check that the blower motor 1 operates smoothly 1 INSTALLATION Reverse removal procedure for installation HEATER AND VENTILATION 1A 7 ...

Page 47: ... resistor 2 by removing its mounting screw 3 INSPECTION Measure each terminal to terminal resistance on resistor Resistance Me Lo 1 5 3 0 at 25 C 77 F Me Hi 0 5 1 5 at 25 C 77 F If measured resistance is incorrect replace blower motor resistor INSTALLATION Reverse removal procedure for installation 1A 8 HEATER AND VENTILATION ...

Page 48: ...r control cables air outlet control 1 temperature control 2 and fresh air control from heater unit and air inlet box or cooling unit if equipped with A C 3 Disconnect heater control panel illumination coupler and A C switch coupler if equipped 4 Loosen steering column assembly refer to STEERING COL UMN in section 3C 5 Remove temperature control knob 1 air outlet control knob 2 and blower fan motor...

Page 49: ...ully in arrow direction as shown in figure ii Push air outlet lever d temperature lever e and door link f fully in arrow direction and fix cable with clamp in position as shown in figure NOTE After installing control cables be sure that control levers move smoothly and stop at proper position 1 Heater unit 2 Air inlet box or cooling unit 3 Air outlet control cable 4 Temperature control cable 5 Fre...

Page 50: ... blower fan motor switch knob 3 5 Remove meter cluster 4 by removing its mounting screws 5 6 Disconnect blower fan switch coupler 7 Loosen blower fan switch screw 1 and then remove blower fan motor switch 2 from instrument panel INSPECTION Check blower fan switch for each terminal to terminal continuity For the detail refer to WIRING CIRCUIT earlier in this section POSITION TERMINAL INSTALLATION R...

Page 51: ...box lid 4 3 Loosen air inlet box mounting nut 1 and screws 2 4 Remove air inlet box 3 INSTALLATION NOTE If vehicle is equipped with air conditioning refer to COOLING UNIT in Section 1B Reverse removal sequence to install air inlet box noting the follow ing point Adjust fresh air control cable refer to HEATER CONTROL LE VER ASSEMBLY in this section 1A 12 HEATER AND VENTILATION ...

Page 52: ... Assembly of Magnetic Clutch 1B 36 REQUIRED SERVICE MATERIALS 1B 37 SPECIAL TOOLS 1B 37 AIR CONDITIONING OPTIONAL 1B 1 SECTION 1B AIR CONDITIONING OPTIONAL CAUTION The air conditioning system of this vehicle uses refrigerant CFC 12 R 12 None of refrigerant compressor oil and component parts is interchangeable between two types of A C one using refrigerant CFC 12 R 12 and the other using refrigeran...

Page 53: ...n be checked by the shape of the service charge valve GENERAL DESCRIPTION 1 Compressor label 2 Service valve REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM 1 Compressor 2 Magnet clutch 3 Condenser assembly 4 Receiver dryer 5 Dual pressure switch 6 Expansion valve 7 Evaporator Liquid Vapor Superheated Vapor 1B 2 AIR CONDITIONING OPTIONAL ...

Page 54: ...assembly 4 Receiver dryer 5 Discharge hose 6 Suction hose 7 Receiver dryer outlet pipe 8 Condenser outlet pipe 9 Expansion valve 10 Ventilation air 11 Foot air 12 Defroster air 13 Demister air 14 Fresh air 15 Recirculation air 16 Heater unit AIR CONDITIONING OPTIONAL 1B 3 ...

Page 55: ...Drive belt loosen or broken Compressor faulty Check A C fuse and check short circuit to ground Check compressor relay Check magnet clutch Adjust or replace drive belt Check compressor Cool air won t come out Radiator and condenser cooling fan motor won t operative RDTR fuse blown Radiator and condenser cooling fan relay faulty Wiring or grounding faulty Radiator fan relay signal faulty Radiator an...

Page 56: ...it Check blower motor Pull out compressor oil in A C system circuit and replace compressor Cool air won t come out only intermittently Wiring connection faulty Expansion valve faulty Excessive moisture in A C system Magnetic clutch faulty Excessive charge of refrigerant Repair as necessary Check expansion valve Replace receiver dryer and evacuation and charging Check magnetic clutch Check charge o...

Page 57: ...ith a leak tester 2 No bubbles observed in sight glass No or insufficient charge of refrigerant in system Refer to the items 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty system Evacuate and charge system and then check it for leaks with a leak tester 4 Noticeable temperature difference between compressor inlet and outlet Proper or too much charge of...

Page 58: ...engine cool ant temperature at 80 90_C 176 194_F and keep it at speci fied idle speed 6 Turn A C switch ON and set blower switch at HI 3rd position temperature knob at COOL air outlet control knob at FACE fresh circulation control knob at CIRCULATION Confirm that A C compressor and condenser fan are working 7 Keep all windows doors and engine food open CAUTION Do not interchange high and low press...

Page 59: ...ure to outlet port temperature rela tionship using graph at the left For example if evaporator inlet port temperature is 25 C 77 F and center duct air outlet temperature is 8 C 46 4 F their crossing point is within acceptable range as shown in graph at the left 11 If crossing point is out of acceptable range diagnose trouble referring to following Diagnosis Test table 1B 8 AIR CONDITIONING OPTIONA...

Page 60: ...pressor malfunction Insufficient compression Check expansion valve Check compressor LOW PRESSURE Pressure low B area of low side graph Insufficient refrigerant Insufficient charge or leakage Expansion valve malfunction valve opens too narrow Clogged refrigerant passage crashed pipe Check for leakage repair if necessary and recharge Check expansion valve Repair or replace MOMETER AT TER DUCT Outlet...

Page 61: ...gs Continuous air bubbles are visible through sight glass Output air is slightly cold Insufficient refrigerant in system Refrigerant leaking Using a gas leak detector check for leaks and repair as necessary Recharge refrigerant to a specified amount If the pressure reading is al most 0 when the manifold gauges are attached check for any leaks repair them and evacuate the system 0 4 0 6 4 6 56 9 85...

Page 62: ... switch 4 Dual pressure switch 5 A C Switch 6 Fuse box 7 Radiator and condenser cooling fan relay 8 Radiator and condenser cooling fan motor 9 Compressor 10 Main relay 11 Ignition switch 12 A C evaporator thermistor 13 ECT sensor 14 Compressor relay AIR CONDITIONING OPTIONAL 1B 11 ...

Page 63: ...to Inspection of ECM and its circuit in ENGINE AND EMISSION CONTROL SYSTEM section NOTE As each terminal voltage is affected by the battery voltage confirm that it is 11V or more when ignition switch is ON TERMINAL ARRANGEMENT OF ECM COUPLER VIEWED FROM HARNESS SIDE 1 Blower fan motor 2 ECM 3 Dual pressure switch 4 A C switch 5 A C evaporator thermistor 6 ECT sensor 7 Radiator fan relay 8 Radiator...

Page 64: ... volt Blower fan motor switch ON with en gine running E34 09 P B blower fan input engine Fig B 10 14 volts Blower fan motor switch OFF with engine running E34 19 Or B A C switch input Ground to 0 1 volts Blower fan motor switch and A C switch ON with engine running E34 19 Or B A C switch in ut engine Fig B 10 14 volt Blower fan motor switch or A C switch OFF with engine running E34 22 B G Sensor c...

Page 65: ...00 N 10 kg 22 lbs force a 7 9 mm 0 27 0 35 in as deflection 100N 10 kg 22 lbs If belt tension is without above specification adjust belt tension by according to following items i Loosen mounting bolts 1 and adjust bolt 2 ii Adjust belt tension rotated compressor 3 by using a wood bar iii Tighten adjust bolt 2 and mounting bolt 1 as rotated com pressor iv Turn the crank pulley one revolution then c...

Page 66: ...harging it into atmosphere would cause adverse effect to envi ronments NOTE When handling recovery and recycling equipment be sure to follow the instruction manual for the equipment EVACUATING AND CHARGING Refer to AIR CONDITIONING BASIC MANUAL 99520 02130 NOTE Specified amount of refrigerant 600 60g A High pressure service valve B Low pressure service valve 1 Manifold gauge set 2 Low pressure gau...

Page 67: ...front bumper Refer to FRONT BUMPER in BODY SERVICE Section 4 Disconnect discharge hose from condenser 5 Disconnect condenser outlet pipe from condenser 6 Loosen radiator upper mounting bolt 7 Remove front center member 1 by loosening its mounting screws 2 8 Loosen condenser mounting bolt 3 9 Remove condenser assembly 4 1B 16 AIR CONDITIONING OPTIONAL ON VEHICLE SERVICE NOTE When refrigerant line m...

Page 68: ...rewdriver or pair of pliers If any leakage is found from fitting or tube repair or replace con denser RECEIVER DRYER REMOVAL 1 Recover refrigerant from refrigeration system by using recovery and recycling equipment 2 Disconnect receiver dryer outlet pipe 1 and condenser outlet pipe 2 from receiver dryer 3 3 Loosen receiver dryer bracket bolts 4 4 Remove receiver dryer with its bracket 5 INSTALLATI...

Page 69: ... continuity proceed to next operation check If not replace Connect battery to radiator and condenser cooling fan motor 1 as shown in figure then check that the radiator and condenser cooling fan motor operates smoothly Reference current approx 8 5 11 5 A at 12 V REMOVAL AND INSTALLATION Refer to RADIATOR in ENGINE COOLING SYSTEM Section 1B 18 AIR CONDITIONING OPTIONAL ...

Page 70: ...ol cable 1 and disconnect evaporator thermistor coupler 2 4 Loosen suction hose and receiver dryer outlet hose 5 Open glove box lid 8 6 Loosen cooling unit mounting bolts 3 nut 4 and screws 5 7 Loosen instrument panel mounting bolt 6 8 Remove cooling unit 7 INSTALLATION Reverse removal sequence to install cooling unit noting the follow ing points If cooling unit or evaporator is replaced pour 25 c...

Page 71: ...be dried with compressed air NOTE Be careful not to damage evaporator fins If evaporator fin is bent straighten it by using a screwdriver or pair of pliers If any leakage is found from fitting or tube repair or replace evaporator When the thermistor removed its should be reinstalled in original position A C EVAPORATOR THERMISTOR Check resistance between evaporator thermistor 1 terminals If check r...

Page 72: ...prox 2650 kPa 26 5 kg cm2 C Approx 230 kPa 2 3 kg cm2 D Approx 2060 kPa 20 6 kg cm2 Tightening torque for dual pressure switch 10 N m 1 0 kg m 8 0 lb ft Continuity No continuity A C SWITCH REMOVAL 1 Disconnect A C switch coupler from instrument panel harness 2 Remove meter cluster refer HEATER CONTROL LEVER in section 1A 3 Pull out A C switch by unlock the locking part INSPECTION Press A C Switch ...

Page 73: ...y 2 from vehicle 3 Check that there is no continuity between terminal c and d If there is continuity replace relay 4 Connect battery positive terminal to terminal b of relay Connect battery negative terminal a of relay Check continuity between terminal c and d If there is no continuity when relay is connected to the battery replace relay 1B 22 AIR CONDITIONING OPTIONAL ...

Page 74: ...g bolt 2 as keep compressor in that position 8 Remove compressor upper bracket 3 by loosening it mount ing bolt 4 9 Remove compressor with magnet clutch assembly 5 10 If compressor is replaced Drain oil from compressor and measure its amount 11 Remove compressor lower bracket 6 by loosening mount bolts 7 INSTALLATION Reverse removal procedure noting the following points If compressor is replaced p...

Page 75: ...removal and installation or for some other reason replenish 50cc oil When replenishing gas only oil replen ishment is not necessary When replacing compressor Compressor oil is sealed in each new compressor by the amount required for air conditioner cycle Therefore when using a new compressor for replacement drain oil from it by the amount calcu lated as follows C A B C Amount of oil to be drained ...

Page 76: ...e leakage c Using ohmmeter measure resistance of clutch coil between clutch lead wire and compressor body ground If measured resistance is not within tolerance replace coil Standard resistance 3 0 3 5 W at 20 C 68 F 1 Fix Pressure plate with special tool A and then remove pres sure plate nut and washer Special Tool A 09991 06020 2 Remove pressure plate 1 by using a special tool B Special Tool B 09...

Page 77: ...ool C 09900 06107 5 Whith special tool D in place remove drive clutch 3 from compressor 2 with puller 1 6 Disconnect coil lead wire from compressor housing 7 Remove circlip by using special tool C 8 Remove clutch coil 1 Special Tool C 09900 06107 1B 26 AIR CONDITIONING OPTIONAL ...

Page 78: ...d valve 16 Front gasket 17 Cylinder front head 18 Blank 19 O ring 20 Seal plate 21 Circlip 22 Oil felt 23 Joint service connector bolt 24 Housing through bolt 1 Joint service connector 2 Diffuser seal 3 O ring 4 Diffuser 5 Rear housing 6 Rear gasket 7 Reed valve 8 Valve rear plate 9 Suction valve AIR CONDITIONING OPTIONAL 1B 27 ...

Page 79: ...r and punch 3 Remove circlip 1 by using special tool E Special Tool E 09900 06108 4 Apply compressor oil to inner bore 5 Remove lip seal by using special tool F The following explains this removal procedure a Fit special tool F into the clutch installation boss Special Tool F 09990 48220 1B 28 AIR CONDITIONING OPTIONAL ...

Page 80: ...en the protru sion 1 and groove 3 are engaged d Turn special tool F by 30 60 e Pull up special tool F to remove lip seal 1 6 Remove joint service connector 1 7 Remove O rings from service connector and discard them 8 Drain oil into container 9 Remove front housing NOTE Do not reuse five washers 1 Bolt 2 Washer AIR CONDITIONING OPTIONAL 1B 29 ...

Page 81: ...ve plate 2 Remove two pins 1 from cylinder block 12 Remove the rear housing 2 by prying its protrusion 1 NOTE Be careful not to scratch sealing surface of rear housing 13 Remove rear valve plate 2 Remove two pins 1 from rear housing 14 Remove front and rear O rings 2 from cylinder block 1 and discard them 1B 30 AIR CONDITIONING OPTIONAL ...

Page 82: ...ine oil stone Red valve 1 Check reed for cracks scratches deformation and corrosion Replace Front housing 1 Check sealing surface for cracks scratches and deformation Replace Piston Cylinder block 1 Check cylinder bore for scratches and corrosion 2 Check radial bearings for poor contact worn out needle scoring or pit 3 Check shaft for excessive axial play 4 Check piston for excessive axial play Re...

Page 83: ...ring in rear cylinder c Install suction reed valve 1 rear valve plate 2 and discharge reed valve 3 onto rear cylinder top For installing positions refer to the figure NOTE Front and rear reed valves suction and discharge are the same Rear valve plate is marked R 4 Pin holes d Lubricate gasket 1 with compressor oil Install gasket 1 on valve plate NOTE Front and rear gasket are different so do not i...

Page 84: ...uction and discharge are the same Front valve plate is marked F 4 Pin holes d Lubricate gasket 1 with compressor oil Install gasket 1 on valve plate NOTE Front and rear gaskets are different so do not inter change them To differentiate them refer to description on rear valve plate Assemble gaskets so that their protruded surfaces face upward 4 Install front housing 1 on front cylinder and tighten ...

Page 85: ...d from compressor 1 Lip seal 2 O ring 3 Seal c Press it slowly by hand until lip seal 4 contacts the stopper 3 of front housing 2 by using special tool H Special Tool H 09990 58220 NOTE With lip seal pressed in completely its upper face must come to the position lower than the circlip fitting groove Check this condition visually Do not use a press machine hammer etc when pressing 1 Circlip install...

Page 86: ...pressor Additional oil after compressor overhauling 40 cc 2 4 cu in Oil capacity in air conditioner system 60 100 cc 3 7 6 1 in3 10 Install service connector a Lubricate new O rings 3 with compressor oil and install them in service connector 1 b Install service connector 1 to compressor NOTE Suction port has larger internal opening than discharge port Tightening Torque a 26 N m 2 6 kg m 19 lb ft 2...

Page 87: ...late 2 Shim 3 Install pressure plate a Adjust clearance between pressure plate 1 and drive clutch 2 by putting shims on compressor shaft Standard clearance a 0 4 0 7 mm 0 016 0 028 in b Fix pressure plate 1 with special tool A then tighten pressure plate fixing nut as specified below Special Tool A 09991 06020 Tightening Torque 16 5 N m 16 5 kg m 12 0 lb ft 1B 36 AIR CONDITIONING OPTIONAL ...

Page 88: ...onent Refrigerant REFRIGERANT DRUM 95793 60D00 000 Refrigerant charge SPECIAL TOOLS 09990 28210 Key pressor 09990 48220 Lip seal remover 09900 06107 Snap ring pliers Opening type 09900 06108 Snap ring pliers Closing type 09990 58210 Pressure plate remover 09990 58230 Lip seal protector 09990 58220 Lip seal pressor 09991 06020 Armature plate spanner 09951 65510 Shaft protector ...

Page 89: ...STEERING WHEEL AND COLUMN SECTION 3C FRONT SUSPENSION SECTION 3D REAR SUSPENSION LEAF SPRING TYPE SECTION 3E REAR SUSPENSION COIL SPRING TYPE SECTION 3E1 WHEELS AND TIRES SECTION 3F CONTENTS DIAGNOSIS GENERAL DIAGNOSIS 3 2 DIAGNOSIS TABLE 3 2 TIRE DIAGNOSIS 3 6 Irregular and or Premature Wear 3 6 Wear Indicators 3 6 Tire Waddle 3 6 Tire Lead 3 8 VIBRATION DIAGNOSIS 3 8 ...

Page 90: ...ted Broken or sagging springs Radial tire lateral force Disturbed front end alignment Disturbed rear wheel alignment Brake dragging in one road wheel Loose bent or broken front or rear sus pension parts Replace tire Adjust tire pressure Replace spring Replace tire Check and adjust front end alignment Check and adjust rear wheel alignment Repair front brake Tighten or replace suspension parts Abnor...

Page 91: ... end alignment Rack and pinion adjustment Bind in steering column Inflate tires to proper pressure Replace tie rod end or front suspension arm Check and adjust front end alignment Check and adjust rack and pinion torque Repair or replace Too Much Play in Steering Wheel bearings worn Loose steering gear case bolts Rack and pinion adjustments Worn steering shaft joints Worn tie rod ends or tie rod i...

Page 92: ...Wander or Poor Steering Stability Mismatched or uneven tires Loosen ball joints and tie rod ends Faulty struts or mountings Loose stabilizer bar Broken or sagging springs Rack and pinion adjustment Disturbed front end alignment Replace or inflate tires to proper pressure Replace suspension arm or tie rod end Replace strut or repair mounting Tighten or replace stabilizer bar or bush Replace spring ...

Page 93: ...Overloaded Faulty struts shock absorber Incorrect broken or sagging springs Check loading Replace strut Replace Body Leans or Sways in Corners Loose stabilizer bar Faulty struts shock absorbers or mountings Broken or sagging springs Overloaded Tighten stabilizer bar bolts or nuts or re place bushes Replace strut or tighten mounting Replace Check loading Cupped Tires Front struts defective Worn whe...

Page 94: ...ors to show when they need replacement These indicators will appear as 12 mm 0 47 in wide bands when the tire tread depth becomes 1 6 mm 0 063 in When the indicators appear in 3 or more grooves at 6 locations tire replacement is recommended TIRE WADDLE Waddle is side to side movement at the front and or rear of the ve hicle It is caused by the steel belt not being straight within the tire It is mo...

Page 95: ... install known good tires in place of all four Then reinstall originals in the same manner as above INFLATE TIRES TO RECOMMENDED PRESSURE SWITCH FRONT TIRES SIDE TO SIDE AND ROAD TEST AGAIN INSTALL A KNOWN GOOD TIRE ON ONE FRONT SIDE ROAD TEST VEHICLE ON LEVEL UNCROWNED ROAD IN BOTH DIRECTIONS LEAD CORRECTED IF ROUGHNESS RESULTS REPLACE TIRES PUT TIRES BACK IN ORIGINAL POSITION AND CHECK ALIGNMENT...

Page 96: ...Part of the lead diagnosis procedure is different from the proper tire rotation pattern currently in the owner and service manuals If a medium to high mileage tire is moved to the other side of the vehicle be sure to check that ride roughness has not developed 2 Rear tires will not cause lead VIBRATION DIAGNOSIS Wheel unbalance causes most of the highway speed vibration problems If a vibration rem...

Page 97: ...caster can t be adjusted Therefore should camber or caster be out of specification due to the damage caused by hazardous road conditions or collision whether the damage is in body or in suspension should be deter mined and damaged body should be repaired or damaged suspension should be replaced TOE SETTING Toe is the turning in or out of the front wheels The purpose of a toe specification is to en...

Page 98: ...ad wear 2 Check for loose ball joints Check tie rod ends if excessive looseness is noted it must be corrected before adjusting 3 Check for run out of wheels and tires 4 Check vehicle trim heights h if out of limits and a correction is to be made the correction must be made before adjusting toe 5 Check for loose control arms 6 Check for loose or missing stabilizer bar attachments 7 Consideration mu...

Page 99: ... CASTER ADJUSTMENT Should camber or caster be found out of specifications upon in spection locate its cause first If it is damaged loose bent dented or worn suspension parts they should be replaced If it is in vehicle body repair it so as to attain specifications To prevent possible incorrect reading of camber or caster vehicle front end must be moved up and down a few times before inspec tion STE...

Page 100: ...lip For inspecting front wheel side slip with side slip tester Side slip limit Less than 3 mm m Less than 0 118 in 3 3 ft If side slip exceeds above limit toe in or front wheel alignment may not be correct 3A 4 FRONT END ALIGNMENT ...

Page 101: ... Steering Wheel Check 3B 2 Steering Rack Boot Check 3B 2 Tie Rod End Boot Check 3B 3 Steering Shaft Joint Check 3B 3 Tie Rod End Check 3B 3 ON VEHICLE SERVICE 3B 3 Lubrication 3B 3 Manual Rack and Pinion Assembly 3B 5 Removal 3B 5 Disassembly 3B 6 Inspection 3B 9 Reassembly 3B 10 Installation 3B 13 REQUIRED SERVICE MATERIALS 3B 15 SPECIAL TOOL 3B 16 GENERAL DESCRIPTION The rack and pinion steering...

Page 102: ...ion control arm joint for wear Steering shaft joint for wear Steering pinion or rack gear for wear or breakage Each part for looseness STEERING RACK BOOT CHECK Hoist vehicle Inspect each boot for tear A torn boot allows entry of dust and wa ter which can cause wear to steering rack and pinion to produce noise as well as rust to result in malfunction of steering system If even a small tear is noted...

Page 103: ...end ball joint In either case if found defective replace ON VEHICLE SERVICE NOTE According to necessity apply works to right and left parts LUBRICATION When inner parts of the steering gear case were disassembled they should be washed clean before reassembly It is recom mended to use the grease as given at the right where grease ap plication is indicated in the text SUZUKI SUPER GREASE E 99000 250...

Page 104: ...Rack plunger spring Tightening Torque Do not reuse 21 Steering rack Apply SUZUKI SUPER GREASE E 99000 25050 to entire surface of rack 22 Tie rod lock washer 23 Steering tie rod Apply SUZUKI SUPER GREASE E 99000 25050 to rack end ball joint 24 Wire 25 Boot Apply SUZUKI SUPER GREASE E 99000 25050 to contacting part of tie rod and boot 26 Clamp 27 Tie rod end lock nut 28 Bracket rack side 29 Steering...

Page 105: ...wer shaft from steering pinion shaft 4 Hoist vehicle and remove front wheels 5 Remove cotter pins 1 and tie rod castle nuts 2 from both knuckles 3 6 Disconnect tie rod ends 4 from knuckle using special tool Special Tool A 09913 65210 7 Remove steering gear case mount bolts 1 and then remove steering gear case mount brackets 2 Right side Left side 8 Remove exhaust pipe 1 MANUAL RACK AND PINION 3B 5...

Page 106: ...mber rear bolts 2 12 Lower engine and then remove manual rack and pinion as sembly 3 as shown DISASSEMBLY 1 For ease of adjustment after installation make marking 1 on tie rod end lock nut position of tie rod thread 2 Loosen tie rod end lock nut 2 and remove tie rod end 3 3 Remove boot wire 1 and clamp 2 4 Remove boot 3 from tie rod 3B 6 MANUAL RACK AND PINION ...

Page 107: ...k damper screw cap 1 rack damper screw 2 rack plunger spring 3 and rack plunger 4 7 Remove pinion bearing plug 1 using special tool Special Tool A 09944 26011 43 mm socket 8 To remove pinion assembly 1 from rack housing 2 tap rack housing 2 using plastic hammer 3 as shown MANUAL RACK AND PINION 3B 7 ...

Page 108: ...l out pinion needle bearing 1 from gear case using special tools Special Tool A 09921 20200 B 09930 30104 11 Remove snap ring 1 12 Pull out rack bushing 2 from rack housing 3 using special tool Special Tool A 09944 48210 CAUTION When removing the rack bushing be careful not to pull out the bushing by holding the gear case in a vise Or the housing pipe may come off the gear case For this work be su...

Page 109: ...on Inspect teeth surface of steering pinion 1 for wear or damage Inspect oil seal 2 for damage Inspect gear case O ring 3 for damage If found defective replace Steering Pinion Bearing Check rotation condition of bearing and inspect for wear If found defective replace Steering Rack Inspect for deflection teeth wear damage rack surface wear or damage Limit of rack deflection 0 35 mm 0 014 in If defl...

Page 110: ...oil seal to pinion bearing plug 1 using spe cial tool Special Tool A 09925 98210 Apply grease to oil seal lip Grease 99000 25050 Apply grease lightly to entire inner surface of bushing 1 Grease 99000 25050 Press fit bushing as far into rack housing 2 as shown by using special tool Special Tool A 09925 98210 Distance a 2 0 3 0 mm 0 08 0 12 in Install snap ring 3 3B 10 MANUAL RACK AND PINION ...

Page 111: ...ring rack bushing is coated with spe cial coating As it is damageable be very careful not to cause damage to it when inserting rack into steer ing gear case Do not use a wire brush when cleaning Apply grease to all around pinion teeth 1 pinion bearing 2 and gear case oil seal lip 3 as shown A Grease 99000 25050 Fill inside 4 of pinion bearing plug 5 with grease A Grease 99000 25050 Fit gear case O...

Page 112: ...that it will be within specified torque range Special Tool A 09944 18211 Rotation torque of pinion 0 8 1 3 NVm 0 08 0 13 kg m 0 6 0 9 lb ft Also check if rack as a whole moves smoothly ii After adjustment put rack damper screw cap 4 as deeply as possible Install new tie rod lock washer 1 as shown and then install tie rod 2 to steering rack 3 Align straight part A of washer with flat part B of stee...

Page 113: ...ner surface of hatched part A Grease 99000 25050 Install tie rod end lock nut and tie rod end to tie rod Position lock nut to marking 1 made in removal NOTE When tie rod was replaced measure length a on removed tie rod end and use it on new replacement tie rod end so as to position lock nut properly INSTALLATION For installation reverse removal procedure note the following instructions Tighten rac...

Page 114: ...e a 55 N m 5 5 kg m 40 0 lb ft Install tie rod ends 1 to knuckles 2 Tighten castle nuts 3 until holes for cotter pin 4 align but within specified torque and then bend new cotter pins 4 as shown Tightening Torque a 43 N m 4 3 kg m 31 5 lb ft NOTE Removed cotter pin should be replaced with new one Tighten tie rod end lock nuts 1 to specified torque Tightening Torque a 45 N m 4 5 kg m 32 5 lb ft 3B 1...

Page 115: ... After completion of installation check wheel alignment and toe setting referring to FRONT END ALIGNMENT in section 3A REQUIRED SERVICE MATERIALS MANUAL RACK AND PINION 3B 15 MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium Grease Should be applicable for 40 C 130 C SUZUKI SUPER GREASE E 99000 25050 Sliding part of rack against steering housing All around rack plunger rack bushing and rack Sliding ...

Page 116: ... 20200 Bearing remover 09944 26011 Pinion bearing plug socket 43 mm 09944 18211 Pinion torque checking socket 09943 88211 Bearing installer 09925 98210 Bearing installer 09930 30104 Sliding shaft 09944 48210 Rack bush remover 3B 16 MANUAL RACK AND PINION SPECIAL TOOL ...

Page 117: ...d those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above procedures are not followed parts or system damage could result CONTENTS GENERAL DESCRIPTION 3C 2 DIAGNOSIS 3C 3 Inspection and Repair Required After Accident 3C 3 ON VEHICLE SERVICE 3C 3 Steering Wheel 3C 4 Combination Switch Assembly 3C 5 Steer...

Page 118: ... important that only the specified screws bolts and nuts be used as designated and that they are tightened to the specified torque When the column assembly is removed from the vehicle special care must be taken in handling it Use of a steer ing wheel puller other than the one recommended in this manual or a sharp blow on the end of the steering shaft leaning on the assembly or dropping the assembl...

Page 119: ...nstallation in this section 11 Steering joint shaft upper bolt Note the tightening procedure the detail referring steering column assembly installation in this section 12 Steering lower shaft 13 Steering joint shaft lower bolt Note the tightening procedure the detail referring steering column assembly installation in this section ON VEHICLE SERVICE STEERING WHEEL AND COLUMN 3C 3 DIAGNOSIS For main...

Page 120: ...alignment marks 4 on steering wheel and shaft 7 Remove steering wheel 1 using special tool Special Tool A 09944 36011 CAUTION Do not hammer the end of the shaft Hammering it will loosen the plastic shear pins which maintain the col umn length and impair the collapsible design of the column INSTALLATION 1 Check that vehicle s front tires are at straight ahead position 2 Apply grease to contact plat...

Page 121: ...OMBINATION SWITCH ASSEMBLY REMOVAL 1 Remove steering wheel from steering column referring to STEERING WHEEL in this section 2 Remove steering column cover screws 1 3 Separate upper cover 2 and lower cover 3 then remove them 4 Disconnect lead wire of combination switch assembly at cou pler Standard screw Tapping screw 5 Remove combination switch 1 from steering column STEERING WHEEL AND COLUMN 3C 5...

Page 122: ...ombination switch lead wire is not caught between covers Standard screw Tapping screw STEERING COLUMN ASSEMBLY AND STEERING LOWER SHAFT NOTE When servicing steering column or any column mounted component remove steering wheel But when removing steering column simply to gain access to instrument panel components leave steering wheel installed on steering col umn CAUTION Once the double tube type st...

Page 123: ... joint bolt steering column side 2 and joint bolt pin ion shaft side 3 9 Make alignment mark 4 on joint of steering lower shaft to pin ion shaft for guide of reinstallation 10 Remove steering column upper and lower nuts 1 11 Remove steering column from vehicle CAUTION Don t separate steering column assembly into steer ing column and shaft If column or shaft is defective replace as an assembly 12 R...

Page 124: ...t hole of joint 5 of steering column as shown and then insert steering col umn assembly into steering lower shaft 4 Install steering column and tighten steering column upper nuts 1 and steering column lower nuts 2 temporarily by hand NOTE For proper installing location of steering column upper and lower nuts refer to figure 5 Install combination switch assembly referring to COMBINA TION SWITCH ASS...

Page 125: ...ing Torque b 25 N m 2 5 kg m 18 0 lb ft 9 Install steering joint cover 6 10 Install steering column upper cover 1 and lower cover 2 and then tighten steering column cover screws 3 CAUTION When installing upper cover 1 and lower cover 2 be careful so that combination switch lead wire is not caught between covers Standard screw Tapping screw 11 Install steering wheel referring to STEERING WHEEL in t...

Page 126: ...ing shaft 2 in the center of hole in column 2 Turn ignition key to ACC or ON position and install steering lock assembly 3 onto column 3 Now turn ignition key to LOCK position and pull it out 4 Align hub on lock with oblong hole 1 of steering shaft 2 and rotate shaft to assure that steering shaft 2 is locked 5 Tighten new bolts 1 until head of each bolt is broken 6 Turn ignition key to ACC or ON p...

Page 127: ...ck or break age if equipped If anything is found faulty replace as steering column assembly 3 Take measurement a as shown If it is shorter than specified length replace column assembly 1 with new one Length a 506 5 508 5 mm 19 9 20 0 in 4 Check steering shaft joints and shaft for any damages such as crack breakage malfunction or excessive play If anything is found faulty replace as lower shaft ass...

Page 128: ...SPECIAL TOOL 09944 36011 Steering wheel remover 3C 12 STEERING WHEEL AND COLUMN REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Grease SUZUKI GREASE CE T 99000 25290 Contact plate ...

Page 129: ...rt There is to be no welding as it may result in extensive damage and weakening of the metal Never attempt to heat quench or straighten any front suspension part or damage to the part may result CONTENTS GENERAL DESCRIPTION 3D 2 DIAGNOSIS 3D 3 Diagnosis Table 3D 3 Stabilizer Bar and or Bushing Check 3D 3 Strut Assembly Check 3D 3 Suspension Control Arm and Bushing Check 3D 4 Suspension Control Arm...

Page 130: ...rson strut type independent suspension system and consists of coil springs front suspension struts steering knuckles stabilizer bar and front suspension arms 1 Front coil spring 2 Front suspension strut 3 Steering knuckle 4 Stabilizer bar 5 Front suspension control arm ...

Page 131: ...e strut resistance both when pushed and re bounding Also note how many times vehicle body rebounds before com ing to stop after hands are off Do the same for strut on the other side Compare strut resistance and number of rebound on the right with those on the left And they must be equal in both With proper strut vehicle body should come to stop the moments hands are off or after only one or two sm...

Page 132: ... disc for dents distortion and cracks A disc in badly damaged condition must be replaced Check wheel nuts for tightness and as necessary retighten them to specification Tightening Torque a 55 N m 5 5 kg m 39 5 lb ft Check wheel bearing for wear When measuring thrust play ap ply a dial gauge to wheel hub Thrust play limit 0 0 mm 0 000 in If measurement exceeds limit when shaft nut is tightened to s...

Page 133: ...d stopper 5 Strut support 6 Strut mount 7 Strut mount seat 8 Strut bearing seat 9 Strut bearing 10 Spring upper seat 11 Strut spring seat 12 Bump stopper 13 Coil spring 14 Strut assembly 15 Strut bearing dust seal 16 Strut bracket bolt Insert from vehicle front side 17 Strut bracket nut 18 Strut support nut Tightening Torque ...

Page 134: ...hang free 2 Remove wheel 3 Remove E ring 1 securing brake hose and take brake hose off strut bracket as shown 4 Remove strut bracket bolts 1 5 Remove strut support nuts 1 Hold strut by hand so that it will not fall off 6 Remove strut 3D 6 FRONT SUSPENSION ...

Page 135: ...strut spring is held stationary Special Tool A 09940 71430 2 While keeping spring compressed with special tool as shown above remove strut nut and then disassemble parts ASSEMBLY 1 Compress spring with special tool until total length becomes about 280 mm 11 0 in as shown Special Tool A 09940 71430 Length a 280 mm 11 0 in 2 Mate spring end with stepped part of lower seat 1 as shown FRONT SUSPENSION...

Page 136: ...nd install it as shown 8 On bearing seat and bearing dust seal 12 install mount seat comp 6 strut mount 5 support 4 and rebound stopper 3 and inner support 2 in this sequence Be careful for installing direction Tighten strut nut 1 to specified torque and then apply waterproof coating paint or lacquer all around nut and strut rod screw part Tightening Torque a 50 N m 5 0 kg m 36 0 lb ft 9 Loosen an...

Page 137: ...Tightening Torque a 27 N m 2 7 kg m 19 5 lb ft b 80 N m 8 0 kg m 58 0 lb ft 3 Install brake hose 1 Don t twist hose when installing it Install E ring 2 as far as bracket end surface 3 as shown 4 Tighten wheel nut to specified torque Tightening Torque c 55 N m 5 5 kg m 39 5 lb ft 5 Confirm front end alignment referring to Section 3A FRONT SUSPENSION 3D 9 ...

Page 138: ...lower control arms to hang free 2 Remove front wheels 3 Remove split pin and castle nut and then disconnect stabilizer bar from front suspension arms right and left as shown 4 Remove stabilizer bar mount bush bracket bolts and stabilizer bar INSTALLATION When installing stabilizer loosely assemble all components while insuring that stabilizer centered side to side Install parts reversing order of ...

Page 139: ...de of bracket to the rear Tighten mount bracket bolt 3 to specified torque Tightening Torque a 43 N m 4 3 kg m 31 0 lb ft Painted A Upper side B Lower side C Forward After tightening castle nut 1 to specified torque be sure to bend split pin 2 as shown Tightening Torque b 65 N m 6 5 kg m 47 0 lb ft FRONT SUSPENSION 3D 11 ...

Page 140: ...edal and hold it there Remove drive shaft nut 2 and then loosen brake disc bolts 3 but don t remove them 3 Remove caliper carrier bolts 1 4 Remove caliper with carrier 1 from knuckle and suspend with a wire hook 2 NOTE Hang removed caliper with a wire hook or the like so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pedal with pads removed 5 Pul...

Page 141: ...ALLATION 1 Insert new stud 3 in hub hole Rotate stud slowly to assure the serrations are aligned with those made by original bolt 1 Oil hydraulic press 2 Rod 2 Install outside inner race 1 to wheel hub 2 using special tool Installing direction is as shown Special Tool A 09940 53111 NOTE When replacing bearing inner race or outer race be sure to replace them with new ones as a set FRONT SUSPENSION ...

Page 142: ...ing new drive shaft nut Do not tap wheel hub 6 Install carrier and caliper 1 7 Tighten caliper carrier bolts 2 to specified torque Tightening Torque d 85 N m 8 5 kg m 61 5 lb ft 8 Depress foot brake pedal and hold it there Tighten drive shaft nut 3 and brake disc bolts 4 to specified torque Tightening Torque e 210 N m 21 0 kg m 152 0 lb ft f 50 N m 5 0 kg m 36 0 lb ft 9 Install wheel and lower veh...

Page 143: ... 9 Washer 10 Castle nut 11 Split pin Forward REMOVAL 1 Hoist vehicle and remove wheel 2 Remove stabilizer bar split pin castle nut washer and bushing 3 Remove stabilizer bar mount bracket right and left bolts and stabilizer bar 4 Remove ball stud bolt 5 Remove control arm bolt 6 Remove control arm DISASSEMBLY Remove bushing with special tool and hydraulic press 1 as shown Special Tool A 09943 7791...

Page 144: ... to use new bushing INSTALLATION For installation reverse removal procedure observing following instructions 1 Install ball stud 2 to knuckle 1 Align ball stud groove with knuckle bolt hole as shown Then drive in ball stud bolt from the direction as shown 2 Install control arm to vehicle body and tighten control arm bolt to specified torque at the position where control arm is installed at angle A...

Page 145: ...ightening check if stabilizer bar is properly centered side to side refer to STABILIZER BAR AND OR BUSHINGS in this section 5 Tighten all bolts and nuts refer to illustration on previous page to each specified torque 6 Install split pin refer to STABILIZER BAR AND OR BUSHINGS in this section 7 Install wheel and lower vehicle 8 Check toe seating adjust as required referring to Section 3A FRONT SUSP...

Page 146: ...h special tool Special Tool C 09913 65210 4 Remove ball stud bolt 1 5 Remove strut bracket bolts 1 nuts 2 and steering knuckle 3 DISASSEMBLY NOTE Once bearing outer race is removed bearing set outer race bearings and inner races should be replaced with new one 1 Remove outside oil seal 1 snap ring 2 outside bearing 3 inside oil seal 7 inside inner race 6 and inside bearing 5 from knuckle 4 in that...

Page 147: ...l tools and hy draulic press 1 Special Tools B 09924 74510 C 09944 78210 D 09944 68210 2 Install snap ring 3 Drive in new outside oil seal 1 until its end contacts snap ring using special tools Special Tools B 09924 74510 C 09944 78210 D 09944 68210 4 Set steering knuckle 1 to wheel hub 2 as shown and take out bearing inner race support from bearing 5 Using special tools and hydraulic press 1 driv...

Page 148: ...h bolt is as shown Align knuckle bolt hole with ball stud groove as shown and install ball stud bolt Tightening Torque a 80 N m 8 0 kg m 58 0 lb ft b 55 N m 5 5 kg m 40 0 lb ft 2 Connect tie rod end 1 to knuckle 2 and tighten tie rod end castle nut 3 to specified torque Install split pin 4 Tightening Torque c 43 N m 4 3 kg m 31 0 lb ft 3 Tighten new drive shaft nut Do not tap wheel hub 4 For insta...

Page 149: ...30 Spring compressor 09913 61110 Bearing puller 09913 75520 Bearing installer 09925 88210 Bearing puller attachment 09944 68210 Bearing oil seal installer 09944 78210 Bearing installer support FRONT SUSPENSION 3D 21 REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithic wheel bearing grease SUZUKI SUPER GREASE A 99000 25010 Wheel bearing SPECIAL TOOL ...

Page 150: ...e used as specified during reassembly to assure proper retention of this part There is to be no welding as it may result in excessive damage and weakening of the metal Never attempt to heat quench or straighten any suspension part Replace it with a new part or damage to the part may result CONTENTS GENERAL DESCRIPTION 3E 2 DIAGNOSIS 3E 3 Diagnosis Table 3E 3 Rear Shock Absorber Check 3E 3 Leaf Spr...

Page 151: ...ckle pin bushes 2 Bump stopper 3 Shock absorber 4 Rear axle Apply water tight sealant 366E 99000 31090 to joint seam of axle and brake back plate 5 Wheel bearing 6 Brake drum 7 Spindle cap 8 Spindle nut 9 Split pin 10 U bolt Tighten both front and rear U bolts protrusion becomes equal 11 U bolt nut Tightening Torque Do not reuse 3E 2 REAR SUSPENSION ...

Page 152: ...n by an arrow in figure and let gas and oil out Lay it down sideways for this work 5 The gas itself is harmless but it may issue out of the hole together with chips generated by the drill There fore be sure to wear goggle Drill hole with approxi mately 3 mm 0 12 in diameter LEAF SPRING BUMP STOPPER AND LEAF SPRING BUSHES CHECK Inspect for crack and damage If found defective replace Also inspect if...

Page 153: ...cation Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft Check wheel bearings for wear When measuring thrust play apply a dial gauge to the drum center after removing wheel cen ter cap from wheel disc Thrust play limit a 0 3 mm 0 012 in When measurement exceeds limit replace bearing By rotating wheel actually check wheel bearing for noise and smooth rotation If it is defective replace bearing 3E 4 RE...

Page 154: ...ue REMOVAL 1 Hoist vehicle 2 Remove lower mounting bolt and nut 3 Remove upper mounting bolt and nut Then remove shock ab sorber INSTALLATION 1 Install shock absorber referring to above figure 2 Tighten nuts to specified torque Tightening torque for upper nut 58 N m 5 8 kg m 42 0 lb ft Tightening torque for lower nut 29 N m 2 9 kg m 21 0 lb ft 3 Lower vehicle REAR SUSPENSION 3E 5 ...

Page 155: ...used place safety stands under body to support raised body Or where possible raise vehicle body with body contact type hoist until tires are off the floor NOTE Don t let rear axle hang on brake hose If it occurs hose may be damaged To prevent it always hold rear axle of raised vehicle with safety stands 2 Remove rear wheel 3 Remove U bolt nuts 4 Remove shackle nuts and leaf spring front nut 5 Pull...

Page 156: ... ft b 43 N m 4 3 kg m 31 0 lb ft 3 Place bump stopper 3 on leaf spring 4 aligning projection of bump stopper to recess in spring Fit pin 5 projection on under side of leaf spring into hole in spring seat 6 on rear axle Put through U bolts 7 from bump stopper side to spring seat side and tighten nuts to specified torque Tightening Torque c 38 N m 3 8 kg m 27 5 lb ft NOTE Tighten so that a and b bec...

Page 157: ... in this section 3 Remove brake shoe refer to BRAKE SHOE in Section 5 4 Remove E ring 1 and brake hose pipe 2 from bracket on axle 5 Disconnect brake pipe flare nut 3 from wheel cylinder and put breeder plug cap onto brake pipe to prevent brake fluid outflow 6 Remove brake hose pipe from bracket on axle 7 Remove parking brake cable securing clip and disconnect park ing brake cable from brake back ...

Page 158: ...er to recess in spring 2 Fit pin 7 projection on under side of leaf spring into hole 8 in spring seat 6 of rear axle 1 3 Tightening U bolt nuts 5 to specified torque Tightening Torque a 38 N m 3 8 kg m 27 5 lb ft NOTE Tightening U bolt 3 so that a and b becomes equal REAR SUSPENSION 3E 9 ...

Page 159: ...water tight sealant where plate and cable contact and run parking brake cable through back plate and secure it with clip refer to BRAKE BACK PLATE in Section 5 8 Install brake shoe refer to BRAKE SHOE in Section 5 9 Install brake drum Refer to WHEEL BEARING AND WHEEL STUD in this section 10 Fill reservoir with brake fluid and bleed brake system For bleeding operation refer to BLEEDING BRAKES in Se...

Page 160: ...le cap 1 as shown by hammering lightly at 3 locations around it so as not to deform or cause damage to seat ing part of cap 3 Remove split pin 1 castle nut 2 and washer 3 4 Release parking brake lever 1 to cancel rear brake 5 Loosen parking brake cable lock nuts 2 FRONT REAR SUSPENSION 3E 11 ...

Page 161: ...move wheel bearing 8 Remove wheel stud 1 by using hydraulic press 2 and general rod 3 INSTALLATION NOTE See NOTE at the beginning of this section 1 Insert new stud in drum hole after rotate stud slowly to assure the serrations are aligned with those mode by replaced bolt 3E 12 REAR SUSPENSION ...

Page 162: ...ody 3 Remove back plate plug attached to the back side of brake back plate so as to increase clearance between brake shoe and brake drum Insert flat head rod or the like till its tip is in the gap between strut and adjust lever and turn it clockwise a little so that shoe adjust lever moves Thus shoe to drum clearance can be increased 4 Install brake drum after making sure that inside of brake drum...

Page 163: ...tted loosely replace with new one 9 Tighten wheel nuts to specified torque Tightening Torque b 55 N m 5 5 kg m 40 0 lb ft 10 Upon completion of all jobs depress brake pedal with about 30 kg 66 lbs load two to three times so as to obtain proper drum to shoe clearance 11 Check to ensure that brake drum is free from dragging and proper braking is obtained Then remove vehicle from hoist and perform br...

Page 164: ...ervoir tank Water tight sealant SEALING COMPOUND 366E 99000 31090 Joint seam of rear axle and brake back plate SILICONE GREASE 99000 25190 By spreading leaf spring hard into thin coat over the entire area SPECIAL TOOLS 09913 76010 Rear wheel bearing installer 09942 15510 Sliding hammer 09943 17912 Brake drum remover ...

Page 165: ...sembly to assure proper retention of this part There is to be no welding as it may result in excessive damage and weakening of the metal Never attempt to heat quench or straighten any suspension part or damage to the part may result CONTENTS GENERAL DESCRIPTION 3E1 2 DIAGNOSIS 3E1 4 Diagnosis Table 3E1 4 Rear Shock Absorber Check 3E1 4 Trailing Arm Lateral Rod Rear Axle and Coil Spring Check 3E1 4...

Page 166: ...ump stopper 3 Rear spring upper seat 4 Rear shock absorber 5 Lateral rod 6 Trailing arm 7 Rear axle 8 Wheel bearing 9 Brake drum 10 Spindle cap 11 Spindle nut 12 Shock absorber lower bolt Install bolt from the center of the vehicle toward the outside 13 Lateral rod bolt Install bolt from the front side of the vehicle toward the rear side Tightening Torque 14 Trailing arm front bolt Install bolt fr...

Page 167: ...ock absorber 5 Lateral rod 6 Trailing arm 7 Bush 8 Rear axle Apply water tight sealant 366E 99000 31090 to joint seam of axle and brake back plate 9 Bearing 10 Spacer 11 Brake drum 12 Split pin 13 Castle nut 14 Spindle cap Tightening Torque Do not reuse REAR SUSPENSION 3E1 3 ...

Page 168: ...to the fire 3 Don t store it where it gets hot 4 Before disposing it be sure to drill a hole in it where shown by an arrow in figure and let gas and oil out Lay it down sideways for this work 5 The gas itself is harmless but it may issue out of the hole together with chips generated by the drill There fore be sure to wear goggle Drill hole with approximately 3 mm 0 12 in diameter TRAILING ARM LATE...

Page 169: ...uts for tightness and as necessary retighten to specification Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft Check wheel bearings for wear When measuring thrust play apply a dial gauge to drum center after removing wheel center cap from wheel disc Thrust play limit a 0 3 mm 0 012 in When measurement exceeds limit replace bearing By rotating wheel actually check wheel bearing for noise and smooth r...

Page 170: ...o figure for proper installing direction of nuts 4 bolt 5 and washer 6 Tighten nuts temporarily at this step FORWARD Rear axle side Body side 2 Lower hoist 3 Tighten lateral rod nuts 1 to specified torque It is the most de sirable to have vehicle off hoist and in nonloaded condition when tightening them Tightening Torque a 45 N m 4 5 kg m 32 5 lb ft b 58 N m 5 8 kg m 42 0 lb ft 3E1 6 REAR SUSPENSI...

Page 171: ...4 referring to the figure 2 Tighten bolts to specified torque Tightening Torque a 58 N m 5 8 kg m 42 0 lb ft 3 Lower vehicle TRAILING ARM AND BUSH REMOVAL 1 Hoist vehicle and remove rear wheel 2 Support center of rear axle 2 by using floor jack 1 to prevent it from lowering CAUTION Never apply floor jack against lateral rod as it may get deformed 3 Remove rear shock absorber lower mounting bolt 1 ...

Page 172: ... NOTE When installing front side bush 2 into trailing arm 1 di rect its slit 3 side toward front and rear 2 Install trailing arm 1 front side to body and then insert bolt 2 3 Install trailing arm rear side to rear axle 3 and tighten trailing arm rear nut 4 to specified torque Tightening Torque a 80 N m 8 0 kg m 58 0 Ib ft 4 Tighten shock absorber lower mounting bolt 5 to specified torque Tightenin...

Page 173: ... lb ft 7 Lower vehicle WHEEL BEARING AND WHEEL STUD REMOVAL 1 Hoist vehicle and remove rear wheel 2 Remove spindle cap 1 as shown by hammering lightly at 3 locations around it so as not to deform or cause damage to seat ing part of cap 3 Remove split pin 1 castle nut 2 and washer 3 REAR SUSPENSION 3E1 9 ...

Page 174: ...ke 5 Loosen parking brake cable lock nuts 2 FRONT 6 Pull brake drum 1 off by using special tools Special Tool A 09942 15510 B 09943 17912 7 Remove wheel bearing 1 8 Remove wheel stud 1 by using hydraulic press 2 and general rod 3 3E1 10 REAR SUSPENSION ...

Page 175: ... installing direction of spacer 2 Direct inner bearing sealed side 1 outward Fill the space indicated by A in figure with bearing grease as much as 40 of space capacity Install outer bearing 3 so that resin side of its retainer faces toward the outside of vehicle body 3 Before installing brake drum to maximize clearance between shoe and drum turn strut adjuster to the direction as shown in figure ...

Page 176: ...damaged or if it is fitted loosely replace with new one 8 Tighten wheel nuts to specified torque Tightening Torque b 55 N m 5 5 kg m 40 0 lb ft 9 Upon completion of all jobs depress brake pedal with about 30 kg 66 lbs load two to three times so as to obtain proper drum to shoe clearance 10 Check to make sure that brake drum is free from dragging and brake works properly Then remove vehicle from li...

Page 177: ... remove rear wheel 2 Pull brake drum Refer to steps 2 to 6 on WHEEL BEARING AND WHEEL STUD in this section 3 From bracket on axle remove E ring 1 4 Disconnect brake pipe flare nut 1 from wheel cylinder 2 5 Put breeder plug cap 3 on to brake pipe 4 to prevent brake fluid outflow 6 Remove brake hose pipe from bracket on axle 7 Remove rear brake back plate bolts 1 and remove back plate from axle 2 8 ...

Page 178: ...g floor jack gradually till tension of suspension spring is relieved and then remove spring 13 Remove trailing arm front bolt and take down rear axle with trailing arm 14 Remove trailing arm from rear axle INSTALLATION 1 Install trailing arm 1 to rear axle 2 2 Install trailing arm with its front side to body 3E1 14 REAR SUSPENSION ...

Page 179: ...rear nut 1 to specified torque Tightening Torque a 80 N m 8 0 kg m 58 0 Ib ft 6 Install shock absorber lower mounting bolt 2 and tighten it to specified torque Tightening Torque b 58 N m 5 8 kg m 42 0 Ib ft 7 Tighten trailing arm front nut 3 to specified torque Tightening Torque c 80 N m 8 0 kg m 58 0 Ib ft 8 Install lateral rod 4 and tighten nuts to specified torque Tightening Torque d 45 N m 4 5...

Page 180: ... tion Tightening Torque g 12 N m 1 2 kg m 9 0 Ib ft 11 Install brake drum Refer to steps 3 to 7 on WHEEL BEAR ING AND WHEEL STUD in this section 12 Fill reservoir with brake fluid and bleed brake system For bleeding operation refer to BLEEDING BRAKES in Section 5 13 Upon completion of all jobs depress brake pedal with about 30 kg 66 lbs load two to three times so as to obtain proper drum to shoe c...

Page 181: ...ring installer 09951 16030 Bearing installer 51 09951 16060 Bearing installer 45 REAR SUSPENSION 3E1 17 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Brake fluid DOT3 Brake reservoir tank Water tight sealant SEALING COMPOUND 366E 99000 31090 Joint seam of rear axle and brake back plate SPECIAL TOOLS ...

Page 182: ...Operations 3F 5 Metric lug nuts and wheel studs 3F 5 Wheel removal 3F 5 Tire mounting and demounting 3F 5 Tire repair 3F 6 Balancing Wheels 3F 6 General Balance Procedures 3F 7 Off vehicle balancing 3F 7 On vehicle balancing 3F 7 GENERAL DESCRIPTION TIRES This vehicle is equipped with the following tire 145 70 SR12 or 5 65 12 4PR The tire is of tubeless type The tire is designed to operate satisfa...

Page 183: ...n in figure may cause objec tional vibrations Replacement wheels must be equivalent to the original equipment wheels in load capacity diameter rim width offset and mounting configuration A wheel of improper size or type may affect wheel and bearing life brake cooling speedometer odometer calibra tion vehicle ground clearance and tire clearance to body and chas sis HOW TO MEASURE WHEEL RUNOUT To me...

Page 184: ...spot of the wheel This is done to provide the smoothest possible ride The high spot of the tire is originally marked by paint dot 1 on the outboard sidewall This paint dot will eventually wash off the tire The low spot of the wheel is originally marked by paint dot 2 on the wheel rim flange Properly assembled the wheel rim s paint dot should be aligned with the tire s paint dot as shown in figure ...

Page 185: ...nd resistance to bruises Tire pressure with tires cold after vehicle has set for three hours or more or driven less than one mile should be checked monthly or before any extended trip Set to the specifications on the tire placard It is normal for tire pressure to increase 28 kPa 4psi when the tires become hot during driving Do not bleed or reduce tire pressure after driving Bleeding reduces the Co...

Page 186: ...ce and brake drum or disc mounting surface by scraping and wire brushing Installing wheels with out good metal to metal contact at mounting surfaces can cause wheel nuts to loosen which can later allow a wheel to come off while vehicle is moving Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft TIRE MOUNTING AND DEMOUNTING Use a tire changing machine to mount or demount tires Follow equipment manufac...

Page 187: ... all of these work on all types of tires tire manufacturers have published detailed instructions on how and when to repair tires These instructions can be obtained from each tire manufacturer BALANCING WHEELS There are two types of wheel and tire balance static and dynamic Static balance is the equal distribution of weight around the wheel Wheels that are statically unbalanced cause a bouncing act...

Page 188: ... disc unbalance as does on ve hicle spin blancing this is overcome by their accuracy usually to within 1 8 ounce ON VEHICLE BALANCING On vehicle balancing methods vary with equipment and tool manufacturers Be sure to follow each manufacturer s instructions during balancing operation WARNING Wheel spin should be limited to 35 mph 55 km h as indicated on speedometer This limit is necessary because s...

Page 189: ...T DRIVE SHAFT 4 1 SECTION 4 FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION 4 2 DIAGNOSIS 4 2 Diagnosis table 4 2 ON VEHICLE SERVICE 4 3 Drive shaft assembly 4 3 REQUIRED SERVICE MATERIAL 4 8 SPECIAL TOOL 4 8 ...

Page 190: ...GREASE H 99000 25120 to inside of outer race 2 Boot 3 Drive shaft RH 4 Boot 5 Differential side joint RH Apply SUZUKI SUPER GREASE H 99000 25120 to inside of outer race and entire surface of cage 6 Differential side joint LH Apply SUZUKI SUPER GREASE H 99000 25120 to inside of outer race and entire surface of cage 7 Boot 8 Drive shaft LH 9 Boot 10 Wheel side joint LH Apply SUZUKI SUPER GREASE H 99...

Page 191: ... 09913 65210 6 Drain transmission fluid 7 Using large size lever 1 pull out drive shaft joint 2 so as to release snap ring fitting of joint spline at differential side 8 Disconnect front suspension control arm ball stud 1 from steering knuckle 2 by pushing down stabilizer bar 4 after re moving stud bolt 3 9 Remove drive shaft assembly CAUTION To prevent breakage of boots be careful not to bring th...

Page 192: ...e and remove circlip 1 used to fix cage 2 by using special tool and then remove cage and boot 3 from shaft Special Tool A 09900 06107 NOTE Do not disassemble wheel side joint outboard joint If any malcondition is found in any joint replace it as assembly INSPECTION Inspect boots for breakage or deterioration Replace them as necessary Inspect circlip snap ring and boot bands for breakage or deterio...

Page 193: ...A a CAUTION Install the cage directing the smaller outside diameter side to the shaft end 3 Install circlip 1 by using special tool Special Tool A 09900 06107 4 Apply grease to entire surface of cage A SUZUKI SUPER GREASE H 99000 25120 5 Insert cage into outer race 2 and fit a snap ring 1 in the groove of outer race CAUTION Locate the opening of the snap ring b so that the opening is not lined up ...

Page 194: ...any problem caused by washing solu tion do not wash joint boots and tripod joint except its housing Degreasing of those parts with cloth is allowed To ensure full performance of joint as designed be sure to distinguish between two types of grease in repair set and apply specified volume to respective joint Refer to the previous page for identification of the grease Bend each boot band against forw...

Page 195: ...ammer Inserting joint only by hands is allowed Make sure that differential side joint is inserted fully and its snap ring is seated as it was Tighten each bolt and nut to the specified torque Tightening Torque a 21 N m 2 1 kg m 15 5 lb ft For 5 speed transmission 28 N m 2 8 kg m 20 5 lb ft For 4 speed transmission b 21 N m 2 1 kg m 15 5 lb ft For 5 speed transmission only c 55 N m 5 5 kg m 40 0 lb...

Page 196: ...R GREASE A 99000 25010 Oil seal lips Lithium grease SUZUKI SUPER GREASE H 99000 25120 Entire surface of the cage and the outer race on drive shaft assembly Sealant SUZUKI BOND NO 1215 99000 31110 Oil drain plug for manual transmission SPECIAL TOOL 09913 65210 Tie rod end remover 09900 06107 Snap ring plier Open type ...

Page 197: ...ly 5 3 Master Cylinder Assembly 5 3 DIAGNOSIS 5 4 Diagnosis Table 5 5 ON VEHICLE SERVICE 5 7 Brake pedal Free Height Adjustment 5 7 Brake Pedal Play Inspection 5 7 Stop Light Switch Adjustment 5 7 Excessive Pedal Travel Check 5 7 Front Brake Pad Inspection 5 8 Brake Disc Inspection 5 8 Rear Drum Brake Shoe Adjustment 5 8 Parking Brake Inspection and Adjustment 5 9 Flushing Brake Hydraulic System 5...

Page 198: ... front left rear right brakes The proportioning valve P valve is included in these circuits between the master cylinder and rear wheels In this brake system the disc brake type is used for the front wheel brake and a drum brake type leading trailing shoes for the rear wheel brake The parking brake system is mechanical It applies brake force to only rear wheels by means of the cable and me chanical...

Page 199: ... components included in repair kits used to service this drum brake Lubricate parts as speci fied WARNING When servicing wheel brake parts do not create dust by grinding or sanding brake linings or by cleaning wheel brake parts with a dry brush or with compressed air A water dampened cloth should be used Many wheel brake parts contain asbestos fibers which can become airborne if dust is created du...

Page 200: ...UBSTANDARD OR CONTAMINATED BRAKE FLUID Improper brake fluid mineral oil or water in the fluid may cause brake fluid to boil or rubber components in the hydraulic system to deteriorate If primary piston cups are swollen then rubber parts have deteriorated This deterioration may also be evi denced by swollen wheel cylinder piston cups on the drum brake wheels If deterioration of rubber is evident di...

Page 201: ...oses Malfunctioning caliper assembly Loose suspension parts Loose calipers Replace Check for inoperative auto adjusting mechanism Replace Inflate equally Repair or replace Adjust as prescribed Tires with approximately the same amount of tread should be used on the same axle Check for soft hoses and damaged lines Replace with new hoses and new brake piping Check for stuck or sluggish pistons and pr...

Page 202: ...r as necessary Replace piston seal Pedal pulsation Pedal pulsates when depressed for braking Damaged or loose wheel bearings Distorted steering knuckle or rear wheel spindle Excessive disc lateral runout Parallelism not within specifications Rear drums out of round Replace wheel bearings Replace knuckle or rear wheel spindle Check per instructions If not within speci fications replace or machine d...

Page 203: ...etween the end of thread and brake pedal contact plate 2 shown as b in figure is within 0 5 1 0 mm 0 02 0 04 in Then tighten lock nut 4 to specified torque Clearance b 0 5 1 0 mm 0 02 0 04 in Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft EXCESSIVE PEDAL TRAVEL CHECK 1 With brake pedal depressed with approximately 30 kg 66 lbs load measure pedal arm to wall clearance c It mustn t be less than 85 mm...

Page 204: ...ted black 3 0 mm 0 118 in for pad rim is painted brown BRAKE DISC INSPECTION Refer to BRAKE DISC of this section for inspection point and pro cedure REAR DRUM BRAKE SHOE ADJUSTMENT Rear brake has self adjusting mechanism but it does require ad justment for proper drum to shoe clearance when brake shoe has been replaced or brake drum has been removed for some other service Adjustment is automatical...

Page 205: ... is found replace parking brake lever ADJUSTMENT NOTE Make sure for following conditions before cable 2 adjust ment No air is trapped in brake system Brake pedal travel is proper Brake pedal has been depressed a few times with about 30 kg 66 lbs load Parking brake lever has been pulled up a few times with about 20 kg force Rear brake pads are not worn beyond limit After confirming that above condi...

Page 206: ...sorber fluid or any other fluid which contains mineral oil Do not use a container which has been used for mineral oil or a container which is wet from water Mineral oil will cause swelling and distortion of rubber parts in hydraulic brake system and water mixed into brake fluid will lower fluid boiling point Keep all fluid containers capped to prevent contamination BRAKE HOSE AND PIPE INSPECTION H...

Page 207: ...g with wheel cylinder far thest from master cylinder and then at front caliper of the same brake line Do the same on the other brake line CAUTION Brake fluid is extremely damaging to paint If fluid should accidentally touch painted surface immediately wipe fluid from paint and clean painted surface Left wheel cylinder Left brake caliper Right wheel cylinder Right brake caliper REAR FRONT 1 Fill ma...

Page 208: ...dal and tighten bleeder plug Tightening torque for bleeder plug FRONT 8 5 N m 0 85 kg m 6 5 lb ft REAR 8 5 N m 0 85 kg m 6 5 lb ft 7 Then attach bleeder plug cap 8 After completing bleeding operation apply fluid pressure to pipe line and check for leakage 9 Replenish fluid into reservoir up to specified level 10 Check brake pedal for sponginess If found spongy repeat entire procedure of bleeding 5...

Page 209: ...ARKING BRAKE INSPECTION AND ADJUSTMENT of this section Then check brake drum for dragging and brake system for proper performance After removing vehicle from hoist perform brake test and check each installed part for fluid leakage 1 Parking brake cable Apply water tight sealant 366E 99000 31090 where plate and cable contact 2 Proportioning valve P valve 3 E ring 4 From master cylinder primary to P...

Page 210: ...9 proportioning valve P valve 10 White mark 11 E ring 12 Washer 13 Clamp A 14 Clamp B 15 Clamp C 16 Clamp D 17 Clamp E 18 Clamp F 19 Clamp G 20 Clamp H 21 Clamp I 22 Clamp J 23 Clamp K 24 Clamp K right hand steering vehicle 25 Clamp K left hand steering vehicle 26 Clamp L 27 Parking brake cable Apply water tight sealant 366E 99000 31090 where plate and cable contact 28 Brake back plate Apply water...

Page 211: ...e of caliper pin 3 Boot 4 Disc brake pad 5 Bleeder plug cap 6 Bleeder plug 7 Disc brake caliper Disc brake cylinder 8 Piston seal Apply brake fluid 9 Disc brake piston Apply brake fluid 10 Cylinder boot 11 Brake disc 12 Disc bolt 13 Caliper bolt Tightening Torque Do not reuse BRAKES 5 15 ...

Page 212: ...ing and may damage disc When pad lin ing requires correction replace it with a new one INSPECTION Check the pad lining for wear When the wear exceeds its limit re place with a new one Timing for pad replacement can be deter mined with the line of the groove which is provided on each pad lining When it has disappeared replace with a new one Data marked with B is applicable to only European market D...

Page 213: ...caliper pin bolt 1 to specified torque Tightening Torque a 27 N m 2 7 kg m 19 5 lb ft 3 Tighten wheel temporarily and lower lift 4 Tighten wheel nuts 1 to specified torque Tightening Torque b 55 N m 5 5 kg m 40 0 lb ft 5 After completion of installation check for brake effectiveness BRAKES 5 17 ...

Page 214: ... pin bolt 1 and remove caliper 2 from caliper carrier 3 DISASSEMBLY 1 Remove piston with air blown into flexible hose bolt installation hole CAUTION Clean around caliper with brake fluid before disassem bly WARNING Do not apply too highly compressed air which will cause piston to jump out of cylinder It should be tak en out gradually with moderately compressed air Do not place your fingers in fron...

Page 215: ...ul not to damage inside bore side of cylin der INSPECTION Pin Boot and Cylinder Boot Check boots for breakage crack and damage If defective re place Piston Seal Excessive or uneven wear of pad lining may indicate unsmooth re turn of piston In such case replace rubber seal BRAKES 5 19 ...

Page 216: ...hem After reassembling brake lines bleed air from them Install a new piston seal into groove in cylinder se curely making sure that it is not twisted Before installing caliper to carrier install caliper pin 1 with rubber grease applied into caliper carrier hole and check for its smooth movement in thrust direc tion Piston Seal Piston seal is used to seal piston and cylinder and to adjust clear anc...

Page 217: ...o cylinder by hand INSTALLATION 1 Install caliper to caliper carrier 2 Tighten caliper pin bolt 1 to specified torque Tightening Torque a 27 N m 2 7 kg m 19 5 lb ft CAUTION Check that pin boot is installed securely 3 Connect flexible hose and tighten flexible hose bolt to specified torque Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft CAUTION Connect hose without twisting Use new washers After ins...

Page 218: ... But when there are deep scratches or scratches all over the surface replace disc When only one side is scratched polish and correct that side Brake disc thickness Standard 10 0 mm 0 394 in Limit 8 0 mm 0 315 in To check disc deflection measure at 2 points on its periphery and center with a dial gauge while rotating the disc Limit on disc deflection 0 15 mm 0 006 in Special Tool A 09900 20606 B 09...

Page 219: ...hoe 3 Shoe return spring 4 Brake strut 5 Shoe return spring 6 Rod spring 7 Shoe hold down spring 8 Shoe hold down pin 9 Wheel cylinder Apply brake fluid to wheel cylinder components Apply water tight sealant 366E 99000 31090 to contact surface of wheel cylinder 10 Rubber plug 11 Wheel cylinder bolt Tightening Torque Do not reuse BRAKES 5 23 ...

Page 220: ...ations using care not to damage seat face of cap 3 Remove split pin 1 castle nut 2 and washer 3 4 Release parking brake lever 1 to cancel rear brake 5 Loosen parking brake cable lock nuts 2 FRONT 6 Pull brake drum 1 off by using special tools Special Tool A 09942 15510 B 09943 17912 7 Remove wheel stud bolt 1 by using hydraulic press 2 and general rod 3 5 24 BRAKES ...

Page 221: ... scoring will cause excessive brake lin ing wear and it will probably be necessary to resurface drum brak ing surface If brake linings are slightly worn and drum is grooved drum should be polished with fine emery cloth but should not be cut NOTE When drum is removed visually inspect wheel cylinder for brake fluid leak Correct leaky point if any INSTALLATION 1 Before installing brake drum check tha...

Page 222: ...OTE If fitting part of cap is deformed or damaged or if it is fitted loosely replace with new one 7 Upon completion of all jobs depress brake pedal with about 30 kg 66 lbs load several times so as to obtain proper drum to shoe clearance Adjust parking brake cable For adjustment refer to PARKING BRAKE INSPECTION AND ADJUSTMENT in this section 8 Check to ensure that brake drum is free from dragging ...

Page 223: ... Brake shoe thickness Standard 6 0 mm 0 24 in Limit 2 6 mm 0 10 in If one of brake linings is worn to or beyond service limit all linings must be replaced at the same time CAUTION Never polish lining with sandpaper If lining is polished with sandpaper hard particles of sandpaper will be de posited in lining and may damage drum When it is re quired to correct lining replace it with a new one Parkin...

Page 224: ...n this section 2 Remove brake shoe refer to BRAKE SHOE in this section 3 Take out fluid with a syringe or such and disconnect brake pipe flare nut 1 from wheel cylinder 4 Remove E ring 2 5 Remove wheel cylinder mounting bolts And put wheel cylinder breeder plug cap onto pipe to prevent fluid from spilling INSPECTION When removing brake drum check wheel cylinder for oil leakage If any leakage is fo...

Page 225: ...acket securely 7 Install brake shoes refer to BRAKE SHOE in this section 8 Install brake drum refer to BRAKE DRUM in this section 9 Fill reservoir with brake fluid and bleed brake system refer to BLEEDING BRAKES in this section 10 Upon completion of all jobs depress brake pedal with about 30kg load two to three times so as to obtain proper drum to shoe clearance Adjust parking brake cable refer to...

Page 226: ...e parking brake cable securing clip 1 and disconnect brake cable 2 from brake back plate 3 5 Remove brake back plate 1 by removing bolts 2 INSTALLATION 1 Apply water tight sealant to mating surfaces of brake back plate 1 and rear axle A Sealant 366E 99000 31090 2 Install brake back plate to rear axle and tighten back plate bolts 1 to specified torque Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft ...

Page 227: ...ntact and run parking cable 1 through brake back plate 2 and secure it with clip 3 A Sealant 366E 99000 31090 4 Install wheel cylinder refer to WHEEL CYLINDER in this sec tion 5 For procedure hereafter refer to WHEEL CYLINDER in this section BRAKES 5 31 ...

Page 228: ... wire at coupler 2 Clean outside of reservoir 1 3 Take out fluid with a syringe or such 4 Remove reservoir connector screw 2 5 Remove reservoir INSTALLATION 1 When using new grommets 3 lubricate them with the same fluid as the one to fill reservoir 1 with Then press fit grommets to master cylinder 2 Install reservoir and tighten screws 2 to specified torque Tightening Torque a 2 5 N m 0 25 kg m 2 ...

Page 229: ...d to get on painted surfaces 7 Remove master cylinder push rod split pin and rod pin from brake pedal arm 8 Remove attaching nuts 5 and washers 9 Remove master cylinder DISASSEMBLY 1 Remove circlip 1 2 Remove primary piston by removing piston stopper bolt 1 Be cautions during removal as primary piston will jump out 3 Pull out secondary piston by tapping flange with a piece of wood or something sof...

Page 230: ...be identified as pits or ex cessive roughness NOTE Polishing bore of master cylinder with cast aluminum body with anything abrasive is prohibited as damage to cylinder bore may occur Rinse cylinder in clean brake fluid Shake excess rinsing fluid from cylinder Do not use a cloth to dry cylinder as lint from cloth cannot be kept from cylinder bore surfaces ASSEMBLY CAUTION Never use any mineral oil ...

Page 231: ...ary piston 5 Piston pressure cap 2 Install secondary piston assembly into cylinder 3 Install primary piston in cylinder 4 Depress using a rod 1 and install circlip 2 5 Install piston stopper bolt 1 with pistons pushed in all the way and tighten it to specified torque Tightening Torque a 3 N m 0 3 kg m 2 5 lb ft BRAKES 5 35 ...

Page 232: ...Tightening Torque c 2 5 N m 0 25 kg m 2 0 lb ft 6 Fill reservoir with specified fluid After installing check brake pedal height bleed air from system Refer to BRAKE PEDAL FREE HEIGHT ADJUSTMENT and BLEEDING BRAKES in this section CAUTION Never use any mineral oil such as kerosene and gaso line when washing and assembling parts Check inside of cylinder wall pistons and cup seals are free from any f...

Page 233: ...ght sealant SEALING COMPOUND 366E 99000 31090 To apply to mating surfaces of brake back plate and rear axle To apply to mating surfaces of brake back plate and parking brake cable To apply to mating surface of wheel cylinder and brake back plate rubber grease To apply to sliding surfaces of caliper pin SPECIAL TOOLS 09942 15510 Sliding hammer 09943 17912 Brake drum remover Front wheel hub remover ...

Page 234: ...tood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation Whenever valve train components pistons piston rings connecting rods r...

Page 235: ...le working on engine that 12 volt electrical system is capable of violent and damaging short cir cuits When performing any work where electrical terminals could possibly be grounded ground cable of the battery should be dis connected at battery Any time the air cleaner air intake hose throttle body or intake manifold is removed the intake opening should be covered This will protect against acciden...

Page 236: ... cover the fitting to be disconnected with a shop cloth Put that cloth in an ap proved container when disconnection is completed Never run engine with fuel pump relay disconnected when en gine and exhaust system are hot Fuel or fuel vapor hose connection varies with each type of pipe When reconnecting fuel or fuel vapor hose be sure to connect and clamp each hose correctly referring to left figure...

Page 237: ...ctions are now safe for servic ing 5 Upon completion of servicing install fuel pump relay to relay box CAUTION This work must not be done when engine is hot If done so it may cause adverse effect to catalyst FUEL LEAKAGE CHECK PROCEDURE After performing any service on fuel system check to make sure that there are no fuel leakages as follows 1 Turn the ignition switch ON position for 3 seconds to o...

Page 238: ...ngine and emission control system which controls the A F mixture ignition tim ing emission etc suitably to engine conditions by ECM ECM has an On Board Diagnostic system which detects a malfunction in this system When diagnosing a trouble in the engine including this system be sure to have understanding of the outline of On Board Diagnostic system and each item in Precaution in Diagnosing Trouble ...

Page 239: ...onfirmation in this section Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and Record of DTC 1 Recheck for DTC referring to DTC Check in Section 6E1 Is there any DTC s Go to Step 9 Go to Step 8 7 Rechecking and Record of DTC 1 Recheck for DTC referring to DTC Check in Section 6E1 Is there any malfunction DTC s Go to Step 10 8 Engine Basic Inspection and Engine Diagnosis Table...

Page 240: ... P S j Other j Other j OTHERS VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather Temperature Frequency Road j Fair j Cloudy j Rain j Snow j Always j Other j Hot j Warm j Cool j Cold _F _C j Always j Always j Sometimes times day month j Only once j Under certain condition j Urban j Suburb j Highway j Mountainous j Uphill j Downhill j Tarmacadam j Gravel j Other Vehi...

Page 241: ...following items that support proper function of the engine INSPECTION ITEM REFERRING SECTION Engine oil level leakage Engine coolant level leakage Fuel level leakage Air cleaner element dirt clogging Battery fluid level corrosion of terminal Water pump belt and or cooling fan belt tension damage Throttle cable play installation Vacuum hoses of air intake system disconnection looseness deterioratio...

Page 242: ...oes engine start Go to Step 5 Go to Step 7 5 Check engine idle speed IAC duty referring to Idle Speed IAC Duty Inspection in section 6E1 Is check result as specified Go to Step 6 Go to ENGINE DIAGNOSIS TABLE in this section 6 Check ignition timing referring to Ignition Timing Inspec tion in section 6F Is check result as specified Go to ENGINE DIAGNOSIS TABLE in this section Adjust ignition timing ...

Page 243: ...indicated ENGINE DIAGNOSIS TABLE Condition Possible Cause Reference Item Hard starting Engine cranks OK Engine and emission control system out of order Faulty CMP sensing rotor Faulty idle air control system Faulty ECT sensor or MAP sensor Faulty ECM Low compression Compression leak from valve seat Sticky valve stem Weak or damaged valve springs Compression leak at cylinder head gasket Sticking or...

Page 244: ...d its circuit in Section 6E1 Previously outlined Diagnosis in Section 5 Diagnosis in Section 7C Improper engine idling or engine fails to idle Ignition system out of order Faulty spark plug Faulty ignition coil Fuel system out of order Fuel pressure out of specification Malfunctioning fuel pressure regulator Engine overheating Engine and emission control system out of order Faulty idle air control...

Page 245: ...3 in Section 6E1 Fuel pressure check in Section 6E1 Refer to Overheating Section Fuel injector in Section 6E1 TP sensor ECT sensor or MAP sensor in Section 6E1 Inspection of ECM and its circuit in Section 6E1 Previously outlined Surges Engine power variation under steady throttle or cruise Feels like the vehicle speeds up and down with no change in the accelerator pedal Ignition system out of orde...

Page 246: ...ter or oil strainer Poor oil pump performance Dragging brakes Slipping clutch Blown cylinder head gasket Thermostat in Section 6B Water pump in Section 6B Radiator in Section 6B Engine oil and oil filter change in Section 0B Oil pressure check in Section 6A or 6A1 Oil pressure check in Section 6A or 6A1 Diagnosis in Section 5 Diagnosis in Section 7C Cylinder head inspection in Section 6A or 6A1 Po...

Page 247: ...l noise make sure that Ignition timing is properly adjusted Specified spark plug is used Specified fuel is used Valve noise Improper valve lash Worn valve stem and guide Weak or broken valve spring Warped or bent valve Loose camshaft housing bolts Piston ring and cylinder noise Worn piston ring and cylinder bore Connecting rod noise Worn crankpin bearing Worn crankpin Loose connecting rod nuts Low...

Page 248: ...valve in Section 6E1 EVAP control system check in Section 6E1 Check oxygen sensor output voltage referring to DTC No 14 Diag Flow Table in Section 6E1 Fuel injector in Section 6E1 Inspection of ECM and its circuit in Section 6E1 Previously outlined Excessive nitrogen oxides NOx emission Fuel system out of order Fuel pressure out of specification Engine and emission control system Lead contaminatio...

Page 249: ...nkshaft 6A 34 Oil Seal Housing 6A 35 Oil Pump 6A 36 Piston and Piston Rings 6A 36 Connecting Rods 6A 38 Oil Pump Strainer 6A 38 Oil Pan 6A 38 Flywheel 6A 39 Cylinder Head 6A 39 Camshaft 6A 42 Rocker Arm Shafts 6A 42 Timing Belt Inside Cover Stud Bolts 6A 43 Crankshaft Timing Belt Guide 6A 43 Camshaft and Crankshaft Timing Belt Pulleys 6A 43 Timing Belt 6A 43 Distributor Gear Case 6A 45 Fuel Pump 6...

Page 250: ...head camshaft valve mechanism arranged for V type valve configuration The single overhead camshaft S O H C is mounted over the cylinder head it is driven from crankshaft through timing belt Unlike conventional overhead valve O H V engines this engine has no pushrods Thus drive for valve is more direct and enables the valves to follow the crankshaft without any delay ...

Page 251: ... bearings is supplied to the connecting rod bearings by means of intersecting passages drilled in the crankshaft and then injected from a small hole provided on the big end of connecting rod to lubricate piston rings and cylinder wall In another path oil goes up to the cylinder head and lu bricates rocker arms valves and camshaft etc after passing through the internal oilway of rocker arm shafts A...

Page 252: ...n 9 Rocker arm spring Replacement or inspection 10 Cam shaft Replacement or inspection 11 Cylinder head Replacement or inspection 12 Radiator Replacement or inspection 13 Distributor gear case Replacement 14 Camshaft timing belt pulley Replacement or inspection 15 Crankshaft timing belt pulley Replacement or inspection 16 Timing belt Replacement or inspection 17 Fuel pump Replacement 18 Throttle b...

Page 253: ...re if plug and cap are taken off too soon 6 Remove radiator with cooling fan and reserve tank refer to Sec tion 6B 7 Remove air cleaner assembly 1 with air cleaner hose 2 and breather hose 3 8 Disconnect following cables Accelerator cable from throttle body Clutch cable from clutch release lever Speedometer cable from transmission case 9 Disconnect following hoses Radiator outlet hose from outlet ...

Page 254: ...ness Ground wire from cylinder block Ground wire from transmission case A C compressor if equipped 11 Remove exhaust center pipe 12 Disconnect gear shift control shaft 1 and extension rod 2 from transmission case 13 Drain engine and transmission oil 14 Remove stabilizer bar refer to Section 3D 15 Disconnect right and left drive shaft joints from differential side gear snap rings 6A 6 ENGINE MECHAN...

Page 255: ...f equipped NOTE Cap open fittings immediately to keep moisture out of system 20 Remove A C compressor upper and lower bracket if equipped 21 Check to ensure all hoses electric wires and cables are dis connected from engine and transmission 22 Set a piece of wire across the hook on intake manifold and transmission case so that engine can be lifted by using chain block 23 Remove transmission left si...

Page 256: ...de the disas sembled parts in an orderly manner Place the parts in the trays and pans in such a way that they can be readily identi fied Put match marks or tags on them as necessary so that they will go back to where they came from Carry out engine disassembly in the following sequence 1 Remove starter motor engine mounting with engine member and clutch housing lower plate and loosen the transmiss...

Page 257: ...4 Remove distributor cap 2 and then remove distributor assem bly 1 5 Remove distributor case 1 6 Remove generator 1 refer to Section 6H 7 Remove generator brackets 1 ENGINE MECHANICAL F8B ENGINE 6A 9 ...

Page 258: ...hat crankshaft will not turn Special Tool A 09924 17810 9 Remove water pump pulley and then remove timing belt cover 1 10 Remove timing belt tensioner 1 after removing a part of ten sioner spring from water pump securing bolt 11 Remove timing belt 1 6A 10 ENGINE MECHANICAL F8B ENGINE ...

Page 259: ...ched as shown to lock camshaft Special Tool A 09930 40113 13 Similarly remove crankshaft timing belt pulley 1 14 After removing pulley key take out timing belt guide 1 15 Remove timing belt inside cover 1 16 Remove water pump case 1 ENGINE MECHANICAL F8B ENGINE 6A 11 ...

Page 260: ...ter by using special tool NOTE Be careful not to spill the oil when removing filter Special Tool A 09915 47310 19 Disconnect PCV outlet hose 1 and bypass hose 2 20 Remove intake manifold 1 with throttle body 2 21 Remove intake manifold plate 1 6A 12 ENGINE MECHANICAL F8B ENGINE ...

Page 261: ...ead cover 1 24 Loosen valve adjusting screws 1 fully Leave the screws in place 25 Loosen rocker arm shaft securing screws 1 26 While drawing out rocker arm shaft 1 separate valve rocker arms 2 and rocker arm springs ENGINE MECHANICAL F8B ENGINE 6A 13 ...

Page 262: ...Tool A 09916 14510 B 09916 48210 C 09916 84511 b Remove valve stem oil seal 1 from valve guide by using flat head rod 2 or the like and then valve spring seat 3 NOTE Do not reuse oil seal once disassembled Be sure to use new oil seal when assembling c Using special tool drive valve guide out from combustion chamber side to valve spring side NOTE Do not reuse valve guide once disassembled Be sure t...

Page 263: ...wheel by using special tool as shown Special Tool A 09924 17810 30 Remove oil level gauge and then remove oil pan 1 31 Remove oil pump strainer 1 32 Remove connecting rod caps 1 33 Install guide hose 1 over threads of rod bolts This is to prevent damage to bearing journal and cylinder wall when removing connection rod ENGINE MECHANICAL F8B ENGINE 6A 15 ...

Page 264: ...r bore CAUTIONS Before pushing piston out scribe cylinder number on its crown Be sure to identify each bearing cap for its con necting rod by using cylinder number Set cap and rod aside in combination a From each piston ease out piston pin circlips 1 as shown b Force piston pin 1 out 36 Remove oil pump case 1 6A 16 ENGINE MECHANICAL F8B ENGINE ...

Page 265: ...a Remove oil pump gear plate 1 b Take out inner gear 2 and outer gear 1 37 Remove oil seal housing 1 38 Remove crankshaft bearing caps 1 and take out crankshaft 2 ENGINE MECHANICAL F8B ENGINE 6A 17 ...

Page 266: ...r to clear internal oil holes and pas sages Do not disturb the set combinations of valves bearings and bearing caps etc Have the sets segregated and identified Cylinder head De carbon cylinder head Deposits of carbon will be found on its combustion chamber sur faces and exhaust ports Remember overheating tendency and loss of output are often due to excessive carbon accumulation De carbon valves to...

Page 267: ...adings to within thelimit replace the cylinder head Leakage of combustion gases from this gasketed joint is often due to warped gasketed surface such leakage results in re duced power output and hence a higher cost of fuel per kilome ter Distortion of manifold seating faces Check the seating faces of cylinder head for manifolds using a straightedge and thickness gauge in order to determine wheth e...

Page 268: ...al gauge check the shaft for straight ness in terms of deflection If the limit is exceeded replace it Wear of rocker arm and adjusting screw If the tip 1 of adjusting screw 2 is badly worn replace the screw The arm must be replaced if its cam riding face 3 is badly worn Visually examine each rocker arm spring for evidence of break age or weakening Be sure to replace springs found in bad condi tion...

Page 269: ...for wear burn or distortion at its face and stem and as necessary replace it Measure the thickness a of valve head If the limit given to this thickness is exceeded the valve must be replaced Valve head thickness a ENGINE MECHANICAL F8B ENGINE 6A 21 Item Standard Limit Valve stem In 6 965 6 980 mm 0 274 0 275 in diameter Ex 6 950 6 970 mm 0 273 0 274 in Valve guide In 7 000 7 015 mm g I D Ex 0 275 ...

Page 270: ...anner namely by giving a uniform coat of marking compound Red lead paste to the valve seat and by rotatingly tapping the seat with the valve head The valve lapper the tool used in valve lap ping must be used The pattern produced on the seating face of the valve must be a continuous ring without any break and the width a of the pat tern must be within the stated range CAUTION The valves to be check...

Page 271: ... the second angle differs as will be noted in figure 3 VALVE LAPPING Lap the valve on the seat in two steps first with a coarsesize lapping compound applied to the face and the second with a fine size compound each time using a valve lapper according to the usual lapping method NOTE After lapping wipe the compound off the valve face and seat and produce a contact pattern with a marking compound re...

Page 272: ...ts camshaft excessively worn or bent or bowed The wear could occur on its cams and journals Camshaft runout Hold the camshaft between two center points with a dial gauge rigged up to measure its runout Replace the camshaft if the amount of runout so measured exceeds the limit Cam wear Measure the height a of each cam If any of the micrometer readings taken is down to or less than the limit replace...

Page 273: ... same method that is prescribed for checking the distortion of the gasketed surface of the cylinder head check the top face of the cylinder block for distortion and if the distortion is found to exceed the limit machine the face with a surface grinder ENGINE MECHANICAL F8B ENGINE 6A 25 Item Standard Limit Thrust clearance 0 050 0 150 mm 0 002 0 006 in 0 300 mm 0 012 in Item Standard Limit Journal ...

Page 274: ...e of the three cylinders has to be re bored re bore the three to the same next oversize This is neces sary for the sake of uniformity and balance Piston and piston rings Piston diameter Piston to cylinder clearance mentioned above is equal to the bore diameter minus the piston diameter which is to be mea sured by measuring at the level of the piston in the direction transverse to piston pin axis a...

Page 275: ...ore and holding it true and square then use a thickness gauge 1 to measure the gap If the gap measured exceeds the limit replace the ring a 120 mm 4 72 in ENGINE MECHANICAL F8B ENGINE 6A 27 Item Standard Limit Ring clearance Top ring 0 03 0 07 mm 0 0012 0 0028 in 0 12 mm 0 0047 in g in the groove 2nd ring 0 02 0 06 mm 0 0008 0 0024 in 0 10 mm 0 0039 in Piston ring Top ring 1 47 1 49 mm 0 0579 0 05...

Page 276: ...l end is badly worn or damaged or if the clearance checked exceeds the limit Connecting rod big end bearings Inspect the bearing shells for signs of fusion pitting burn or flak ing and observe the contact pattern Bearings found in defective condition through this inspection must be replaced CAUTION Bearing shells are not meant to be repaired by scrap ing or grinding with sandpaper or by any machin...

Page 277: ...two ends right and left 3 Remove the cap and measure the width of flattened gaging plastic 1 piece with the gaging plastic envelope scale 2 This measurement must be taken at the widest part 4 If the limit indicated above is exceeded re grind the crank pin to the undersize and use the undersize bearing both of which are stated below Where undersize bearings are used the clearance specifica tion is ...

Page 278: ...shows up as a difference in diameter at a cross section or along its length or both This difference if any is to be determined from microme ter readings taken as shown in figure If any of the journals or crankpins is badly damaged or if the amount of uneven wear in the sense explained above exceeds the limit repair by re grinding or replace the crankshaft NOTE Where journal or crankpin re grinding...

Page 279: ...aps to the specified torque value It is assumed that a gaging plastic piece is pinched at each journal Do not rotate the crankshaft when gaging plastic is in Tightening Torque a 46 N m 4 6 kg m 33 5 Ib ft CAUTION Each of the four bearing caps has an arrow marked on it Be sure to position each cap with its arrow pointing to crankshaft pulley side and to match it by the cylinder number to its journa...

Page 280: ...th wear Inspect the teeth for wear and for evidence of crack chipping or any other damage Replace the ring gear if its teeth are found in bad condition Oil seals Carefully inspect the oil seals removed in disassembly examining the lip portion 1 of each oil seal for wear and damage Use of new oil seals in reassembly is recommended 6A 32 ENGINE MECHANICAL F8B ENGINE Bearing size Journal diameter Sta...

Page 281: ...as necessary 2 Inspect outer and inner gears gear plate and oil pump case for excessive wear or damage Radial clearance Check radial clearance between outer gear 2 and case 3 us ing thickness gauge 1 If clearance exceeds its limit replace outer gear or case Side clearance Using straight edge and thickness gauge measure side clear ance ENGINE MECHANICAL F8B ENGINE 6A 33 Item Standard Limit Radial c...

Page 282: ...que is specified for important fasteners bolts and nuts in the main of the engine and other compo nents Use torque wrenches and constantly refer to the spe cified values given in the text of this manual Do not disregard the match marks provided on parts Some of them are those given at the time of disassembly There are many sets of parts Crankshaft bearings con necting rods pistons etc are in combi...

Page 283: ... 4 6 kg m 33 5 Ib ft Gradual and uniform tightening is important for bearing cap bolts Make sure that the four caps become tight equally and uniformly progressively to the stated torque value NOTE After tightening cap bolts check to be sure that crankshaft ro tates smoothly when turned over by hand A Crankshaft pulley side B Flywheel side Oil seal housing This housing demands a new gasket do not r...

Page 284: ... engine oil to it Special Tool A 09926 18210 3 Before fitting the pump case apply sealant to mating surfaces around the oil discharging port of both the oil pump case and the cylinder block install oil pump to crankshaft and cylinder block After installing oil pump check to be sure that oil seal lip is not upturned and then remove special tool A Sealant 99000 31110 4 Edge of oil pump gasket might ...

Page 285: ...y in inserting pistons into cylinder block Using this spe cial tool feed the piston and connecting rod combination into the bore from the upper side of cylinder block Special Tool A 09916 77310 Pay attention to these reminders Point the piston crown arrow to pulley side Be sure that the number marked on the crown at the time of dis assembly tallies with the cylinder number Liberally oil the big en...

Page 286: ...eing sure to equalize tightness between right and left on each cap The sequence here is similar to that for crankshaft bear ing caps Tightening Torque a 30 N m 3 0 kg m 22 0 Ib ft Oil pump strainer Bear in mind that O ring 1 is often forgotten and left out in reas sembly Absence of this ring defeats the purpose served by the strainer Oil pan 1 After fitting the oil pan to the block run in the secu...

Page 287: ...e installing new valve guide into cylinder head ream guide hole with special tool 12 mm reamer to remove burrs making sure that guide hole diameter after reaming comes within specified range b Install valve guide to cylinder head Heat cylinder head uniformly at a temperature of 80 to 100 C 176 to 212 F using care not to distort head and drive new valve guide into hole with special tools Drive in n...

Page 288: ...oil seal disassembled Be sure to install new oil seal When installing never tap or hit special tool with a ham mer or else Install seal to guide only by pushing special tool with hand Tapping or hitting special tool may cause damage on seal 4 Install valve to valve guide Before installing valve to valve guide apply engine oil to stem seal valve guide bore and valve stem 5 Install spring and spring...

Page 289: ... side and EX mark comes on exhaust side 8 Install cylinder head onto cylinder block 9 Apply engine oil to cylinder head bolts and tighten them gradual ly as follows a Tighten all bolts to 34 N m 3 4 kg m 24 5 Ib ft according to numerical order in figure b In the same manner as a tighten them to 54 N m 5 4 kg m 39 0 Ib ft c Loosen all bolts to 0 N m 0 kg m 0 Ib ft reversing to numer ical order in f...

Page 290: ...s springs and rocker arm shafts The two rocker arm shafts are identical there being no need to dis tinguish between the two However each shaft takes but one posi tion in place See figure On the intake side 1 the stepped end 3 comes on camshaft pulley side 5 On the exhaust side 2 the stepped end 4 comes on flywheel side 6 As to the positions of rocker arms and springs on each rocker arm shaft refer...

Page 291: ...ave a punch mark 1 to show that the marked side faces the timing belt outside cover When installing each pulley di rect this mark to timing belt outside cover side Tighten camshaft pulley bolt to specified torque Tightening Torque for camshaft pulley bolt 55 N m 5 5 kg m 40 0 Ib ft 2 Keyway Timing belt A certain sequence must be followed installing the timing belt Here s the sequence 1 Put the ten...

Page 292: ... match arrow mark on tim ing belt with rotating direction of crankshaft 5 After putting the belt hook the spring on the water pump secur ing bolt as shown in figure The spring with its own tension ad just the belt tension to the specified value Rotate the crankshaft clockwise fully twice and tighten the bolt 7 first and then the bolt 8 Tightening Torque a 19 N m 1 9 kg m 14 Ib ft CAUTION After set...

Page 293: ...sion for ad justment displace the alternator in place For belt tension specification refer to MAINTENANCE SERVICE of SECTION 0B in this manual Clutch disc and cover Install clutch disc and cover For installation refer to SECTION 7A CLUTCH in this manual and torque each bolt to specification Distributor Install distributor to case For installation be sure to refer to SECTION 6F IGNITION SYS TEM in ...

Page 294: ...unting to transmission case and body 3 Install A C compressor upper and lower bracket and then con nect suction and discharge hoses to A C compressor if equipped Refer to Section 1B 4 Install A C compressor belt 3 and adjust its tension refer to Section 1B if equipped 5 Install water pump belt 1 after installed water pump pulley 2 and adjust its tension refer to Section 0B 6A 46 ENGINE MECHANICAL ...

Page 295: ...refer to Section 7C 12 Install air cleaner assembly with air cleaner hose and breather hose 13 Install radiator with cooling fan and reserve tank refer to Sec tion 6B 14 Install engine hood and connect windshield washer hose 15 Install front bumper 16 Connect negative cable at battery 17 Refill engine with engine oil refer to Section 0B 18 Refill cooling system with coolant refer to Section 6B 19 ...

Page 296: ...tween engine and transmission to gain visual access to the T mark Turn over crankshaft to index mark to timing match mark and see if the rocker arms of No 1 cylinder are off the respec tive cam lobes of camshaft if so valves 1 and 2 in figure are ready for clearance checking and adjustment if not turn over crankshaft further by 360_ to index mark to mark again This 360_ turning should bring about ...

Page 297: ...shaft 240 from T mark check and adjust the valves 5 and 6 Turn over the crankshaft 240 from 3 mark check and adjust the valves 3 and 4 Measuring valve clearance Adjusting valve clearance ENGINE MECHANICAL F8B ENGINE 6A 49 ...

Page 298: ...pecial Tool A 09915 77310 4 Start engine and warm it up to normal operating temperature 5 After warming up raise engine speed to 3 000 r min and mea sure oil pressure 6 After checking oil pressure stop engine and remove oil pres sure gauge 7 Before reinstalling oil pressure switch be sure to wrap its screw threads with sealing tape and tighten switch to specified torque Tightening Torque Oil press...

Page 299: ...ompression gauge into spark plug hole Special Tool A 09915 64510 7 Disengage the clutch to lighten starting load on engine and depress the accelerator all the way to make the throttle full open 8 Crank the engine with the starter motor and read the highest pressure on the compression gauge 9 Carry out the steps 5 through 7 on each cylinder to obtain three readings NOTE For measuring compression pr...

Page 300: ...S C 3 way joint 09367 04002 3 Run the engine at the specified idling speed and under this run ning condition read the vacuum gauge The vacuum should be not lower than 53 7 kPa 40 cm Hg 15 7 in Hg A low vacuum reading means that any combination of the fol lowing malconditions is the cause which must be corrected be fore releasing the machine to the customer a Leaky cylinder head gasket b Leaky inta...

Page 301: ...INE COOLING SYSTEM Exhaust line and muffler Inspect each exhaust line connection for tightness and examine the muffler and other parts for evidence of breakage and leakage of gases Repair or replace defective parts if any Oil filler cap The cap has a packing Be sure that packing is in good condition free of any damage and signs of deterioration and is tight in place If any defective replace ENGINE...

Page 302: ...ud bolts Threads of distributor gear case bolts SPECIAL TOOLS 09915 47310 Oil filter wrench 09915 77310 Oil pressure gauge 09916 44511 Valve guide remover 09916 77310 Piston ring compressor 09916 37310 12 mm reamer 09916 57321 Valve guide installer handle 09916 34520 7 mm reamer 09916 84511 Forceps 09915 67310 Vacuum gauge 1 09916 14510 Valve lifter 2 09916 48210 Valve lifter attachment 09915 6451...

Page 303: ...INE MECHANICAL F8B ENGINE 6A 55 09924 17810 Flywheel holder 09930 40113 Camshaft lock holder 09926 18210 Oil seal guide Vinyl resin 09917 98210 Valve stem seal installer 09918 08210 Vacuum gauge hose joint ...

Page 304: ...10 Throttle Body and Intake Manifold 6A1 11 Exhaust Manifold 6A1 13 Timing Belt and Belt Tensioner 6A1 15 Oil Pan and Oil Pump Strainer 6A1 20 Oil Pump 6A1 23 Rocker Arms Rocker Arm Shaft and Camshaft 6A1 26 Valves and Cylinder Head 6A1 32 Piston Piston Rings Connecting Rods and Cylinders 6A1 42 UNIT REPAIR OVERHAUL 6A1 51 Engine Assembly 6A1 51 Main Bearings Crankshaft and Cylinder Block 6A1 52 R...

Page 305: ...ft valve mechanism ar ranged for V type valve configuration and 12 valves IN 2 and EX 2 one cylinder The single overhead camshaft is mounted over the cylinder head it is driven from crankshaft through tim ing belt and opens and closes its valves via the rocker arms 6A1 2 ENGINE MECHANICAL F8D ENGINE GENERAL DESCRIPTION ENGINE ...

Page 306: ... two paths inside the cylinder block In one path oil reaches the crankshaft journal bearings and big end bearings on crankpins Some of this oil goes to the connecting rod small ends and lubricates piston pins there and also the walls of cylinder bores In the other path oil goes up to the cylinder head and enters the oil gallery of rocker arm shafts to lubricate the sliding parts of these shafts an...

Page 307: ...n cords 1 and all spark plugs referring to Section 6F 5 Disconnect ignition coil wire harness at coupler 1 WARNING Failure in disconnecting the coupler can cause spark to occur in engine room possibly resulting in a dan gerous explosion 6 Install special tool Compression gauge into spark plug hole Special Tool A 09915 64510 001 B 09915 64510 002 C 09915 64530 D 09915 64550 7 Disengage clutch to li...

Page 308: ... up engine to normal operating temperature NOTE After warming up engine place transmission gear shift le ver in Neutral and set parking brake and block drive wheels 9 Carry out steps 5 through 7 on each cylinder to obtain three readings 10 After checking install spark plugs and high tension cords 1 and connect injector and ignition coil wire harness connector securely ENGINE MECHANICAL F8D ENGINE ...

Page 309: ...ithin following specification Vacuum specification at sea level at specified idling speed 53 7 60 4 kPa 40 45 cmHg 15 7 17 7 in Hg 4 After checking connect vacuum hose to canister purge control valve OIL PRESSURE CHECK NOTE Prior to checking oil pressure check following items Oil level in oil pan If oil level is low add oil up to Full level hole on oil level gauge Oil quality If oil is discolored ...

Page 310: ...eed to 4 000 r min and mea sure oil pressure Oil pressure specification 300 450 kPa 3 0 4 5 kg cm2 42 7 64 0 psi at 4 000 r min rpm 5 Stop engine and remove oil pressure gauge 6 Before reinstalling oil pressure switch 1 be sure to wrap its screw threads with sealing tape and tighten switch to specified torque NOTE If sealing tape edge is bulged out from screw threads of switch cut it off Tightenin...

Page 311: ...o 2 piston C Top dead center of No 3 piston 6 If valve lash is out of specification adjust it to specification by turning adjusting screw after loosening lock nut After adjustment tighten lock nut to specified torque while hold ing adjusting screw stationary and then make sure again that valve lash is within specification Special Tool A 09917 18210 Tightening Torque a 12 N m 1 2 kg m 9 0 lb ft 6A1...

Page 312: ...d check the same valves at 2 and 5 Adjust them as necessary A Top dead center of No 1 piston B Top dead center of No 2 piston C Top dead center of No 3 piston AIR CLEANER FILTER REMOVAL AND INSTALLATION 1 Remove air cleaner case bracket bolts 1 2 Remove air cleaner case clamps 2 3 Remove air cleaner filter from case 4 Check air cleaner filter for dirt 5 If necessary blow off dust by compressed air...

Page 313: ... rings B grease 99000 25010 NOTE Be sure to check each of these parts for deterioration or any damage before installation and replace if found defec tive 2 Install cylinder head cover to cylinder head and tighten cover bolts to specified torque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft NOTE When installing cylinder head cover use care so that cylin der head cover gasket cylinder head side seal...

Page 314: ...ng system WARNING To help avoid danger of being burned do not remove drain plug and radiator cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon 4 Remove air cleaner case 1 5 Disconnect following electric lead wires Injectors lead wires at the coupler Canister purge control valve Throttle position sensor Idle a...

Page 315: ... surface or replace intake manifold Limit of distortion 0 05 mm 0 002 in INSTALLATION Reverse removal procedure for installation noting the followings Use new intake manifold gasket Tighten bolts and nuts to specified torque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft Adjust accelerator cable play referring to Section 6E Check to ensure that all removed parts are back in place Rein stall any nec...

Page 316: ...service exhaust system while it is still hot Service should be performed after system cools down REMOVAL 1 Disconnect negative cable at battery 2 Disconnect oxygen sensor coupler if equipped 3 Remove exhaust manifold covers of exhaust manifold 4 Remove exhaust pipe from exhaust manifold 5 Remove exhaust manifold and its gasket from cylinder head ENGINE MECHANICAL F8D ENGINE 6A1 13 EXHAUST MANIFOLD...

Page 317: ...haust manifold Before installing pipe gasket check it for deterioration or dam age and replace as necessary Tighten pipe fasteners to specified torque Tightening Torque b 55 N m 5 5 kg m 40 0 lb ft 4 Install upper cover 3 to exhaust manifold 5 Connect oxygen sensor connector 4 and fit connector to bracket 6 Connect negative cable at battery 7 Check exhaust system for exhaust gas leakage 6A1 14 ENG...

Page 318: ...de cover Tightening Torque Do not reuse REMOVAL 1 Disconnect negative cable at battery 2 Remove air cleaner case and hose 3 Remove water pump drive belt 1 and water pump pulley 2 4 Remove A C compressor belt 3 if equipped 5 Remove clutch housing lower plate 1 6 Remove crankshaft pulley 1 with crankshaft locked ENGINE MECHANICAL F8D ENGINE 6A1 15 TIMING BELT AND BELT TENSIONER ...

Page 319: ...own in figure If turned interference may occur among piston and valves and parts re lated to piston and valves may be damaged D Never bend timing belt 1 Camshaft allowable turning range By timing mark within 90_ from timing mark on timing belt inside cover on both right and left 2 Crankshaft allowable turning range By timing mark within 90_ from timing mark on oil pump case on both right and left ...

Page 320: ...ming belt pulley is aligned with mark 2 on timing belt inside cover If not align two marks by turning camshaft but be careful not to turn it more than its allowable turning range which is described on previous page 4 Check that punch mark 2 on crankshaft timing belt pulley is aligned with arrow mark 1 on oil pump case If not align two marks by turning crankshaft but be careful not to turn it more ...

Page 321: ... belt tension is specification by turning hexagon wrench clockwise as shown in figure and measure timing belt tension by using special tool Special Tool A 09919 56010 Belt tension under pressure 7 kg or 15 5 Ib a 10 5 mm 0 413 in New belt 12 0 mm 0 472 in Reuse belt b Tighten tensioner bolt Tightening Torque a 19 N m 1 9 kg m 14 0 lb ft c To take up slack of timing belt turn crankshaft two rotatio...

Page 322: ... pulley with crankshaft locked and tighten pulley bolts to specified torque Tightening Torque a 84 N m 8 4 kg m 61 0 lb ft 12 Install A C compressor belt 3 if equipped Adjust its belt tension referring to Section 0B 13 Install water pump pulley 1 and water pump drive belt 2 Adjust water pump drive belt tension referring to Section 6B 14 Install air cleaner case and hose 15 Connect negative cable a...

Page 323: ...Seal 4 Drain plug gasket 5 Drain plug 6 Oil pan bolt and nut 7 Strainer bolt Tightening Torque Do not reuse 1 Drain engine oil by removing drain plug 1 2 Remove clutch housing lower plate 1 3 Disconnect exhaust pipe from exhaust manifold 4 Remove oil pan 2 and then oil pump strainer 1 6A1 20 ENGINE MECHANICAL F8D ENGINE ...

Page 324: ... block Remove oil old sealant and dusts from mating surfaces and oil pan inside Clean oil pump strainer screen INSTALLATION 1 Apply sealant to oil pan mating surface continuously as shown in figure A Sealant 99000 31150 ENGINE MECHANICAL F8D ENGINE 6A1 21 ...

Page 325: ... tightening one bolt at a time Tighten bolts to specified torque Tightening Torque b 11 N m 1 1 kg m 8 0 lb ft b 3 Install new gasket and drain plug 1 to oil pan Tighten drain plug 1 to specified torque Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft 4 Install clutch torque converter housing lower plate 5 Connect exhaust manifold pipe to exhaust manifold 6 Refill engine with engine oil referring to...

Page 326: ...ect negative cable at battery 2 Remove timing belt as previously outlined 3 Remove generator 1 and its bracket 2 4 Remove A C compressor 3 and its bracket 4 if equipped 5 Remove camshaft timing pulley 5 by using special tool Special Tool A 09917 68221 6 Remove timing belt inside cover 6 7 Remove oil pan and oil pump strainer as previously outlined 8 Remove oil pump assembly 7 after removing bolts ...

Page 327: ...tor or case Limit on radial clearance between outer rotor and case 0 320 mm 0 0126 in Side clearance Using straight edge and thickness gauge measure side clear ance Limit on side clearance 0 17 mm 0 0067 in ASSEMBLY 1 Wash clean and then dry all disassembled parts 2 Apply thin coat of engine oil to inner and outer rotors oil seal lip portion and inside surfaces of oil pump case and plate 3 Install...

Page 328: ...ll timing belt tensioner oil pump strainer oil pan and oth er parts as previously outlined 6 Check to ensure that all removed parts are back in place Rein stall any necessary parts which have not been reinstalled 7 Adjust water pump drive belt tension referring to Section 0B 8 Adjust A C compressor belt tension if equipped Refer to Sec tion 0B 9 Refill engine with engine oil referring to item ENGI...

Page 329: ... of each part REMOVAL 1 Disconnect negative cable at battery 2 Remove timing belt as previously outlined 3 Remove camshaft timing belt pulley 1 by using special tool and then remove timing belt inside cover 2 Special Tool A 09917 68221 4 Remove cylinder head cover as previously outlined 5 After loosening all valve adjusting screw lock nuts 2 turn ad justing screws 1 back all the way to allow all r...

Page 330: ...uch or der as indicated in figure a little at a time 9 Remove exhaust rocker arms INSPECTION Adjusting Screw and Rocker Arm If tip of adjusting screw 1 is badly worn replace it Rocker arm 2 must be replaced if its cam riding face 3 is badly worn Rocker Arm Shaft Runout Using V blocks and dial gauge check runout If runout exceeds its limit replace rocker arm shaft Runout limit 0 06 mm 0 0024 in ENG...

Page 331: ... limit replace camshaft Runout limit 0 10 mm 0 0039 in Camshaft Journal Wear Check camshaft journals and camshaft housings for pitting scratches wear or damage If any malcondition is found replace camshaft or cylinder head with housing Never replace cylinder head without replacing housing 6A1 28 ENGINE MECHANICAL F8D ENGINE Item Standard Limit Rocker arm I D 15 985 16 005 mm 0 629 0 630 in Rocker ...

Page 332: ...kg m 8 0 lb ft NOTE Do not rotate camshaft while gaging plastic is installed 6 Remove housing and using scale 1 on gaging plastic 2 enve lope measure gaging plastic width at its widest point If measured camshaft journal clearance exceeds limit measure journal housing bore and outside diameter of camshaft jour nal Replace camshaft or cylinder head assembly whichever the difference from specificatio...

Page 333: ...tion as to thrust direction make sure to first fit No 1 housing to No 1 journal of camshaft securely Indicates position from timing belt side Install in numerical order starting from timing belt side Indicates direction of housing Install so that arrow is directed toward timing belt side After applying engine oil to housing bolts tighten them tem porarily first Then tighten them by following seque...

Page 334: ...itting pin on camshaft into slot 10 Using special tool tighten pulley bolt to specified torque Tightening Torque a 54 N m 5 4 kg m 39 0 lb ft Special Tool A 09917 68221 11 Install belt tensioner timing belt outside cover crankshaft pulley A C compressor belt if equipped and water pump belt as previously outlined 12 Adjust valve clearance as previously outlined 13 Install cylinder head cover 14 Con...

Page 335: ...head bolt 12 Oil gallery plug Tightening Torque Do not reuse Apply engine oil REMOVAL 1 Relieve fuel pressure according to fuel pressure relief proce dure described in Section 6 2 Disconnect negative cable at battery 3 Drain cooling system 4 Remove cylinder head cover as previously outlined Loosen all valve lash adjusting screws fully 6A1 32 ENGINE MECHANICAL F8D ENGINE VALVES AND CYLINDER HEAD ...

Page 336: ...ected and remove or disconnect what ever necessary 9 Remove cylinder head with intake manifold and exhaust man ifold DISASSEMBLY 1 For ease in servicing cylinder head remove intake manifold ex haust manifold and thermostat case from cylinder head 2 Using special tool Valve lifter compress valve springs and then remove valve cotters by using special tool Forceps as shown Special Tool A 09916 14510 ...

Page 337: ... guides to check stem to guide clearance Be sure to take reading at more than one place along the length of each stem and guide If clearance exceeds limit replace valve and valve guide If caliper gauge is not available check end deflection of valve stem with a dial gauge instead Move stem end in directions 1 and 2 to measure end deflection If deflection exceeds its limit replace valve stem and val...

Page 338: ...place valve D Seating contact width Create contact pattern on each valve in the usual manner i e by giving uniform coat of marking compound to valve seat and by rotatingly tapping seat with valve head Valve lapper tool used in valve lapping must be used Pattern produced on seating face of valve must be a continuous ring without any break and the width a of pattern must be within specified range EN...

Page 339: ...0 0 0807 in 2 INTAKE VALVE SEAT Cutting sequence is the same as for exhaust valve seats 1 Seat width for intake valve seat 1 80 2 20 mm 0 0709 0 0866 in 3 VALVE LAPPING Lap valve on seat in two steps first with coarse size lapping compound applied to face and the se cond with fine size compound each time using valve lapper according to usual lapping method Cylinder Head D Remove all carbon from co...

Page 340: ...t of distortion 0 05 mm 0 002 in Distortion of manifold seating faces Check seating faces of cylinder head for manifolds using a straightedge and thickness gauge in order to determine wheth er these faces should be corrected or cylinder head replaced Limit of distortion 0 10 mm 0 004 in Valve Springs Referring to data given below check to be sure that each spring is in sound condition free of any ...

Page 341: ...ormly at a temperature of 80 to 100_C 176 to 212_F so that head will not be distorted and drive new valve guide into hole with special tools Drive in new valve guide until special tool Valve guide installer contacts cylinder head After installing make sure that valve guide protrudes by 13 0 mm 0 51 in from cylinder head Special Tool C 09916 57340 D 09916 58210 NOTE D Do not reuse valve guide once ...

Page 342: ...t special tool with a ham mer or else Install seal to guide only by pushing special tool by hand Tapping or hitting special tool may cause damage to seal 6 Install valve to valve guide Before installing valve to valve guide apply engine oil to stem seal valve guide bore and valve stem 7 Install valve spring and spring retainer Each valve spring has top end large pitch end 1 and bottom end small pi...

Page 343: ...n installing it be sure to tighten to specified torque Tightening Torque a 5 N m 0 5 kg m 4 0 lb ft 3 Apply engine oil to cylinder head bolts and tighten them gradu ally as follows 1 Tighten all bolts to 30 N m 3 0 kg m 22 0 lb ft according to numerical order in figure 2 In the same manner as in 1 tighten them to 48 N m 4 8 kg m 35 0 lb ft 3 Loosen all bolts to 0 N m 0 kg m 0 lb ft reversing to nu...

Page 344: ...rator cable play Refer to Section 6E 9 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been reinstalled 10 Refill cooling system referring to Section 6B 11 Connect negative cable at battery 12 Verify that there is no fuel leakage coolant leakage and ex haust gas leakage at each connection 13 Confirm that ignition timing is within specification ...

Page 345: ...ned 2 Drain engine oil 3 Remove oil pan and oil pump strainer as previously outlined 4 Mark cylinder number on all pistons connecting rods and rod bearing caps using silver pencil or quick drying paint 5 Remove rod bearing caps 6 Install guide hose 1 over threads of rod bolts This is to prevent damage to bearing journal and rod bolt threads when removing connecting rod 7 Decarbon top of cylinder b...

Page 346: ...ion rings Top and 2nd and oil ring from piston 2 Remove piston pin from connecting rod Ease out piston pin circlips 1 as shown Force piston pin out CLEANING Clean carbon from piston head and ring grooves using a suitable tool ENGINE MECHANICAL F8D ENGINE 6A1 43 ...

Page 347: ... Cylinder bore dia limit 68 57 mm 2 6996 in Taper and out of round limit 0 10 mm 0 0039 in NOTE If any one of three cylinders has to be rebored rebore all three to the same next oversize This is necessary for the sake of uniformity and balance 1 50 mm 1 96 in 2 90 mm 3 54 in Pistons Inspect piston for faults cracks or other damaged Damaged or faulty piston should be replaced Piston diameter As ind...

Page 348: ...2 If clearance is out of specification replace piston Ring groove clearance Top 0 03 0 07 mm 0 0012 0 0027 in 2nd 0 02 0 06 mm 0 0008 0 0023 in Piston Pin Check piston pin connecting rod small end bore and piston bore for wear or damage paying particular attention to condition of small end bore bush If pin connecting rod small end bore or pis ton bore is badly worn or damaged replace pin connectin...

Page 349: ...he normal manner If measured clearance is found to exceed its limit replace con necting rod Connecting rod alignment Mount connecting rod on aligner to check it for bow and twist and if limit is exceeded replace it Limit on bow 0 05 mm 0 0020 in Limit on twist 0 10 mm 0 0039 in 6A1 46 ENGINE MECHANICAL F8D ENGINE Item Standard Limit Top ring 0 12 0 26 mm 0 0047 0 0102 in 0 7 mm 0 0275 in Piston ri...

Page 350: ... 25 mm undersize bearing has the stamped number US025 on its backside as indicated in figure but standard size one has no number Rod bearing clearance 1 Before checking bearing clearance clean bearing and crank pin 2 Install bearing in connecting rod and bearing cap 3 Place a piece of gaging plastic 1 to full width of crankpin as contacted by bearing parallel to crankshaft avoiding oil hole 4 Inst...

Page 351: ...ure to match piston with cylinder as follows a Each piston has painted color red or blue 2 as shown It repre sents outer diameter of piston b There are paints 1 on the cylinder block as shown The color red or blue of each paint represents cylinder bore diameter The first paint from crank pulley side represents inner diameter of No 1 cylinder the second paint of No 2 cylinder the third paint of No ...

Page 352: ... in thickness shape and color of surface contacting cylinder wall Distinguish 1st ring from 2nd ring by referring to figure When installing oil ring install spacer first and then two rails 3 After installing three rings 1st 2nd and oil rings distribute their end gaps as shown in figure 1 Arrow mark 2 1st ring end gap 3 2nd ring end gap and oil ring spacer gap 4 Oil ring upper rail gap 5 Oil ring l...

Page 353: ...2 0 lb ft 6 Reverse removal procedure for installation as previously out lined 7 Adjust water pump drive belt tension referring to Section 0B 8 Adjust A C compressor belt tension if equipped Refer to Sec tion 0B 9 Adjust intake and exhaust valve lashes as previously outlined 10 Adjust accelerator cable play Refer to Section 6E 11 Check to ensure that all removed parts are back in place Rein stall ...

Page 354: ...UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL AND INSTALLATION Refer to Section 6A ENGINE MECHANICAL F8D ENGINE 6A1 51 ...

Page 355: ...7 Crankshaft Apply engine oil to crankshaft journals 8 Thrust bearing Apply engine oil 9 Rear oil seal 10 Pin 11 Oil seal housing gasket 12 Oil seal housing 13 Housing bolt 14 Input shaft bearing Apply engine oil 15 Flywheel 16 Flywheel bolt Tightening Torque Do not reuse 6A1 52 ENGINE MECHANICAL F8D ENGINE MAIN BEARINGS CRANKSHAFT AND CYLINDER BLOCK ...

Page 356: ...side cover and crankshaft timing pulley 4 Remove cylinder head assembly as previously outlined 5 Remove oil pan and oil pump strainer as previously outlined 6 Remove oil pump 1 7 Remove oil seal housing 8 Remove connecting rod bearing caps 9 Loosen crankshaft bearing cap bolts in such order as indicated in figure a little at a time and remove bearing caps 10 Remove crankshaft from cylinder block E...

Page 357: ...ust play Out of round and taper uneven wear of journals An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length or both This differ ence if any is determined by taking micrometer readings If any one of journals is badly damaged or if amount of uneven wear in the sense explained above exceeds its limit regrind or replace crankshaft Out of roun...

Page 358: ...cified torque Inspection Check bearings for pitting scratches wear or damage If any malcondition is found replace both upper and lower halves Never replace one half without replacing the other half Main bearing clearance Check clearance by using gaging plastic according to following procedure 1 Remove bearing caps 2 Clean bearings and main journals 3 Place a piece of gaging plastic 1 to full width...

Page 359: ... 1 First check journal diameter by using following procedure As shown in figure crank webs of No 1 cylinder have four stamped numerals Three kinds of numerals 1 2 and 3 represent following journal diameters The first second third and fourth left to right stamped numer als represent journal diameters at bearing caps 1 2 3 and 4 respectively For example in figure the first leftmost numeral 1 indicat...

Page 360: ...t cap bore dia of cap 4 is within 54 006 54 012 mm 3 There are five kinds of standard bearings differing in thickness To distinguish them they are painted in following colors at the position as indicated in figure Each color indicates following thickness at the center of bear ing ENGINE MECHANICAL F8D ENGINE 6A1 57 Numeral stamped Bearing cap bore diameter without bearing 1 54 000 54 006 mm 2 1260...

Page 361: ... bearing If clearance still exceeds its limit use next thicker bearing and recheck clearance 6 When replacing crankshaft or cylinder block due to any reason select new standard bearings to be installed by referring to nu merals stamped on new crankshaft or alphabets stamped on mating surface of new cylinder block UNDERSIZE BEARING 0 25 mm 0 25 mm undersize bearing is available in five kinds varyin...

Page 362: ...ize bearing by referring to table given below Check bearing clearance with newly selected undersize bear ing Green Red Black Red Red only Black Red Red only Yellow Red Red only Yellow Red Blue Red 1 2 3 Measured journal diameter Numeral stamped on mating surface of cylinder block Undersize bearing to be installed 49 744 49 750 mm 1 9584 1 9587 in 49 738 49 744 mm 1 9582 1 9584 in 49 732 49 738 mm ...

Page 363: ...t Honing or reboring cylinders 1 When any cylinder needs reboring all other cylinders must also be rebored at the same time 2 Select oversized piston according to amount of cylinder wear 3 Using micrometer measure piston diameter a 20 mm 0 79 in 4 Calculate cylinder bore diameter to be rebored D A B C D Cylinder bore diameter to be rebored A Piston diameter as measured B Piston clearance 0 025 0 0...

Page 364: ...s Journal bearings bearing caps connecting rods rod bear ings rod bearing caps pistons and piston rings are in com bination sets Do not disturb such combination and make sure that each part goes back to where it came from when installing 1 Install main bearings to cylinder block 1 One of two halves of main bearing 2 has an oil groove 3 Install it to cylinder block and the other half without oil gr...

Page 365: ...ow 5 Install new gasket and oil seal housing Do not reuse gasket removed in disassembly Apply engine oil to oil seal lip before installation Tighten housing bolts to specifi cation Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft NOTE As there are 2 types long bolts 1 and short bolts 2 of housing bolts refer to figure for their correct use After installing oil seal housing gasket edges might bulge ou...

Page 366: ... cylinder head bolts to specified torque as pre viously outlined 11 Install camshaft crankshaft timing belt pulley timing belt crankshaft pulley water pump pulley etc as previously out lined 12 Install clutch to flywheel For clutch installation refer to Section 7C 13 Install transmission and engine member to engine 14 Install engine assembly to vehicle as previously outlined ENGINE MECHANICAL F8D ...

Page 367: ...GREASE A 99000 25010 O rings of plug cap SPECIAL TOOLS 09913 75520 Bearing installer 1 09915 64510 001 Compression gauge 2 09915 64510 002 Connector 3 09915 64530 Hose 4 09915 64550 Attachment 09915 67310 Vacuum gauge 09915 77310 Oil pressure gauge 09915 78211 Oil pressure gauge attachment 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 34542 Reamer handle 09916 34550 Reamer 5 5...

Page 368: ...der 09918 08210 Vacuum gauge hose joint 09926 18210 Oil seal guide Vinyl resin 09916 77310 Piston ring compressor 09917 18210 Tappet adjuster wrench 09917 68221 Camshaft pulley holder 09917 98221 Valve stem seal installer 09916 58210 Valve guide installer handle ...

Page 369: ...MAINTENANCE 6B 4 Coolant 6B 4 Coolant Level 6B 5 Cooling System Service 6B 5 Cooling System Flush and Refill 6B 6 Water Pump Belt Tension 6B 7 ON VEHICLE SERVICE 6B 8 Cooling System Draining 6B 8 Cooling Water Pipes or Hoses 6B 8 Thermostat 6B 9 Water Pump Belt 6B 10 Radiator 6B 11 Water Pump 6B 12 REQUIRED SERVICE MATERIALS 6B 14 ...

Page 370: ...at closed Throttle body Heater unit Water inlet pipe Intake manifold F8D engine F8B engine 2 When coolant is warmed up to normal operating temperature and the thermostat opens coolant passes through the radiator core to be cooled as well as the above flow circuit 1 Radiator inlet hose 2 Radiator outlet hose 3 Intake manifold 4 Thermostat 5 Water pump 6 Throttle body 7 Cylinder block 8 Cylinder hea...

Page 371: ... on cooling system Defective cooling fan motor Faulty fan motor control circuit Plugged radiator Faulty radiator cap Improper ignition timing Dragging brakes Slipping clutch Adjust or replace Check coolant level and add as necessary Replace Replace Clean or remedy Repair Check and replace as necessary Refer to SECTION 6E1 Check and replace radiator as necessary Replace Adjust Adjust brake Adjust o...

Page 372: ...nt has to be added because of coolant loss or to provide added protection against freezing at temperature lower than 36 C 33 F NOTE Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time as damage to cooling sys tem could occur Even in a market where no freezing tempera ture is anticipated mixture of 70 water and 30 ethylene glycol antifreeze Antifre...

Page 373: ... proper operation of system and are unnecessary expense WARNING To help avoid danger of being burned do not remove reservoir tank cap while coolant is boil ing and do not remove radiator cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pres sure if either cap is taken off too soon COOLING SYSTEM SERVICE Cooling system should be serviced as follows 1 Check...

Page 374: ...le turning it Wait until pressure is relieved indicated by a hissing sound then press down on cap and continue to turn it counterclock wise 2 With radiator cap removed run engine until upper radiator hose is hot this shows that thermostat is open and coolant is flowing through system WARNING To help avoid danger of being burned do not remove radiator cap while engine and radiator are still hot Sca...

Page 375: ...f cap lines is parallel to radiator WATER PUMP BELT TENSION 1 Inspect belt for cracks cuts deformation wear and cleanliness If it is necessary to replace belt refer to page 6B 10 for proce dure WARNING Disconnect negative cable at battery before checking and adjusting belt tension See WARNING described in COOLING SYSTEM SER VICE 2 Check belt 1 for tension Belt is in proper tension when it de flect...

Page 376: ... After draining coolant be sure to tighten drain plug securely 4 Fill cooling system Refer to Item COOLANT of MAINTE NANCE COOLING WATER PIPES OR HOSES Tightening Torque Do not reuse without heater HEATER if equipped F8D engine REMOVAL 1 Drain cooling system 2 To remove these pipes or hoses loosen clamp on each hose and pull hose end off INSTALLATION Install removed parts in reverse order of remov...

Page 377: ...t valve from seating tight 4 Check thermostatic movement of wax pellet as follows 1 Immerse thermostat in water and heat water gradually 2 Check that valve starts to open at specific temperature 3 If valve starts to open at a temperature substantially below or above specific temperature thermostat unit should be re placed with a new one Such a unit if reused will bring about overcooling or overhea...

Page 378: ... cable at battery 8 After installation check each part for leakage WATER PUMP BELT REMOVAL 1 Disconnect negative cable at battery 2 Loosen drive belt adjusting bolt 1 and generator pivot bolts 2 3 Slacken belt by displacing generator and then remove it INSTALLATION 1 Install belt to water pump pulley crankshaft pulley and genera tor pulley 2 Tighten water pump belt adjusting bolt and pivot bolts 3...

Page 379: ... inlet and outlet hoses and reservoir tank hose from radiator 6 Remove radiator from vehicle INSPECTION Check radiator for leakage or damage Straighten bent fins if any CLEANING Clean frontal area of radiator cores INSTALLATION Reverse removal procedures NOTE Refill cooling system with proper coolant referring to COOLANT item of MAINTENANCE Refer to the figure at REMOVAL for tightening torque Afte...

Page 380: ... by using special tool Special Tool A 09930 40113 6 Remove crankshaft timing belt pulley and timing belt inside cov er 7 Remove generator adjusting arm 8 Remove water pump gasket and rubber seal F8D engine 1 Disconnect negative cable at battery 2 Drain cooling system 3 Remove water pump belt A C compressor drive belt if equipped and water pump pulley 4 Remove crankshaft pulley and timing belt outs...

Page 381: ...haft timing belt pulley Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft 5 Remove cylinder head cover and loosen all valve adjusting screws of intake and exhaust rocker arms fully 6 Install belt tensioner tensioner spring and timing belt and ad just timing belt tension according to procedure described in TIMING BELT AND TENSIONER of SECTION 6A 7 Install timing belt outside cover crankshaft pulley wa...

Page 382: ...elt and adjust timing belt ac cording to procedure described in item TIMING BELT AND TENSIONER of SECTION 6A1 5 Adjust drive belt tension 6 Fill cooling system 7 After installation check each part for leakage 6B 14 ENGINE COOLING REQUIRED SERVICE MATERIAL MATERIALS USE Ethylene glycol base coolant Anti freeze Anti corrosion coolant Additive to engine cooling system for improving cooling efficiency...

Page 383: ...AUTION THE ENGINE OF THIS VEHICLE REQUIRES THE USE OF UNLEADED FUEL ONLY USE OF LEADED AND OR LOW LEAD FUEL CAN RESULT IN ENGINE DAMAGE AND REDUCE THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM GENERAL DESCRIPTION FUEL SYSTEM The main components of the fuel system are fuel tank fuel pump fuel filter and fuel level gauge and it includes three lines fuel feed line fuel return line and fuel vapor l...

Page 384: ...ank as shown in figure and filters the fuel sent under pressure from the fuel pump As it can t be disassembled it must be replaced as an assembly FUEL FILLER CAP A ratchet tightening device on the threaded fuel filler cap reduces the chances of incorrect installation which would prevent sealing fuel vapors After the gasket 2 on fuel filler cap and the filler neck flange con tact the ratchet produc...

Page 385: ...y open flames such as gas hot heater Wear safety glasses To relieve fuel vapor pressure in fuel tank remove fuel filler cap from fuel filler neck and then reinstall it As fuel feed line is still under high fuel pressure even after engine was stopped loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected Before loosening or disco...

Page 386: ...cloth Be sure to put that cloth in an approved con tainer when disconnection is completed INSTALLATION 1 Install clamps to marked position on pipes referring to the figure in p 6C 2 If clamp is deformed or its claw is bent or broken re place it with new one 2 Install pipes with pipe clamp to body 3 Install pipe cover to body Be sure to use new nuts 4 Connect fuel hoses to fuel pipes 5 With engine ...

Page 387: ...on is completed INSTALLATION 1 Install filter 2 Connect outlet and inlet hoses Clamp hoses securely 3 Connect negative cable to battery 4 With engine OFF and ignition switch ON check for fuel leaks FUEL TANK REMOVAL 1 Relieve fuel pressure in fuel feed line according to procedure described on p 6 4 2 Disconnect negative cable at battery 3 Hoist vehicle WARNING Refer to the WARNING at the beginning...

Page 388: ...pport fuel tank with jack and lower fuel tank gradually until connector of fuel pump and terminal of fuel level gauge can be disconnected Then disconnect wire harness at connector and terminal 8 Remove fuel tank from vehicle INSPECTION After removing fuel tank check hoses and pipes connected to fuel tank for leaks loose connections deterioration or damage Also check fuel pump level gauge and fuel ...

Page 389: ...losion resulting in personal injury could occur CAUTION Never remain water in fuel tank after washing or fuel tank inside will get corrosion INSTALLATION 1 Install fuel pump 1 and fuel level gauge 2 to fuel tank Use new gaskets 2 Connect fuel hoses and pipes to fuel tank as shown Clamp hoses and wire harness securely 3 Connect fuel breather hose to fuel tank 4 Install fuel tank to vehicle after co...

Page 390: ...embly 1 from fuel tank INSPECTION Check fuel pump assembly for damage For inspection of fuel pump itself refer to Section 6E1 of this manu al INSTALLATION 1 Clean mating surfaces of fuel pump assembly 1 and fuel tank 2 Install new gasket 2 to fuel pump assembly then install fuel pump assembly to fuel tank 3 Install fuel tank to vehicle Refer to FUEL TANK INSTALLATION in this section 6C 8 ENGINE FU...

Page 391: ...Pressure Check 6E1 34 B 4 Idle Air Control System Check 6E1 36 B 5 Evaporative Emission Control System Check 6E1 37 B 6 Engine Start Signal Check 6E1 38 B 7 Radiator Fan Control System Check 6E1 39 B 8 A C Control Signal Check If equipped 6E1 40 B 9 Electric Load Signal Circuits Check 6E1 41 B 10 Fuel Cut Operation Check 6E1 42 Inspection of ECM and Its Circuits 6E1 43 Voltage Check 6E1 43 Resista...

Page 392: ...nic control system and emission control sys tem Air intake system includes air cleaner MAP sensor throttle body IAC valve and intake manifold Fuel delivery system includes fuel pump delivery pipe fuel pressure regulator fuel injectors etc Electronic control system includes ECM various sen sors and controlled devices Emission control system includes EVAP and PCV systems ...

Page 393: ... Three way catalytic convertor 19 CMP sensor 20 Main relay 21 Ignitor 22 Blank 23 ECM 24 Radiator fan 25 Radiator fan control relay 26 VSS in combination meter 27 A C compressor control relay 28 Malfunction indicator lamp in combination meter 29 Blank 30 Ignition switch 31 Starter magnetic switch 32 Main fuse 33 Battery 34 Blank 35 Blank 36 Monitor connector 36 1 Diagnosis switch terminal 36 2 Tes...

Page 394: ... 12 Engine coolant FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank fuel pump fuel filter fuel pressure regulator delivery pipe and fuel injectors The fuel in the fuel tank is pumped up by the fuel pump filtered by the fuel filter and fed under pressure to each injector through the delivery pipe As the fuel pressure applied to the injector the fuel pressure in the fuel feed ...

Page 395: ...ition control system Radiator fan control system Evaporative emission control system A C control system if equipped INFORMATION SENSORS 1 MAP sensor 2 TP sensor 3 IAT sensor 4 ECT sensor 5 Oxygen sensor 6 VSS 7 Battery 8 CMP sensor 9 Blank 10 A C evaporator temp sensor if equipped 11 A C dual pressure switch if equipped CONTROL DEVICES a Fuel injectors b EVAP canister purge valve c Fuel pump relay...

Page 396: ...6E1 6 ENGINE AND EMISSION CONTROL SYSTEM ...

Page 397: ...34 14 E34 15 E34 16 E34 17 E34 18 E34 19 E34 20 E34 21 E34 22 E33 201 E33 202 E33 203 E33 204 E33 205 E33 206 E33 207 E33 208 E33 209 E33 210 E33 211 E33 212 E33 213 E33 214 E33 215 E33 216 Blank IAC valve Blank Blank Blank Blank Test switch terminal Diagnosis switch terminal Electric load signal for blower fan motor Stop light switch brake pedal switch Blank Data link connector Engine starter swi...

Page 398: ...MP sensor Oxygen sensor 3 WAY CATALYTIC CONVERTER Camshaft and each piston position FUEL INJECTOR Intake air temp Throttle valve opening Fuel pump Engine coolant temp Exhaust oxygen concentration Battery voltage Vehicle speed Engine start signal Diagnosis signal Test signal Electric load signal ECM Fuel pump relay Fuel injection control Idle air control EVAP canister purge valve Radiator fan contr...

Page 399: ...sensor ECT sensor IAT sensor O2 sensor VSS Electric load signal Starter switch Battery voltage Stop lamp switch A C switch Diagnosis switch Test switch Fuel injector f f f f f f f f IAC valve f f f f f f f f Fuel pump relay f f Igniter f f f f f f EVAP canister purge valve f f f f f f MIL f f f f f f f f Radiator fan relay f f A C compressor relay f f f f f ...

Page 400: ...start while engine is running malfunction indicator lamp turns OFF When ECM detects a trouble which has occurred in the areas it makes malfunction indicator lamp turn ON while the engine is running to warn the driver of such occurrence of trouble and at the same time it stores the exact trouble area in ECM back up memory PRECAUTIONS IN DIAGNOSING TROUBLES Before identifying diagnostic trouble code...

Page 401: ...nector DLC 1 located on underside of instrument panel at driver s seat side Special Tool A 09931 76011 SUZUKI scan tool B Mass storage cartridge C 09931 76030 16 14 pin DLC adapter 4 Turn ignition switch ON 5 Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down Refer to SUZUKI scan tool oper ator s manual for further details If communication between SUZUKI...

Page 402: ... section NOTE If abnormality or malfunction lies in two or more areas malfunction indicator lamp indicates applicable codes three times each And flashing of these codes is repeated as long as diag nosis terminal 3 is grounded and ignition switch is held at ON position Take a note of diagnostic trouble code indicated first 4 After completing the check turn ignition switch OFF and discon nect servic...

Page 403: ...further details 5 After completing the clearance turn ignition switch OFF and disconnect SUZUKI scan tool from data link connector DLC Not using SUZUKI scan tool 1 Turn OFF ignition switch 2 Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM memory and re connect it Time required to erase DTC ENGINE AND EMISSION CONTROL SYSTEM 6E1 13 Ambient t...

Page 404: ...SIS P0105 11 Manifold absolute pressure sensor P0120 13 Throttle position sensor P0130 14 Oxygen sensor P0340 15 Camshaft position sensor Diagnose trouble according to DIAG NOSTIC FLOW TABLE corresponding to each code No P0500 16 Vehicle speed sensor P0110 18 Intake air temperature sensor P0115 19 Engine coolant temperature sensor 12 Normal This code appears when none of the oth er codes above cod...

Page 405: ... ON position check voltage between E34 7 terminal of ECM coupler and ground Is voltage 4 5V Go to Step 2 P W wire test switch terminal shorted to ground circuit If OK substitute a known good ECM and recheck 2 MIL bulb and circuit check 1 Using service wire ground E32 317 termi nal of ECM coupler Does MIL turn ON at ignition ON position Go to TABLE A 4 MIL bulb burned out IG COIL METER fuse s blown...

Page 406: ...p 6 Monitor connector 7 ECM 8 Main relay STEP ACTION YES NO 1 MIL Flashing Pattern Check 1 Turn ignition switch ON Does lamp flashing pattern indicate diagnostic trouble code Go to Step 2 Substitute a known good ECM and recheck 2 Diag Switch Circuit Check Is diag switch terminal connected to ground via ser vice wire System is in good condition V G circuit shorted to ground If circuit is OK substit...

Page 407: ...h OFF and disconnect connec tors from ECM Does MIL turn ON at ignition switch ON V Y circuit shorted to ground Go to Step 2 2 ECM Connection Check 1 Turn ignition switch OFF Is connector E34 8 connection connected to ECM properly Go to Step 3 Poor connector connection 3 Diag Switch Terminal Circuit Check 1 Connect connectors to ECM 2 Using service wire ground E34 8 terminal with connectors connect...

Page 408: ... good condition Go to Step 3 Check for short in circuits connected to this fuse 3 Main Relay Check 1 Turn OFF ignition switch and remove main relay 2 Check for proper connection to main relay at terminal a and b 3 If OK check main relay for resistance and operation referring to MAIN RELAY INSPECTION in this section Is check result satisfactory Go to Step 4 Replace main relay 4 ECM Power Circuit Ch...

Page 409: ...on switch ON Is it 10 14 V Check ground circuits Bl B and B for open If OK then substitute a known good ECM and re check Go to Step 6 6 Is operating sound of main relay heard in Step 1 Go to Step 7 B Y or B R wire open 7 Main Relay Check 1 Check main relay according to procedure in Step 3 Is main relay in good condition B Y or B R wire open Replace main relay Fig for STEP 2 Fig for STEP 3 1 FI fus...

Page 410: ...tage between a wire terminal of MAP sensor coupler and ground with igni tion switch ON Is voltage about 4 5 V Go to Step 3 Lg R wire open or short Poor E33 205 connection If wire and connection are OK substitute a known good ECM and recheck 3 1 Connect a and b wire terminals of MAP sensor coupler using service wire 2 Check voltage between Lg R wire termi nal of MAP sensor coupler and ground Is vol...

Page 411: ...ONTROL SYSTEM 6E1 21 Fig for STEP 1 Fig for STEP 2 Fig for STEP 3 NOTE Upon completion of inspection and repair work perform DTC Confirmation Procedure referring to page 6E1 30 to confirm that the trouble has been corrected ...

Page 412: ...nection are OK substitute a known good ECM and recheck 2 1 Check voltage between b wire terminal of TP sensor coupler and ground with ignition switch ON Is voltage about 4 5 V Go to Step 3 Gr wire open or short Poor E33 206 connection If wire and connection are OK substitute a known good ECM and recheck 3 1 Connect b and c wire terminal of TP sensor coupler using service wire 2 Check voltage betwe...

Page 413: ...ONTROL SYSTEM 6E1 23 Fig for STEP 1 Fig for STEP 2 Fig for STEP 3 NOTE Upon completion of inspection and repair work perform DTC Confirmation Procedure referring to page 6E1 30 to confirm that the trouble has been corrected ...

Page 414: ...e 2 Connect voltmeter between E33 213 terminal of ECM coupler and body ground 3 Maintain engine speed at 2000 rpm and after 60 seconds check volt meter Does the voltage deflect between above and below 0 45 V repeatedly Oxygen sensor and its circuit closed loop system A F ratio feed back sys tem are in good condition Intermittent trouble or faulty ECM Recheck referring to INTERMITTENT AND POOR CONN...

Page 415: ...OL SYSTEM 6E1 25 Fig for STEP 1 1 ECM coupler connected 2 Body ground NOTE Upon completion of inspection and repair work perform DTC Confirmation Procedure referring to page 6E1 30 to confirm that the trouble has been corrected ...

Page 416: ... sensor resistance 185 275 W at 10 50 C 14 122 F 3 Measure resistance between E33 203 ter minal of ECM coupler and ground Insulation resistance 1 MW or more Were measured resistance values in above 2 and 3 as specified Go to Step 2 Bl wire open or short B W wire open or short Poor terminal connec tion of CMP sensor cou pler If wire and connection are OK replace CMP sensor 2 1 Check CMP sensor refe...

Page 417: ...ont end of car and lock front right tire 4 Turn front left tire slowly Does ohm meter indicator deflect between 0 and a few times while tire is turned one revolution Poor E33 204 connection If connection is OK intermit tent trouble or faulty ECM Recheck referring to IN TERMITTENT TROUBLE Go to Step 3 3 1 Remove combination meter 2 Check speed sensor referring to VE HICLE SPEED SENSOR VSS IN SPECTI...

Page 418: ...nsor coupler terminals using service wire 2 Check voltage between Lg W wire termi nal of IAT sensor coupler and ground with ignition switch ON Is voltage 0 15 V or less Go to Step 3 B G wire open or poor E34 22 connection If wire and connection are OK substitute a known good ECM and recheck 3 1 Perform IAT SENSOR INSPECTION in this section Is IAT sensor in good condition Poor connection of IAT sen...

Page 419: ...nect ECT sensor couple terminals using service wire 2 Check voltage between Lg B wire terminal of ECT sensor coupler and ground with igni tion switch ON Is voltage 0 15 V or less Go to Step 3 B G wire open or poor C51 22 connection If wire and connection are OK substitute a known good ECM and recheck 3 1 Perform ECT SENSOR INSPECTION in this section Is ECT sensor in good condition Poor connection ...

Page 420: ...mperature 2 Increase engine speed to 4 000 r min in 3rd gear 3 Release accelerator pedal and with engine brake applied keep vehicle coasting for 5 to 8 seconds till engine speed reaches 2 000 r min 4 Repeat above steps 2 and 3 3 times or more 5 Stop vehicle Driving Test Condition for Code No 14 P0130 1 Start engine and warm up engine to normal operating temperature 2 Increase vehicle speed to 31 t...

Page 421: ...h OFF 2 Connect two terminals a and b of relay connector as shown in figure using service wire Is fuel pump heard to operate with ignition switch ON Go to Step 3 B R or P wire open poor fuel pump relay to coupler connection or faulty fuel pump 3 1 Check fuel pump relay referring to p 6E1 68 Is it in good condition Poor fuel pump relay to coupler con nection Br B B W wire open or poor E32 318 conne...

Page 422: ...ing sound Fuel injector circuit is in good condition Go to Step 2 2 Does none of 3 injectors make operating sound at Step 1 Go to Step 4 Go to Step 3 3 Check fuel injector s referring to p 6E1 58 Is it in good condition Check coupler connection and wire harness of injector not making operating sound Faulty fuel injector s 4 Check power circuit of injectors for open and short Is it in normal condit...

Page 423: ...ENGINE AND EMISSION CONTROL SYSTEM 6E1 33 Blank ...

Page 424: ...Go to Step 3 Go to Step 4 3 1 Start engine and warm it up to normal operating temperature 2 Keep it running at specified idle speed Is fuel pressure then within 200 240 kPa 2 0 2 4 kg cm2 28 4 34 1 psi Normal fuel pressure Clogged vacuum passage for fuel pressure regulator or faulty fuel pressure regulator 4 Is there fuel leakage from fuel feed line hose pipe or their joint Fuel leakage from hose ...

Page 425: ...pressure regulator Clogged fuel filter restricted fuel feed hose or pipe Faulty fuel pump or fuel leakage from hose connection in fuel tank 10 1 Disconnect fuel return hose from pressure regulator and connect new return hose to it 2 Insert the other end of new return hose into approved gasoline container 3 Check again if specified pressure is obtained While doing so does fuel come out of return ho...

Page 426: ...air passage A C signal Go to Step 3 3 Closed throttle position recheck 1 With the ignition switch OFF position disconnect negative battery cable for 30 seconds and con nect it 2 Recheck closed throttle position referring to Step 2 Is each check result as specified Recheck engine idle speed Go to Step 4 4 TP sensor signal voltage check 1 With the ignition switch ON position check volt age between E...

Page 427: ...eck EVAP canister referring to p 6E1 76 and fuel filler cap referring to Section 6C If OK system is in good condition Go to Step 2 2 Check vacuum passage hoses and EVAP canister purge valve referring to p 6E1 74 Are they in good condition O Y wire open O Y wire shorted to ground Poor EVAP canister purge valve coupler connection Poor E32 307 connection Poor performance of ECT sensor or MAP sensor o...

Page 428: ...ing motor STEP ACTION YES NO 1 1 With ignition switch OFF disconnect couplers from ECM 2 Is 6 12 V voltage applied to E34 13 terminal of coupler only when cranking engine Engine starter signal circuit is in good condition B Y wire open or Poor E34 13 connection Fig for STEP 1 1 ECM coupler disconnected 2 Body ground ...

Page 429: ...radiator fan control system referring to p 6E1 71 Is it in good condition RFC system is in good condition Go to Step 2 2 Check RFC relay referring to p 6E1 71 Is it in good condition Go to Step 3 Faulty RFC relay 3 Check wire harnesses and connections for open or short Are they in good condition Poor performance of ECT sensor If ECT sensor is OK substitute a known good ECM and recheck Wire open or...

Page 430: ...STEP ACTION YES NO 1 1 Check voltage at E34 19 terminal under each condition given in table below 2 Is check result satisfactory Ignition switch ON A C switch OFF Blower fan switch OFF Ignition switch ON A C switch ON Blower fan switch ON 10 14 V 2 V or less A C control signal is in good condition G B wire open or short Poor E34 19 terminal connection If wire and connection are OK check dual press...

Page 431: ...rned OFF 0 V Small light turned ON 10 14 V Is check result satisfactory Go to Step 2 Br R wire open or short Poor E34 18 ter minal connection 2 Check voltage at E34 9 terminal under each condition given below Ignition switch ON and heater blower fan turned OFF 10 14 V Ignition switch ON and heater blower fan turned ON 2 V or less Is check result satisfactory Electric load signal circuit are in goo...

Page 432: ... each check result as specified Substitute a known good ECM and re check Go to step 3 3 Closed throttle position recheck 1 With the ignition switch OFF position disconnect neg ative battery cable for 30 seconds and connect it 2 Recheck closed throttle position referring to Step 2 Is each check result as specified Recheck fuel cut op eration Go to step 4 4 TP sensor signal voltage check 1 With the ...

Page 433: ... disconnected from it VOLTAGE CHECK 1 Remove ECM from body with ignition switch OFF referring to ECM REMOVAL 2 Connect ECM couplers to ECM 3 Check voltage at each terminal of couplers connected NOTE As each terminal voltage is affected by the battery voltage confirm that it is 11V or more when ignition switch is ON 1 ECM 2 Couplers 3 Body ground TERMINAL ARRANGEMENT OF ECM COUPLER VIEWED FROM HARN...

Page 434: ...ector lever L range E34 15 Blank E34 16 Blank E34 17 Duty output terminal 1 V or less Ignition switch ON E34 18 Electric load signal for small 1 V or less Ignition switch ON and Small light turned OFF E34 18 g light switch 10 14 V Ignition switch ON and Small light turned ON E34 19 A C ON signal from A C 10 14 V Ignition switch ON A C switch OFF Blower fan switch OFF E34 19 g switch if equipped 2 ...

Page 435: ... 309 Blank E32 310 Ignition coil assembly 1 V or less Ignition switch ON E32 311 Fuel injector No 3 10 14 V Ignition switch ON E32 312 Fuel injector No 1 10 14 V Ignition switch ON E32 313 Ground E32 314 Power source for backup 10 14 V E32 315 Power source 10 14 V Ignition switch ON E32 316 Blank E32 317 Malfunction indicator light About 0 5 V or less Ignition switch ON engine stops E32 317 Malfun...

Page 436: ... ENGINE AND EMISSION CONTROL SYSTEM TERMINAL CIRCUIT NORMAL RESISTANCE CONDITION E32 312 E32 302 Fuel Injector No 1 11 3 13 8 E32 325 E32 302 Fuel injector No 2 11 3 13 8 E32 311 E32 302 Fuel Injector No 3 11 3 13 8 E32 307 E32 302 EVAP canister purge valve 37 44 F8D engine E32 307 E32 302 EVAP canister urge valve 28 36 F8B engine E32 320 E32 302 Radiator fan control relay 90 110 omron made E32 32...

Page 437: ...ENGIINE AND EMISSION CONTROL SYSTEM 6E1 47 ON VEHICLE SERVICE 1 MAP sensor 2 EVAP canister 3 EVAP canister purge valve if equipped 4 PCV valve ...

Page 438: ...edal play which should be within the following specification Pedal play a 2 7 mm 0 08 0 27 in If measured value is out of specification adjust it to specification with cable adjusting nut 1 Accelerator cable 2 Adjusting nut 3 Lock nut 2 With accelerator pedal depressed fully check clearance be tween throttle lever 2 and lever stopper 1 throttle body which should be within following specification C...

Page 439: ...speed and IAC duty as follows NOTE Before starting engine place transmission gear shift lever in Neutral and set parking brake and block drive wheels Using SUZUKI scan tool 1 Connect SUZUKI scan tool to DLC 1 with ignition switch OFF Special Tool A 09931 76011 SUZUKI scan tool B Mass storage cartridge C 09931 76030 16 14 pin DLC cable 2 Start engine and warm it up to normal operating temperature 3...

Page 440: ...itor connector 2 Service wire 3 Duty meter A Blank B Diagnosis switch terminal C Blank D Ground terminal E Test switch terminal F Duty output terminal NOTE Duty values with are applicable to vehicle used at high place higher than 2000 m or 6560 ft Above duty values are on duty meter indications high voltage rate IAC duty can be checked roughly by using voltmeter IAC duty to voltage relation is as ...

Page 441: ...ottle body 4 Remove air cleaner outlet hose 1 ENGIINE AND EMISSION CONTROL SYSTEM 6E1 51 AIR INTAKE SYSTEM THROTTLE BODY 1 Throttle body 2 Throttle stop screw 3 TP sensor 4 O ring 5 IAC valve 6 MAP sensor CAUTION Do not remove or adjust throttle stop screw as it is factory adjusted precisely CAUTION Do not disassemble IAC valve Disassembly spoils its original performance Tightening torque Do not r...

Page 442: ...ottle body bore and idle air passage by blowing com pressed air CAUTION TP sensor IAC valve MAP sensor or other compo nents containing rubber must not be placed in a sol vent or cleaner bath A chemical reaction will cause these parts to swell harden or get distorted Do not blow compressed air through bypass air pas sage with IAC valve installed to throttle body This will cause IAC valve to malfunc...

Page 443: ...purge valve hose 4 Connect couplers to TP sensor MAP sensor and IAC valve se curely 1 Engine coolant hose 2 TP sensor 3 IAC valve 4 MAP sensor 5 EVAP canister purge valve hose 6 Throttle body 5 Install air cleaner outlet hose 1 6 Connect accelerator cable and adjust cable play to specification 7 Refill cooling system 8 Connect negative cable at battery ENGIINE AND EMISSION CONTROL SYSTEM 6E1 53 ...

Page 444: ...ns on ignition switch while the other checks valve operation As valve operation is momentary it may be overlooked To prevent this perform this operation check 3 times or more continuously If rotary valve of lAC valve does not operate at all check wire harnesses for open and short If wire harnesses are in good condition replace lAC valve and recheck INSTALLATION 1 Install new O ring 2 to IAC valve ...

Page 445: ...ner 5 Turn ignition switch ON to operate fuel pump and after 2 se conds turn it OFF Repeat this 3 or 4 times and then check fuel pressure 6 Start engine and warm it up to normal operating temperature 7 Measure fuel pressure at idling If measured pressure doesn t satisfy specification refer to B 3 FUEL PRESSURE CHECK in this section and check each possibly defective part Replace if found defective ...

Page 446: ...tall fuel filler cap after checking If above check result is not satisfactory advance to DIAGNOS TIC FLOW TABLE B 1 1 Fuel filler 2 Ignition switch 2 Fuel pressure should be felt at fuel return hose for 2 seconds after ignition switch ON If fuel pressure is not felt advance to DIAGNOSTIC FLOW TABLE B 3 REMOVAL 1 Remove fuel tank from body according to procedure described in Section 6C and remove f...

Page 447: ...se 3 from fuel pressure regulator 7 Remove fuel pressure regulator from fuel delivery pipe 4 CAUTION A small amount of fuel may be released when hose is disconnected Cover hose to be disconnected with a shop cloth CAUTION A small amount of fuel may be released when it is from delivery pipe Place a shop cloth under delivery pipe so that re leased fuel is absorbed in it INSTALLATION For installation...

Page 448: ... REMOVAL 1 Relieve fuel pressure according to procedure described in Sec tion 6 2 Disconnect battery negative cable at battery 3 Remove air cleaner outlet hose referring to Section 6A 4 Remove intake manifold stiffener 5 Disconnect fuel injector couplers 6 Remove fuel delivery pipe bolts 7 Remove fuel injector s CAUTION A small amount of fuel may come out after removal of fuel injectors cover them...

Page 449: ...o injector con nect two terminals of disconnected connecter 1 by using ser vice wire 2 as shown in figure CAUTION Check to make sure that connections made between correct terminals Wrong connection can cause dam age to ECM wire harness etc 8 Apply battery voltage to injector for 15 seconds and measure in jected fuel volume with graduated cylinder Test each injector two or three times If not within...

Page 450: ... with new one using care not to damage it Check if cushion is scored or damaged If it is replace with new one Apply thin coat of fuel to O rings and then install injectors into de livery pipe and intake manifold Make sure that injectors rotate smoothly If not probable cause is incorrect installation of O ring Replace O ring with new one Tighten delivery pipe bolts and make sure that injectors rota...

Page 451: ... INSTALLATION 1 Install ECM to body 2 Connect couplers to ECM securely 3 Connect battery negative cable at battery MAP SENSOR OUTPUT VOLTAGE CHECK 1 Remove ECM according to previously outlined 2 Connect couplers 1 to ECM securely 3 With coupler connected to ECM connect digital type voltmeter 2 as shown and check that ECM supply voltage 4 75 5 25 V is applied to coupler terminal E33 201 ENGIINE AND...

Page 452: ...hen engine is started it is possible that vacuum passage is clogged Clean them Another possibility is that filter in MAP sensor is clogged from freezing If it is suspected leave it at room temperature 205C 685F for a while and recheck 5 Upon completion of checking install ECM and connect ECM couplers securely MAP SENSOR INDIVIDUAL CHECK 1 Remove MAP sensor referring MAP sensor removal 6E1 62 ENGII...

Page 453: ... to MAP SENSOR INSTALLATION REMOVAL 1 Disconnect battery negative cable at battery 2 Disconnect coupler from MAP sensor 3 Remove MAP sensor from throttle body INSTALLATION 1 Before installation check vacuum passage hole for clogged install MAP sensor 1 to throttle body Tightening Torque a 2 0 N m 0 2 kg m 1 5 Ib ft 2 Connect coupler to MAP sensor 3 Connect battery negative cable to battery ENGIINE...

Page 454: ...age terminal REMOVAL 1 Disconnect battery negative cable at battery 2 Disconnect coupler from TP sensor 3 Remove TP sensor from throttle body INSPECTION 1 Install TP sensor 1 to throttle body Fit TP sensor to throttle body in such way that its holes 3 are a little away from TP sensor screw holes 2 as shown and turn TP sensor clockwise 4 so that those holes align Tightening Torque a 2 5 N m 0 25 kg...

Page 455: ...SIDE Not using SUZUKI scan tool 4 Turn TP sensor 1 clockwise or counterclockwise and tighten TP sensor screw at a position where voltage as specified below is obtained TP sensor output voltage when throttle is fully close 0 805 0 025 V 5 Tighten TP sensor screw to specified torque Tightening Torque a 2 0 N m 0 20 kg m 2 0 lb ft 6 Check to make sure that TP sensor voltage is as shown below when thr...

Page 456: ... in water or ice and measure resistance between sensor terminals while heating water gradually If measured resistance doesn t show such characteristic as shown in left figure replace IAT sensor for reference INSTALLATION Reverse removal procedure noting the following Clean mating surfaces of IAT sensor 1 and air cleaner outlet hose Connect IAT sensor coupler securely 6E1 66 ENGIINE AND EMISSION CO...

Page 457: ...ature sensing part of ECT sensor in water or ice and measure resistance between sensor terminals while heating water gradually If measured resistance doesn t show such characteristic as shown in left figure replace ECT sensor for reference INSTALLATION Reverse removal procedure noting the following Clean mating surfaces of ECT sensor and water outlet pipe Check O ring for damage and replace if nec...

Page 458: ...s in table below If check results are as specified proceed to next operation check If not replace 4 Check that there is continuity between terminals A and B when battery is connected to terminals C and D If found defective replace 5 Install the relay and connect its coupler securely 6E1 68 ENGIINE AND EMISSION CONTROL SYSTEM TERMINALS RESISTANCE Between A and B R infinity Between C and D 80 100 at...

Page 459: ...ble at battery 2 Disconnect coupler of oxygen sensor and release its wire har ness from clamps 3 Remove oxygen sensor 1 from exhaust manifold INSTALLATION Reverse removal procedure noting the followings Tighten oxygen sensor 1 to specified torque Tightening Torque a 45 N m 4 5 kg m 32 5 lb ft Connect coupler of oxygen sensor and clamp wire harness se curely After installing oxygen sensor start eng...

Page 460: ...operation of injector stops when throttle valve is closed instantly and it is heard again when engine speed is reduced to less than about 2 000 r min A C COMPRESSOR CONTROL RELAY IF EQUIPPED INSPECTION 1 Disconnect negative cable at battery 2 Remove A C compressor control relay from its connecter 3 Structure of A C compressor control relay 1 is the same as that of main relay Check its resistance a...

Page 461: ...g The fan can start automatically in response to the ECT sensor with the ignition switch in the ON position RADIATOR FAN CONTROL RELAY RFC RELAY INSPECTION 1 Disconnect negative cable at battery 2 Remove RFC relay 1 from its connecter 3 Check resistance between each two terminals as in table below If check results are as specified proceed to next operation check If not replace 4 Check that there i...

Page 462: ...rminal and ground terminal of combination meter and turn cable joint of speedometer with a screwdriver Ohmmeter indicator should move back and forth between conti nuity and infinity 4 times while cable joint is turned one full revo lution Replace speedometer if check result is not satisfactory 6E1 72 ENGIINE AND EMISSION CONTROL SYSTEM ...

Page 463: ...rating temperature 2 Disconnect purge hose 1 from EVAP canister 3 Place finger against the end of disconnected hose and check that vacuum is not felt there when engine is running at idle speed 4 Also check that vacuum is felt when engine speed is increased to higher than about 3000 r min If check result is not satisfactory check vacuum passage hoses EVAP canister purge valve 1 way valve if equippe...

Page 464: ...disconnect coupler from EVAP canis ter purge valve 2 Check resistance between two terminals of EVAP canister purge valve Resistance of EVAP canister purge valve 28 36 at 20_C 68_F F8B engine 37 44 at 20_C 68_F F8D engine If resistance is as specified proceed to next operation check If not replace 3 Connect coupler to EVAP canister purge valve 4 Connect SUZUKI scan tool to DLC 1 with ignition switc...

Page 465: ...r purge valve 1 2 Check resistance between two terminals of EVAP canister purge valve 1 Resistance of EVAP canister purge valve 28 36 at 20_C 68_F F8B engine 37 44 at 20_C 68_F F8D engine If resistance is as specified proceed to next operation check If not replace 3 Disconnect vacuum hoses from intake manifold 4 With coupler disconnected blow into hose A Air should not come out of hose B 5 Connect...

Page 466: ...rge pipes B and C 3 If operation differs from above description EVAP canister must be replaced 4 Disconnect vacuum hoses from 1 way valve F8B engine 5 Air should pass through valve smoothly from EVAP canister side green side of valve 1 when blown hard 6 Air should not pass through valve from EVAP canister purge valve 2 side to EVAP canister side 7 If operation differs from above description 1 way ...

Page 467: ...en when blown softly air should come out of black side 4 If air doesn t pass through valve in step 2 or hard blow is re quired in step 3 replace tank pressure control valve WARNING DO NOT SUCK air through tank pressure control valve Fuel vapor inside the valve is harmful 5 Install tank pressure control valve NOTE When connecting tank pressure control valve between hoses refer to left figure for in...

Page 468: ...NSPECTION 1 Disconnect PCV valve from cylinder head cover and install plug to head cover hole 2 Run engine at idle speed 3 Place your finger over end of PCV valve to check for vacuum If there is no vacuum check for clogged valve Replace as nec essary 4 After checking vacuum stop engine and remove PCV valve Shake valve and listen for the rattle of check needle inside the valve If valve does not rat...

Page 469: ...tachment 4 4 Holder 4 5 Return hose clamp 4 6 Body attachment 2 washer 4 7 Hose attachment 1 4 8 Hose attachment 2 09917 47910 Vacuum pump gauge 09930 88530 Injector test lead 09931 76011 SUZUKI scan tool Tech 1A kit 1 Storage case 2 Operator s manual 3 SUZUKI scan tool Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter Mass storage cartridge 09931 7...

Page 470: ...ts 6F 2 System Wiring 6F 3 DIAGNOSIS 6F 4 Diagnostic Flow Table 6F 4 Ignition Spark Test 6F 6 ON VEHICLE SERVICE 6F 6 High Tension Cords 6F 6 Spark Plugs 6F 7 Noise suppressor 6F 8 Igniter 6F 8 Ignition Coil 6F 9 Distributor 6F 9 Ignition Timing 6F 11 DISTRIBUTOR UNIT 6F 13 SPECIAL TOOLS 6F 15 ...

Page 471: ...ording to the signal from ECM Ignition coil When the ignition coil primary current is turned OFF a high voltage is induced in the secondary winding Distributor It distributes a high voltage current to each plug High tension cords spark plugs and noise suppressor CMP sensor Camshaft position Sensor Located in the distributor it converts the crank angle into voltage variation and sends it to ECM For...

Page 472: ...ON SYSTEM 6F 3 SYSTEM WIRING 1 Battery 2 Main fuse box 3 Ignition switch 4 Main relay 5 Ignition coil 6 Igniter 7 Noise suppressor 8 Distributor 9 Distributor rotor 10 Signal rotor 11 CMP sensor 12 Spark plug ...

Page 473: ... SECTION 6 2 Ignition Spark Test 1 Check all spark plug for condition and type refer ring to SPARK PLUG in this section 2 If OK perform ignition spark test referring to IGNI TION SPARK TEST in this section Is spark emitted from all spark plugs Go to Step 11 on the next page Go to Step 3 3 Diagnostic Trouble Code DTC Check 1 Check DTC stored in ECM referring to DIAGNOS TIC TROUBLE CODE DTC CHECK in...

Page 474: ...st or replace 10 Ignition Trigger Signal Circuit Check 1 Check ignition trigger signal Br W wire circuit for open short and poor connection Are circuits in good condition Go to Step 11 Repair or replace 11 Ignition Timing Check 1 Check initial ignition timing and ignition timing ad vance referring to IGNITION TIMING in this sec tion Is check result satisfactory Substitute a known good ECM and then...

Page 475: ...N CORDS REMOVAL 1 Remove high tension cord at ignition coil while gripping its cap 2 Remove distributor cap 1 installed with high tension cords 3 Remove high tension cord clamp from cylinder head cover 4 Pull out high tension cords from spark plugs while gripping each cap CAUTION Removal of high tension cords together with clamps will be recommended so as not to damage their inside wire resistive ...

Page 476: ...parts Insert each cap portion fully when installing high tension cords SPARK PLUGS REMOVAL 1 Remove high tension cords referring to HIGH TENSION CORDS under ON VEHICLE SERVICE earlier in this section 2 Remove spark plugs INSPECTION 1 Inspect them for Electrode wear Carbon deposits Insulator damage 2 If any abnormality is found adjust air gap clean with spark plug cleaner or replace them with speci...

Page 477: ...sor 2 Disconnect coupler of noise suppressor 1 3 Remove noise suppressor INSPECTION Using ohmmeter 1 check to be sure that capacitor Condenser in noise suppressor 2 is not conductive If check result is not satisfactory replace noise suppressor 2 INSTALLATION Reverse removal procedure for installation IGNITER Before this inspection prepare 5V power supply 3 new 1 5V bat teries one 12V 3 4W light bu...

Page 478: ...y Check that the light bulb illuminate when positive terminal of batteries is connected to a terminal of igniter If inspection result is not satisfactory replace igniter 6 Install igniter IGNITION COIL 1 Pull out high tension cord by gripping its cap 2 Disconnect ignition coil coupler 3 Measure primary and secondary coil resistances Ignition coil resistance at 20_C 68_F Primary 1 33 1 63 A Seconda...

Page 479: ...make sure that CMP sensor signal generator tooth is free from any metal particles 4 Install distributor cap and rotor CMP Sensor Resistance 1 Disconnect distributor lead wire coupler 1 2 Measure resistance of CMP sensor by using ohmmeter CMP sensor resistance 185 275 at 10 50 C 14 122 F 240 325 at 50 100 C 122 212 F 3 If resistance is out of specification replace CMP sensor as fol lows 4 Remove di...

Page 480: ...mal operating temperature 3 Make sure that all of electrical loads except ignition are switched off 4 Check to be sure that idle speed is within specification Refer to SECTION 6E1 5 Set timing light to No 1 high tension cord 6 Fix ignition timing to initial one as follows When using SUZUKI scan tool a Select MISC mode on SUZUKI scan tool and fix ignition timing to initial one When not using SUZUKI...

Page 481: ...ghtening distributor flange bolts recheck that ignition timing is within specification 10 After checking and or adjusting initial ignition timing release ignition timing fixation by SUZUKI scan tool or disconnect ser vice wire from monitor coupler 11 With engine idling test switch terminal ungrounded vehicle stopped check that ignition timing is about 8 BTDC Constant variation within a few degrees...

Page 482: ...te re installation turn crankshaft in normal direction clockwise as viewed from crank shaft pulley side so that distributor rotor is positioned at No 1 terminal of distributor cap 5 Remove distributor flange bolt 6 Pull out distributor housing assembly IGNITION SYSTEM 6F 13 DISTRIBUTOR UNIT 1 Cap 2 Cap seal 3 Cap screw 4 Rotor 5 CMP sensor Signal generator 6 Housing 7 O ring ...

Page 483: ...g is installed apply engine oil to it 3 Align punch mark on gear with dent mark on housing 4 Insert distributor into gear case in such a way that the center of distributor flange bolt 1 will coincide with distributor flange bolt hole 2 provided in distributor gear case When inserting the distributor completely position of distributor rotor becomes as shown in figure Secure distributor in place ten...

Page 484: ...IGNITION SYSTEM 6F 15 SPECIAL TOOLS 09900 27301 Timing light DC 12 V 09930 76420 Timing light Dry cell type 09900 25002 Pocket tester ...

Page 485: ...mounting and Remounting 6G 6 Disassembly 6G 6 Reassembly 6G 7 Inspection 6G 8 Plunger 6G 8 Magnetic switch 6G 8 Brush 6G 9 Brush holder 6G 9 Armature 6G 9 Yoke 6G 10 Over running clutch 6G 10 Performance Test 6G 11 Pull in test 6G 11 Hold in test 6G 11 Pinion return test 6G 12 No load performance test 6G 12 SPECIFICATIONS 6G 13 REQUIRED SERVICE MATERIAL 6G 13 SPECIAL TOOL 6G 13 ...

Page 486: ... STARTING MOTOR CIRCUIT The magnetic switch coils are magnetized when the ignition switch is closed The resulting plunger and pinion drive lever movement causes the pinion to engage the engine flywheel gear and the magnetic switch main contacts to close and cranking takes place When the engine starts the pinion over running clutch protects the armature from excessive speed until the switch is open...

Page 487: ...erioration Poor contact in battery terminal connection Loose grounding cable connection Fuse set loose or blown off Poor contacting action of ignition switch and magnetic switch Lead wire coupler loose in place Open circuit between ignition switch and magnetic switch Open circuit in pull in coil Brushes are seating poorly or worn down Poor sliding of plunger and or pinion Recharge battery Replace ...

Page 488: ...ting motor running but not cranking engine Worn pinion tip Poor sliding of over running clutch Over running clutch slipping Worn teeth of pinion gear or flywheel Replace over running clutch Repair Replace over running clutch Replace pinion or flywheel Noise Abnormally worn bush Worn pinion or worn teeth of pinion gear Poor sliding of pinion failure in return movement Lack of oil in each part Repla...

Page 489: ... Apply grease A 99000 25010 to joint of drive housing bush over running clutch and armature shaft bush 7 Pinion drive lever Apply grease A 99000 25010 to joint of magnetic switch and over running clutch 8 Seal 9 Boot 10 Magnetic switch 11 Rear housing 12 Brush spring 13 Brush holder 14 Insulator 15 Bush Apply grease A 99000 25010 to inside and outside 16 Brush 17 Yoke assembly 18 Housing bolt Do n...

Page 490: ...up its rear portion so as to inside hook is disconnected from drive lever NOTE Do not disassemble magnetic switch Replace it as assem bly when required A Pull up to disconnect hook 3 Remove housing bolts through bolts and then pull out commu tator end housing 4 Remove insulator brush springs 1 and then brush holder 2 5 Remove yoke armature 1 and drive lever 2 from drive hous ing 3 6 Draw pinion st...

Page 491: ...with armature 1 Then assemble them with drive housing 3 A Grease 99000 25010 4 Install yoke and brush holder 3 then set 4 brushes 1 with their springs 2 Install insulator NOTE When installing brushes make sure that brushes and commutator have been degreased thoroughly Check to confirm that brush parts do not have unneces sary contacts with others 5 Install rear housing applied with grease in its b...

Page 492: ...without fail Face boot 2 breather down Upon completion of assembly carry out PERFORMANCE TEST INSPECTION PLUNGER Inspect plunger for wear Replace if necessary MAGNETIC SWITCH Push in plunger and release it The plunger should return quickly to its original position Replace if necessary Pull In Coil Open Circuit Test Check for continuity across magnetic switch S terminal 1 and M terminal 2 If no con...

Page 493: ...t 6 0 mm 0 236 in BRUSH HOLDER Check brush springs for rust or breakage Also check brush holder for rust and insulation Replace it as assembly if required ARMATURE Ground Test Between commutator segment and armature core should be in sulated Use ohmmeter for inspection Open Circuit Test Check for continuity between segments If there is no continuity at any test point there is an open circuit and a...

Page 494: ...epth and correct it as required Commutator insulator depth a Limit minimum value 0 2 mm 0 008 in 1 Mica insulator 2 Commutator segment YOKE Check field coil for continuity There should be continuity between following terminals Between A terminals Between B terminals Between B terminal and C bare metal part of yoke body OVER RUNNING CLUTCH Inspect pinion for wear damage or other abnormal conditions...

Page 495: ...gure and check that pinion over running clutch move outward If it does not replace magnetic switch NOTE Before testing disconnect field coil lead wire 3 from M ter minal 2 HOLD IN TEST While connected as the above with pinion out disconnect negative lead from M terminal 1 and check that pinion remains out If not replace magnetic switch CRANKING SYSTEM 6G 11 ...

Page 496: ...heck to make sure that pinion returns inward quickly NO LOAD PERFORMANCE TEST Connect test leads as shown in left figure and check that motor runs without fail with pinion moved out Also check that ammeter indicates specified current Specified Current 50A at 11 5V 6G 12 CRANKING SYSTEM ...

Page 497: ...on teeth 8 Performance Condition Guarantee No load characteristic 11 5 V 50 A maximum 6 000 rpm minimum Around at 20 C 68 F Load characteristic 9 V 150 A 2 75 N m minimum 1 900 rpm minimum 20 C 68 F Locked rotor current 5 5 V 400 A maximum 5 89 N m 0 5 kg m 4 6 Ib ft minimum Magnetic switch operating voltage 8 volts maximum REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium ...

Page 498: ...Jump starting in case of emergency with auxiliary booster battery 6H 10 Removal 6H 11 Handling 6H 11 Installation 6H 11 Generator 6H 12 Removal 6H 12 Installation 6H 12 Generator Water Pump Belt 6H 13 Belt tension inspection 6H 13 Removal 6H 13 Installation 6H 13 UNIT REPAIR OVERHAUL 6H 14 Generator 6H 14 Disassembly 6H 15 Inspection 6H 17 Replace Brush 6H 19 Assembly 6H 20 SPECIFICATIONS 6H 22 ...

Page 499: ...carrier the hold down bolts should be tight enough but not over tightened ELECTROLYTE FREEZING The freezing point of electrolyte depends on its specific gravity Since freezing may ruin a battery it should be protected against freezing by keeping it in a fully charged condition If a battery is fro zen accidentally it should not be charged until it is warmed SULFATION If the battery is allowed to st...

Page 500: ...tions clean The cable connections particularly at the positive terminal post tend to become corroded The product of corrosion or rust on the mating faces of conductors resists the flow of cur rent Clean the terminals and fittings periodically to ensure good met al to metal contact and grease the connections after each cleaning to protect them against rusting WARNING Never expose battery to open fl...

Page 501: ...es integrated circuits and controls the voltage produced by the generator and the voltage setting cannot be adjusted The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication Two brushes carry current through the two slip rings to the field coil mounted on the rotor and under normal conditions will provide long period of attention free service The stator win...

Page 502: ... Stator coil 5 Stator core 6 Field coil 7 Regulator 8 Brush 9 Rear end frame 10 Drive end frame B Generator output Battery terminal D Dummy terminal E Ground F Field coil terminal IG Ignition terminal L Lamp terminal CHARGING SYSTEM 6H 5 ...

Page 503: ...reezing As the S G varies with the temperature if battery temperature is not at 20 C 68 F you have to correct your S G reading taken with your hydrometer to the value at 20 C 68 F and apply the corrected S G value to the three point guide stated value For the manner of correction refer to the graph showing the rela tion between S G value and temperature at the left HOW TO USE THE TEMPERATURE CORRE...

Page 504: ... or indica tor dark 3 Overcharged battery as evidenced by excessive spewing of electrolyte from vents Noise from generator may be caused by a loose drive pulley loose mounting bolts worn or dirty bearings defective diode or defec tive stator CHARGING SYSTEM 6H 7 FAULTY INDICATOR LAMP OPERATION PROBLEM POSSIBLE CAUSE CORRECTION Charge light does not light with ignition ON and engine off Fuse blown ...

Page 505: ...er and ignition ground cable 5 Connect voltmeter and ammeter as shown in figure Voltmeter Set between generator B terminal and ground Ammeter Set between generator B terminal and battery terminal NOTE Use fully charged battery 6 Measure current and voltage 1 Generator 2 Ammeter 3 Voltmeter 4 Battery 5 Load 6 Switch Ammeter between generator B terminal and battery terminal Voltmeter between generat...

Page 506: ... Generator itself has problem check the generator Load Check 1 Run engine at 2 000 rpm and turn on head light and heater mo tor 2 Measure current and if it is less than 20 A repair or replace gen erator OVERCHARGED BATTERY 1 To determine battery condition refer to Battery section in this DIAGNOSIS 2 If obvious overcharge condition exists as evidenced by exces sive spewing of electrolyte proceed to...

Page 507: ...her end to a solid engine ground such as exhaust manifold at least 45 cm 18 in away from battery of vehicle being started 5 Start engine of vehicle with booster battery and turn off electrical accessories Then start engine of the vehicle with discharged battery 6 Disconnect jumper cables in the exact reverse order WARNING Departure from these conditions or procedure de scribed below could result i...

Page 508: ... following safety precautions should be fol lowed Hydrogen gas is produced by battery A flame or spark near bat tery may cause the gas to ignite Battery fluid is highly acidic Avoid spilling on clothing or other fabric Any spilled electrolyte should be flushed with large quan tity of water and cleaned immediately INSTALLATION 1 Reverse removal procedure 2 Torque battery cables NOTE Check to be sur...

Page 509: ... 3 Disconnect B terminal wire 3 and coupler 4 from generator 5 4 Remove adjusting bolt 1 and pivot bolts 2 5 Remove generator INSTALLATION Reverse above procedure giving specified tension to drive belt Refer to Generator Water Pump Belt for belt tension Tightening Torque a 22 N m 2 2 kg m 16 0 lb ft b 50 N m 5 0 kg m 36 5 lb ft c 7 N m 0 7 kg m 5 0 lb ft 6H 12 CHARGING SYSTEM ...

Page 510: ... and adjust it to proper tension by displacing generator 4 position 4 Tighten generator adjusting bolt and pivot bolts Tightening Torque a 22 N m 2 2 kg m 16 0 lb ft b 50 N m 5 0 kg m 36 5 lb ft 5 Connect negative cable at battery terminal REMOVAL 1 Disconnect negative cable at battery 2 Remove front bumper 3 Loosen generator adjusting bolt 1 and generator pivot bolts 2 4 Slacken belt 3 by displac...

Page 511: ...aring cover 10 End housing bearing 11 Bearing cover 12 Washer 13 Rear end frame 14 Rectifier 15 Insulator 16 Regulator 17 Brush 18 Brush holder 19 Rear end cover 20 Retainer plate screw 21 Rear end frame nut 22 Rear end frame bolt 23 Rectifier holder screw 24 B terminal inner nut 25 IC regulator screw 26 Brush holder screw 27 Rear end cover screw Tightening Torque ...

Page 512: ...h and remove pulley nut 1 and then pull out pulley 2 CAUTION To hold shaft use hexagonal box Duodecimal box may cause slipping and consequential shaft or tool damage Do not attempt to hold pulley by using vise or pipe wrench so as not to distort it 9 Remove rear end frame nuts 3 and bolts 4 10 Drive out rear end frame 1 with rotor tapping shaft 2 lightly by using plastic hammer 11 Separate rear en...

Page 513: ...st be exercised so as not to distort cooling fan blade while applying puller 13 If required remove 4 screws retainer plate 1 and then drive out drive end bearing 2 14 If required remove stud bolts and then pull out stator NOTE Heating drive end frame may facilitate removal of stator 6H 16 CHARGING SYSTEM ...

Page 514: ...k slip rings for roughness or scoring If rough or scored re place rotor Using a vernier caliper measure slip ring diameter Standard diameter 14 4 mm 0 567 in Minimum diameter 12 8 mm 0 504 in If the diameter is less than minimum replace the rotor Stator Open Circuit Using ohmmeter check all leads for continuity If there is no conti nuity replace stator Ground Using ohmmeter check that there is no ...

Page 515: ...1 and the other to each rectifier terminal 2 2 Reverse the polarity of tester probes and repeat step 1 3 Check that one shows continuity and the other shows no conti nuity If there is continuity replace rectifier holder Negative Rectifier 1 Using ohmmeter connect one tester probe to each negative ter minal 1 and the other to each rectifier terminal 2 2 Reverse the polarity of tester probes and rep...

Page 516: ... REPLACE BRUSH 1 Unsolder and remove brush and spring 2 Run wire of new brush through the hole in the brush holder and insert spring and brush into brush holder 3 Solder brush wire to brush holder at specified exposed length Exposed length a 10 5 mm 0 413 in 4 Check that brush moves smoothly in brush holder 5 Cut off excess wire 6 Apply insulation paint to the soldered area CHARGING SYSTEM 6H 19 ...

Page 517: ... 8 8 N m 0 88 kg m 6 5 lb ft b 2 6 N m 0 26 kg m 2 0 lb ft 6 Place space collar and drive end frame 2 on pulley and then install rotor 1 to drive end frame 7 Install rear end frame to drive end frame 8 Tighten bolts and nuts to specified torque Tightening Torque a 4 5 N m 0 45 kg m 3 5 lb ft 9 Install pulley 1 and tighten pulley nut 2 with holding shaft us ing hexagonal box wrench to specified tor...

Page 518: ...h holder cover to brush holder 12 Place IC regulator 1 together with brush holder 2 horizon tally on rear end frame 3 13 Install 5 screws Tightening Torque a 2 0 N m 0 2 kg m 1 5 lb ft 14 Install rear end cover 1 Tightening Torque a 3 7 N m 0 37 kg m 3 0 lb ft 15 Install insulator 2 and tighten B terminal inner nut 3 to speci fied torque Tightening Torque b 3 6 N m 0 36 kg m 3 0 lb ft 16 Make sure...

Page 519: ...erator used in each vehicle is one of the following two types depending on specification Type 40 A type 50 A type Rated voltage 12 V Nominal output 40 A at 13 5 V 50 A at 13 5 V Permissible max speed 18 000 rpm No load speed 1 110 r min rpm Setting voltage 14 2 to 14 8 V Permissible ambient temperature 30 to 90 C 22 to 194 F Polarity Negative ground Rotation Clockwise viewed from pulley side ...

Page 520: ...NTS GENERAL DESCRIPTION 6K 2 MAINTENANCE 6K 3 ON VEHICLE SERVICE 6K 4 CAUTION THE ENGINE OF THIS VEHICLE REQUIRES THE USE OF UNLEADED FUEL ONLY USE OF LEADED AND OR LOW LEAD FUEL CAN RESULT IN DAMAGE AND REDUCE THE EFFECTIVE NESS OF THE CATALYTIC CONVERTER ...

Page 521: ...xhaust system to lower the levels of Hydrocarbon HC Carbon Monoxide CO and Oxides of Nitrogen NOx pollutants in the exhaust gas Tightening Torque Do not reuse 1 Exhaust manifold cover 2 Exhaust manifold cover bolt 3 Exhaust manifold gasket 4 Exhaust manifold 5 Oxygen sensor 6 Exhaust manifold nut 7 Seal ring 8 Exhaust pipe bolt 9 Exhaust pipe 10 Rubber mounting 11 Mounting bolt 12 Exhaust pipe nut...

Page 522: ...osition Check exhaust system for leakage loose connection dent and damage If bolts or nuts are loosened tighten them to specified torque Refer to GENERAL DESCRIPTION in this section for torque data Check nearby body areas for damaged missing or misposi tioned part open seam hole loose connection or any other de fect which could permit exhaust fumes to seep into vehicle Make sure that exhaust syste...

Page 523: ...eplace them as necessary EXHAUST PIPE For replacement of exhaust pipe be sure to hoist vehicle and ob serve WARNING under Maintenance and the following CAUTION Exhaust pipe have three way catalytic converter in it it should not be exposed to any impulse Be careful not to drop it or hit it against something Tighten bolts and nuts to specified torque when reassembling Refer to GENERAL DESCRIPTION in...

Page 524: ...IPTION 7A 2 Components 7A 2 DIAGNOSIS 7A 4 ON VEHICLE SERVICE 7A 5 Transmission Oil 7A 5 Gear Shift Control 7A 6 UNIT REPAIR OVERHAUL 7A 9 Dismounting Remounting 7A 9 Inspection of Transmission Components 7A 12 Important Steps in Reassembly 7A 17 REQUIRED SERVICE MATERIALS 7A 26 SPECIAL TOOLS 7A 26 ...

Page 525: ...eeve on the countershaft and the reverse drive gear on the input shaft Transmission case is in two piece construction consisting of upper case and lower case The lower case has the three fork shifting mechanism built in it The upper case houses the reverse shaft 1 Final gear 2 Differential case 3 Side pinion 4 Side gear 5 Top gear 6 Third gear 7 Second gear 8 Low speed synchronizer sleeve 9 Low ge...

Page 526: ...sher 20 Second gear 21 Needle bearing 22 Bush 23 Thrust washer 24 Spring 25 Third gear 26 Synchronizer ring 27 Synchronizer spring 28 High speed sleeve 29 Key 30 Thrust washer 31 High speed hub 32 Top gear 33 Needle bearing 34 Thrust washer 35 Bearing 36 C ring 37 Steel ball 38 Counter shaft 39 Pin 40 Plug 41 plug 42 C ring 43 Bearing 44 Input shaft 45 Bearing 46 Oil seal 47 Plug 48 Pin 49 Reverse...

Page 527: ...eve and gear Hard shifting Inadequate lubricant Improper clutch pedal free travel Distorted or broken clutch disc Damaged clutch pressure plate Worn synchronizer ring Worn chamfered tooth on sleeve or gear Worn gear shift control shaft extension rod bush Distorted shift shaft Replenish Adjust Replace Replace clutch cover Replace Replace sleeve or gear Replace Replace Noise Inadequate or insufficie...

Page 528: ...plugs 2 When installing drain plugs 2 apply sealant to the screw part of the plug before reassembling and be sure to tighten the plug to specification using hexagon socket Sealant SUZUKI BOND NO 1215 99000 31110 Tightening Torque for oil drain plugs 28 N m 2 8 kg m 20 Ib ft When changing oil fill transmission with new oil specified below NOTE For the vehicles used in the areas where the ambient te...

Page 529: ...ft rear boot 12 Gear shift control shaft 13 Extension rod bush Apply SUZUKI SUPER GREASE A 99000 25010 14 Control shaft joint 15 Control shaft rear bush Apply SUZUKI SUPER GREASE A 99000 25010 16 Lever housing bolt 17 Lever housing nut A 18 Lever housing nut B 19 Extension rod nut 20 Control shaft nut Tightening Torque Do not reuse Apply SUZUKI SUPER GREASE A 99000 25010 7A 6 MANUAL TRANSMISSION 4...

Page 530: ... remove control shaft 1 remove bolt 2 connecting gearshift control shaft and the gearshift shaft on the transmission side Then remove bolt 3 from the control shaft Inspection Boots dust seals and bushes Check them for damage and wear Replace if defective Gearshift lever housing Check rubber for damage or crack and replace if defective Installation Install in reverse order of removal noting the fol...

Page 531: ...bolts 1 Adjust gear shift lever position by displacing it toward front and rear so that each shift stroke is equal and each gear is in complete mesh 1 Guide plate bolt 2 Guide plate 3 Gear shift control lever 4 Right angle 5 Front side Lubrication Apply grease SUZUKI SUPER GREASE A to gear shift control lever seal and control rod bushes periodically For greasing points refer to page 7A 6 7A 8 MANU...

Page 532: ...te or combine transmis sion and engine DISASSEMBLY 1 Remove back up light switch 2 Remove clutch release bearing 1 3 Remove clutch release shaft return spring 1 from release lever 2 4 Remove clutch release bearing retainer 1 Inserting bolts in the upper and lower points of retainer will facili tate removal MANUAL TRANSMISSION 4 SPEED 7A 9 ...

Page 533: ...pper case is removed all parts should be left on the lower case 8 Remove input shaft assembly 1 from the lower case 9 Remove counter shaft assembly 1 from the lower case 10 Tap the spring pin out of the 3 shift fork shafts with special tool Special Tool A 09922 85811 7A 10 MANUAL TRANSMISSION 4 SPEED ...

Page 534: ... fork shafts Take care when drawing out shafts so that locating balls do not fall out 12 Fit special tool on low speed synchronizer sleeve and fix it se curely with a vice as shown below Loosen countershaft nut and draw out speedometer drive gear Special Tool B 09921 57810 13 Remove bearing After removing bearing all the parts on counter shaft can be removed Special Tool C 09913 61110 MANUAL TRANS...

Page 535: ...d damage Replace if de fective Combination of gear and synchronizer ring Fit ring to cone of the gear top gear or third second or low gear and measure the clearance between the two at the peripher al teeth as shown in below figure If the clearance has reached or exceeds the service limit replace the worn part Inspect the external cone of gear and internal cone of ring for abnormal wear Be sure tha...

Page 536: ... lets go of the keys and rides over to the ring At this moment the initial contact be tween the chamfered ends of teeth of ring and those of internal teeth of sleeve occurs This contact is such that the internal teeth of sleeve align themselves to those of the ring When the sleeve advances and slides into ring ring will be rotating nearly with the speed of gear so that sleeve is enabled smoothly t...

Page 537: ...lengths are less than the service limits Gear shift arm spring is used to arrest shift lever when it is shifted into reverse gear Also replace it if its free length is less than the below specified ser vice limit 7A 14 MANUAL TRANSMISSION 4 SPEED Key slot width Standard Service Limit Low gear 8 0 mm 0 31 in 8 3 mm 0 32 in Second gear 10 0 mm 0 39 in 10 3 mm 0 40 in Third and top gear 9 6 mm 0 38 i...

Page 538: ...ontact with locating spring ball for wear Differential case bolts Check differential case bolts for looseness and retighten if loose Tightening Torque for Differential Case Bolts 90 N m 9 0 kg m 65 Ib ft MANUAL TRANSMISSION 4 SPEED 7A 15 Gear Standard Service Limit Low Second 0 05 0 10 mm 0 0019 0 0039 in 0 30 mm 0 0118 in Third Top 0 15 0 20 mm 0 0059 0 0078 in 0 30 mm 0 0118 in Reverse 0 15 0 30...

Page 539: ...use If the backlash exceeds the specified value adjust it by varying the thickness of thrust washer 1 at the back of side gear back of the toothed surface 7A 16 MANUAL TRANSMISSION 4 SPEED Side gear back lash specification 0 05 0 10 mm 0 002 0 004 in Side gear thrust play specification 0 15 0 40 mm 0 006 0 016 in Available thrust washer sizes thickness 0 8 1 0 1 2 mm 0 03 0 04 0 05 in ...

Page 540: ...speed synchronizer sleeve Point groove 1 on the outer surface of sleeve in the direction of the low gear side High speed synchronizer sleeve Point groove 2 on the outer surface of sleeve in the direction of the clutch side High speed synchronizer sleeve Low speed synchronizer sleeve Second and third gear bush When assembling the second and third gear bush make sure that oil hole of counter shaft a...

Page 541: ...ub fit snugly into the slots pro vided in ring Synchronizer ring spring Do not forget to install spring 1 between low gear synchronizer ring 2 and synchronizer hub 3 1 Synchronizer ring spring 2 Low gear synchronizer ring 3 Synchronizer hub 2ND 3RD driven gear spring Do not forget to install spring 1 between the 2nd and 3rd driven gears on counter shaft This prevents noise due to play 7A 18 MANUAL...

Page 542: ...t use special tool Special Tool A 09913 80112 Counter shaft nut Fit special tool on low speed synchronizer sleeve and fix it securely with a vice as shown below And then tighten nut to the below speci fied tightening torque Special Tool A 09921 57810 Tightening Torque for Countershaft Nut 70 N m 7 0 kg m 40 Ib ft 1 Torque wrench 2 Vice MANUAL TRANSMISSION 4 SPEED 7A 19 ...

Page 543: ... locating steel balls pushed down against fork shafts REVERSE HIGH and LOW for the purpose of arresting these shafts at respective operating positions CAUTION Locating steel balls and gear shift arm shaft steel ball used have an outside diameter of 7 9 mm 0 311 in When installing locating springs distinguish between reverse locating spring and low high ones by its free length For their free length...

Page 544: ... shifter fork and shaft stopper pins Drive the shifter fork pins low speed high speed and reverse into the shifter fork and shaft completely Drive the shifter shaft stopper pins into the shifter shaft so that di mension H is obtained as illustrated in below figure A Shifter fork pin Length 20 mm 10 79 in A 1 Shifter fork pin Length 18 mm 10 71 in B Stopper pin Length 18 mm 10 71 in H Low speed sto...

Page 545: ...Before installing gear shifter fork shaft plugs apply SUZUKI BOND NO 1215 99000 31110 to the outer surface of the plugs Caulk transmission case with punch as shown below to prevent plugs from coming off 1 Caulking C ring Do not forget to fit counter shaft bearing C rings and input shaft C ring in transmission case Counter shaft Install the countershaft in lower case with gears on countershaft in n...

Page 546: ...al load Never use bolts other than the specified ones Tightening Torque for Differential Case Bolts 90 N m 9 0 kg m 65 Ib ft Differential side oil seals Apply grease to the lip of the differential side oil seal and install with spring 1 of the oil seal positioned inside transmission oil side Counter shaft bearing plug Install the countershaft bearing plug directing the rib 1 flange of the plug out...

Page 547: ...ces and then apply liquid sealing compound to the joint faces coating each face uniformly with the compound and a few minutes after this application match the two cases together Sealant SUZUKI BOND No 1215 99000 31110 Clutch release shaft Before fitting upper case on lower case apply grease to sliding sur faces between clutch release shaft and its bushes Lithium Grease SUZUKI SUPER GREASE A Upper ...

Page 548: ...rt the retainer into the transmission case taking care not to damage O ring 1 Apply grease to spline part of input shaft Lithium Grease SUZUKI SUPER GREASE I 99000 25210 After assembling check to be sure that gear shift shaft can be shifted to each gear position smoothly Clutch release arm For release arm installation refer to SECTION 7C CLUTCH Differential side gear snap rings When replacing diff...

Page 549: ...RVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCTS USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 SUZUKI SUPER GREASE I 99000 25210 Oil seal lips Gear shift control lever Gear shift control shaft bushes Input shaft spline and front end Sealant SUZUKI BOND NO 1215 99000 31110 Oil drain plug Gear shift shaft bolt Mating surface of transmission case Mating surface of clutch release bearing r...

Page 550: ...ears 7A1 10 Gear shifter main shaft and countershaft 7A1 11 Right case 7A1 13 Sub Assembly Service 7A1 15 Right case 7A1 15 Left case 7A1 16 Input shaft assembly 7A1 16 Countershaft assembly 7A1 19 Gear shifter 7A1 22 Differential assembly 7A1 24 Assembling Unit 7A1 26 Differential to left case 7A1 26 Fifth gears 7A1 29 Gear shift select shaft assembly 7A1 32 REQUIRED SERVICE MATERIALS 7A1 33 SPEC...

Page 551: ...eve hub 6 Input shaft 3rd gear 7 Left case 8 Reverse gear shaft 9 Reverse idler gear 10 Right case 11 Countershaft 12 Left cover 13 Countershaft 5th gear 14 Countershaft 4th gear 15 Countershaft 3rd gear 16 Countershaft 2nd gear 17 Low speed sleeve hub 18 Countershaft 1st gear 19 Final gear 20 Differential case 21 Differential side oil seal Apply lithium grease 99000 25010 to oil seal lip 22 Rever...

Page 552: ...key 21 5th synchronizer hub plate 22 Circlip 23 Reverse gear shaft 24 Reverse idler gear 25 Reverse shaft washer 26 Countershaft right bearing 27 Countershaft 28 Countershaft 1st gear 29 1st gear synchronizer ring 30 Low speed synchronizer spring 31 Low speed sleeve hub 32 Low speed synchronizer key 33 Circlip 34 2nd gear synchronizer ring 35 1st 2nd gear bearing 36 Countershaft 2nd gear 37 Counte...

Page 553: ...hift shaft 17 Reverse gear shift lever bolt 18 Gear shift arm bolt Apply thread lock cement 99000 32110 to thread part Tightening Torque GEAR SHIFT MECHANISM Movement of gear shift control lever is transmitted to gear shift shaft through gear shift control shaft and gear shift select shaft through gear shift arm and gear shift yoke and then gear shift select lever to each gear shift yoke shaft and...

Page 554: ...lockwise with gear shift select shaft 1 and it is pushed up by cam guide return spring 3 to the position where interlock guide bolt 7 prevents the cam from being shifted to re verse straight 2 Shifting from 5th to neutral is available and further shift to re verse is interrupted However when shift select shaft 1 is moved to neutral of 3rd 4th position shift limit cam mechanism is canceled as shown...

Page 555: ...eve and gear Hard shifting Inadequate lubricant Improper clutch pedal free travel Distorted or broken clutch disc Damaged clutch pressure plate Worn synchronizer ring Worn chamfered tooth on sleeve or gear Worn gear shift control shaft joint bush Distorted shift shaft Replenish Adjust Replace Replace clutch cover Replace Replace sleeve or gear Replace Replace Noise Inadequate or insufficient lubri...

Page 556: ...ealant 99000 31110 Tightening Torque a 21 N m 2 1 kg m 15 5 lb ft 4 Fill new specified oil by specified amount up to level hole NOTE It is recommended to use API GL 4 75W 90 gear oil Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage Oil specification API GL 4 For SAE classification refer to viscosity chart at the left Oil capacity 2 1 lite...

Page 557: ...g fitting of joint spline at differential side Pushing knuckle portion outward detach drive shaft at differen tial side 1 Drive shaft 2 Flat end rod or the like 6 Remove oil seal and install a new one until it becomes flush with case surface by using special tool and hammer NOTE When installing oil seal face its spring side inward Special Tool A 09913 75810 for right side oil seal 09913 75520 for ...

Page 558: ...ten bolts to specified torque referring to Section 3D 12 Fill transmission oil as specified and make sure that oil has been sealed with oil seal CAUTION Be careful not to scratch oil seal lip with drive shaft joint while inserting Make sure to insert drive shaft joint fully and seat its snap ring as it was Do not hit joint boot with hammer or the like Noth ing but hands is allowed to use when inse...

Page 559: ...d then hub plate 2 CAUTION Care should be taken not to distort side cover when it is removed from left case Special Tool A 09900 06107 3 Remove shift fork plug 1 and guide ball 2 NOTE Use of magnet would facilitate removal of guide ball 4 Drive out spring pin 3 by using special tool and hammer Special Tool B 09922 85811 5 Remove circlip 4 6 Remove gear shift fork 1 sleeve hub assembly 2 synchro ni...

Page 560: ...agement NOTE Do not reuse counter shaft nut 8 Remove input shaft 5th gear needle bearing and counter shaft 5th gear Gear puller would be necessary if spline fitting of count er shaft 5th gear is tight 9 Remove 5 screws and take off left case plate 1 and then re move bearing set shim 2 GEAR SHIFTER MAIN SHAFT AND COUNTERSHAFT 1 Remove 3 bolts from left case cap and then take off cap 2 Remove gear s...

Page 561: ... interlock bolt 3 with washer 6 Remove back up light switch 4 NOTE Removal of 5th to REV interlock bolt 5 is not necessary for removing gear shift select shaft assembly 7 Pull out gear shift select shaft assembly 1 8 Remove reverse shaft bolt 4 with washer 9 Remove 11 case bolts from outside and another 4 from clutch housing side 10 Tapping left case flanges with plastic hammer remove left case 11...

Page 562: ... shaft and shift it to 4th to fa cilitate removal of 5th REV shifter 15 Tapping input shaft 1 end with plastic hammer push it out as assembly from case a little then take out input shaft assembly counter shaft assembly 2 high speed gear shift shaft 3 and low speed gear shift shaft 4 all at once 16 Remove countershaft L bearing cup from left case 5 17 Remove differential side L oil seal also from l...

Page 563: ...g re mover 09941 64511 with sliding shaft 09930 30102 NOTE If counter shaft R bearing has been left in right case pull it out by using bearing remover 09923 73210 with sliding shaft 09930 30102 5 Remove bolt 1 and then pull out gear shift arm 2 6 Remove gear shift shaft bolt 1 with washer 2 then take out spring 3 and steel ball 4 7 Remove gear shift shaft 5 boot 6 and oil seal 7 8 Remove different...

Page 564: ...l 1 at its lip and install it up to bottom of the bore by using special tool and hammer B SUZUKI SUPER GREASE A 99000 25010 Special Tool D 09925 58210 4 Install gear shift shaft 1 boot 2 steel ball spring and tighten bolt 3 with washer applied with sealant C SUZUKI BOND NO 1215 99000 31110 Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft NOTE Bring breather of gear shift shaft boot downward 5 Install...

Page 565: ...hread lock 1322 99000 32110 Tightening Torque a 10 N m 1 0 kg m 7 5 lb ft 2 Install differential side L oil seal 1 until it becomes flush with case surface by using special tool with hammer and then apply grease to its lip NOTE Face oil seal spring side inward B SUZUKI SUPER GREASE A 99000 25010 Special Tool A 09913 75510 3 Install countershaft L bearing cup into case bore by tapping it with plast...

Page 566: ...07 5 Drive out high speed synchronizer sleeve hub assembly 1 together with 3rd gear 2 by using puller 3 and press CAUTION Make sure to use flat side of puller to avoid causing dam age to 3rd gear tooth 6 Take out 3rd gear needle bearing from shaft 7 Disassemble synchronizer sleeve hub assembly 1 Inspection and Reassembly 1 Clean all components thoroughly inspect them for any ab normality and repla...

Page 567: ...ammer Special Tool A 09925 98221 6 Install 3rd gear needle bearing apply oil to it then install 3rd gear 1 and synchronizer ring 2 7 Drive in high speed sleeve hub assembly 3 by using special tool and hammer NOTE While press fitting sleeve hub 3 make sure that syn chronizer ring key slots are aligned with keys in sleeve hub assembly Check free rotation of 3rd gear 1 after press fitting sleeve hub ...

Page 568: ...3 and press CAUTION Use puller and press that will bear at least 5 ton 11 000 lb safely To avoid tooth damage support 4th gear at flat side of puller 2 Apply puller 1 to 2nd gear 2 and drive out 3rd 4th gear spacer 3 together with 2nd gear 2 by using press Needle bearing would come out with 2nd gear 2 CAUTION If compression exceeds 5 ton 11 000 lb release com pression once reset puller support and...

Page 569: ...d to be repaired check clearance a between ring 1 and gear 2 each chamfered tooth of gear ring and sleeve then determine parts replacement Clearance a Standard 1 0 1 4 mm 0 039 0 055 in Service limit 0 5 mm 0 019 in 3 To ensure lubrication air blow oil holes 1 and make sure that they are free from any obstruction 4 Fit low speed synchronizer sleeve 1 to hub 2 insert 3 keys 3 in it and then set spr...

Page 570: ...m 0 35 in Needle bearings for 1st and 2nd gear are identical 7 Drive in low speed sleeve hub assembly 1 by using special tool and hammer NOTE Support shaft with special tool as illustrated left so that retainer of bearing cone 4 will be free from compres sion Make sure that synchronizer ring key slots are aligned with keys while press fitting sleeve hub assembly Check free rotation of 1st gear 3 a...

Page 571: ...ss fit 4th gear 1 by using the same procedure as the above 11 Install L bearing cone 2 by using special tool and hammer NOTE For protection of bearing cone always support shaft with special tool as illustrated Special Tools A 09923 78210 E 09925 98221 GEAR SHIFTER Gear Shift Select Shaft Assembly 1 To disassemble component parts use special tools and 2 8 3 0 mm 0 11 in pin remover in addition Spec...

Page 572: ...t carefully in spect contact portion of fork and sleeve Clearance a Service limit 1 0 mm 0 039 in 2 Insert each gear shift shaft into case and check that it moves smoothly If it doesn t correct by using oilstone reamer or the like 5th REV Gear Shifter 1 Disassemble component parts by using special tool and ham mer Special Tool A 09922 85811 4 5 mm 2 Replace or correct parts as required and assembl...

Page 573: ...e out differential side pinion shaft pin and then disassemble component parts Special Tool C 09922 85811 4 5 mm Adjustment and Reassembly Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly prepare replacing parts and proceed to reassembly Make sure that all parts are clean 1 Assemble differential gear and measure thrust pla...

Page 574: ...btained Available thrust washer thickness 0 9 1 0 and 1 1 mm 0 035 0 039 and 0 043 in 3 Drive in spring pin 3 from right side till it is flush with differential case surface 4 Press fit L bearing by using special tool and copper hammer Special Tools C 09913 76010 D 09951 16060 5 Install speed sensor rotor 2 drive gear support differential as sembly as illustrated so as to L bearing is floating and...

Page 575: ...portion of case when inserting it Such attempt may cause case to break Tightening Torque a 5 5 N m 0 55 kg m 4 0 lb ft 3 Join input shaft 1 countershaft 2 low speed gear shift shaft 3 and high speed gear shift shaft 4 assemblies all together then install them into right case 5 NOTE Input shaft R bearing on shaft can be installed into right case by tapping shaft with plastic hammer Be careful not t...

Page 576: ...case NOTE Make sure that washer has been installed in shaft at above the gear Check to confirm that reverse gear shift lever 2 end has clearance a 1 mm 0 04 in to idler gear groove 7 Clean mating surfaces of both right and left cases coat mating surface of left case with sealant evenly then mate it with right case Sealant SUZUKI BOND No 1215 99000 31110 8 Tighten case bolts from outside to specifi...

Page 577: ...ocating spring for deterioration and replace with new one as necessary Locating spring free length Standard Service Limit 5th REV Pink painted 33 8 mm 1 331 in 32 7 mm 1 287 in High speed Low speed Green painted 33 6 mm 1 323 in 32 5 mm 1 280 in 12 Install steel ball and locating spring for respective gear shift shaft and tighten with bolt Tightening Torque d 13 N m 1 3 kg m 9 5 lb ft ...

Page 578: ...ting above step select a suitable shim which adjusts clearance a to specification and put it on bearing cup NOTE Insert 0 1 mm 0 004 in feeler to know whether or not a shim fulfills specification quickly Available shim thickness 0 40 0 45 0 50 0 55 0 6 0 65 0 7 0 75 0 8 0 85 0 9 0 95 1 0 1 05 1 1 and 1 15 mm 0 015 0 017 0 019 0 021 0 023 0 025 0 027 0 029 0 031 0 033 0 035 0 037 0 039 0 041 0 043 ...

Page 579: ...y way F Chamfered spline Inward 6 Install countershaft 5th gear 1 to counter shaft facing ma chined boss A inward 7 Apply oil to needle bearing and install it to input shaft 8 Install input shaft 5th gear to input shaft 9 Install new counter shaft nut 1 as follows a Shift low speed gear shift shaft 2 to 1st gear position and high speed gear shift shaft 3 to 3rd gear position b Tighten nut with abo...

Page 580: ...ward 14 Install steel ball tighten shift fork plug 1 applied with thread lock cement A Thread lock cement 99000 32110 Tightening Torque a 9 N m 0 9 kg m 6 5 lb ft 15 Fit hub plate 2 and fix it with circlip 16 Install circlip 3 to the end of 5th reverse gear shift guide shaft Make sure circlip is installed in shaft groove securely CAUTION Coat shift fork plug with thread lock cement reasonably If i...

Page 581: ...ssembly 2 position gear in neutral so that gear shift interlock plate 4 will go in smoothly 5 Tighten yoke and shaft with bolt 3 applied with thread lock ce ment B Thread lock 1322 99000 32110 Tightening Torque a 34 N m 3 4 kg m 24 5 lb ft 6 Install gear shift interlock bolt 5 with washer and tighten it to specification Tightening Torque b 23 N m 2 3 kg m 17 0 lb ft 7 Clean mating surface of left ...

Page 582: ...ZUKI SUPER GREASE A 99000 25010 Oil seal lips Gear shift control lever Gear shift control shaft bushes Sealant SUZUKI BOND NO 1215 99000 31110 Oil drain plug Gear shift shaft bolt Mating surface of transmission case Mating surface of side cover Mating surface of gear shift guide case Thread lock cement THREAD LOCK 1322 99000 32110 Control lever knob Reverse gear shift lever bolts Oil gutter bolt L...

Page 583: ...ing installer 09913 75520 Bearing installer 09913 80112 Bearing installer 09913 84510 Bearing installer 09916 46010 Valve guide remover 09917 58010 Bearing remover 09922 85811 Spring pin remover 4 5 mm 09923 73210 Bearing remover 09923 74510 Bearing remover 09923 78210 Bearing installer 09924 74510 Installer attachment 09925 18010 Bearing installer SPECIAL TOOLS ...

Page 584: ...Bearing outer race installer 09925 78210 Spring pin remover 6 mm 09925 88210 Bearing puller attachment 09925 98221 Bearing installer 09930 30102 Sliding shaft 09940 53111 Bearing installer 09941 64511 Bearing remover 09951 16060 Bush remover 09951 76010 Bearing installer ...

Page 585: ...GNOSIS 7C 4 ON VEHICLE SERVICE 7C 5 MAINTENANCE SERVICE 7C 5 Clutch Pedal 7C 5 Clutch Cable 7C 6 UNIT REPAIR OVERHAUL 7C 7 Clutch Cover Clutch Disc and Flywheel 7C 7 Clutch release system For 5 speed Transmission 7C 11 REQUIRED SERVICE MATERIALS 7C 14 SPECIAL TOOLS 7C 14 ...

Page 586: ...ase bearing is held back This is the en gaged condition of the clutch Depressing the clutch pedal causes the release bear ing to advance and pushes on the tips of the tapered fingers of the diaphragm spring When this happens the diaphragm spring pulls the pressure plate away from the flywheel thereby interrupting the flow of drive from flywheel through clutch disc to transmission input shaft 1 Clu...

Page 587: ...ithium grease 99000 25010 to pin for release bearing 6 Transmission lower case 7 Clutch disc 8 Torsional spring 9 Input shaft bearing 10 Input shaft Apply lithium grease 99000 25210 to spline part 11 Crankshaft 12 Flywheel 13 Flywheel bolt 14 Clutch cover bolt Tightening Torque 4 speed Manual Transmission ...

Page 588: ... with oil Release bearing slides unsmoothly on input shaft bearing retainer Wobbly clutch disc or poor facing contact Weakened torsion springs in clutch disc Clutch disc rivets loose Distorted pressure plate or flywheel surface Weakened or loosened engine mounting bolt or nut Repair or replace disc Replace disc Lubricate or replace input shaft bearing retainer Replace disc Replace disc Replace dis...

Page 589: ...5 N m 0 6 kg m 4 5 lb ft CLUTCH PEDAL FREE TRAVEL 1 Depress clutch pedal 1 stop the moment clutch resistance is felt and measure distance clutch pedal free travel Free travel should be within the following specification Pedal free travel b 15 20 mm 0 6 0 8 in 2 If free travel is out of specification adjust it with cable joint nut 3 Release arm 4 free travel c For 5 speed manual transmission 0 2 mm...

Page 590: ...on Frayed cable Bent or kinked cable Broken boots Worn end INSTALLATION Reverse removal procedure for installation noting the following Apply grease to cable end hook and also joint pin before instal ling cable Grease 99000 25010 Screw in joint nut and adjust free travel of pedal to specification by turning nut Check clutch for proper function with engine running For 4 speed transmission the clear...

Page 591: ...hium grease 99000 25010 to inside 10 Clutch release shaft seal Apply lithium grease 99000 25010 to inside 11 Lock washer 12 Clutch retainer spring 2 pcs 13 Cover reamer bolt 2 pcs 14 Release bearing retainer Tightening Torque 5 speed Manual Transmission 4 speed Manual Transmission DISMOUNTING REMOUNTING Dismount or mount transmission with engine referring to SECTION 6A and separate or combine tran...

Page 592: ...distance between rivet head and facing surface If depression is found to have reached service limit at any of holes replace disc assembly Rivet head depth Standard 1 2 mm 0 05 in Service limit 0 5 mm 0 02 in Clutch Cover Check diaphragm spring 1 for abnormal wear or damage Inspect pressure plate 2 for wear or heat spots If abnormality is found replace it as assembly Do not disas semble it into dia...

Page 593: ...d transmission B 09943 88210 For 4 speed transmission 3 Aligning clutch disc to flywheel center using special tool install clutch cover 1 and bolts Then tighten bolts to specification 4 speed Transmission NOTE While tightening clutch cover bolts compress clutch disc with special tool by hand so that disc centered For 4 speed manual transmission be sure to use 2 ream er bolts 2 as shown Special Too...

Page 594: ...put shaft 1 then joint transmission assembly with engine A Grease 99000 25010 B Grease 99000 25210 NOTE Turn crankshaft with wrench from front while inserting transmission input shaft to clutch disc until splines mesh 7C 10 CLUTCH ...

Page 595: ...hook return spring 1 using pliers 4 Drive out No 2 bush using special tool and hammer Release shaft seal will also be pushed out Special Tool A 09922 46010 5 Remove release shaft 2 and return spring 1 6 Install tap M14 1 5 1 to clutch release shaft No 1 bush 7 Pull No 1 bush out by using special tools Special Tool B 09923 46030 C 09930 30102 CLUTCH 7C 11 ...

Page 596: ... new clutch release shaft No 1 bush 1 using special tools and then apply grease to bush inside Special Tool A 09943 77910 B 09923 46030 A Grease 99000 25010 2 Install release shaft with return spring applied to it 3 Apply grease to clutch release shaft No 2 bush 1 inside and press fit it using the same special tool as in removal Grease 99000 25010 Special Tool C 09922 46010 4 Apply grease to shaft...

Page 597: ...ng 2 inside and release shaft arm 3 then set bearing A Grease 99000 25010 8 Apply small amount of grease to input shaft spline 4 and front end as well B Grease 99000 25210 9 Set release arm 1 to release shaft aligning their punching marks 2 and tighten nut 3 Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft CLUTCH 7C 13 ...

Page 598: ...I SUPER GREASE I 99000 25210 Input shaft spline front end SPECIAL TOOLS 09917 58010 For 5 speed M T 09921 20200 For 4 speed M T Bearing remover 09922 46010 Bush remover 09923 36330 Clutch center guide 09923 46030 Joint pipe 09924 17810 Flywheel holder 09925 98210 For 5 speed M T 09943 88210 For 4 speed M T Input shaft bearing installer 09925 98221 Bearing installer 09930 30102 Sliding shaft 09943 ...

Page 599: ...e Unit 8 7 Engine Coolant Temp ECT Meter and ECT Sensor 8 7 Oil Pressure Light 8 7 Brake and Parking Brake Warning Light 8 8 Windshield Wiper and Washer 8 8 Front Wiper and Washer 8 8 Interior Light 8 8 Horn 8 8 ON VEHICLE SERVICE 8 9 Headlight 8 9 Turn Signal and Hazard Warning Light 8 11 Ignition Switch 8 12 Combination Meter 8 12 Fuel Meter Fuel Gauge Unit 8 13 Engine Coolant Temperature ECT Me...

Page 600: ...necting cables from the battery be sure to discon nect the one from the negative terminal first and then the oth er from the positive terminal Reverse the above order when connecting the cables to the bat tery terminals When disconnecting connectors never pull the wiring har nesses Unlock the connector lock first and then pull them apart by holding connectors themselves When connecting connectors ...

Page 601: ... to the harness protect its part which may con tact against a part forming a sharp angle by winding tape or the like around it When replacing a fuse make sure to use a fuse of the specified capacity Use of a fuse with a larger capacity will cause a dam age to the electrical parts and a fire Always be careful not to handle electrical parts computer relay etc in a rough manner or drop them BODY ELEC...

Page 602: ...first or first two alphabet s of each color There are two kinds of colored wire used in this vehicle One is single colored wire and the other is dual colored striped wire The single colored wire uses only one color symbol i e G The dual colored wire uses two color symbols i e G Y The first symbol represents the base color of the wire G in the figure and the second symbol represents the color of th...

Page 603: ...itch turn R 10 To ground 11 To ECM 12 Blank R Y B Y R G R B W Y W R B G Y B BI V 1 To alternator 2 To parking brake switch 3 To ECM 4 Blank 5 Blank 6 Blank 7 To main fuse 8 To combination switch dimmer passing switch 9 To oil pressure switch 10 Blank W R R B V Y W R Y B COUPLER K NOTE Terminal arrangement of coupler viewed from harness side Coupler K Coupler L COUPLER L BODY ELECTRICAL SYSTEM 8 5 ...

Page 604: ...e existing between combination switch turn signal hazard warning switch and light on one side Wiring or grounding faulty Replace bulb Replace bulb Replace relay Repair circuit Repair circuit No flashing HAZARD HORN and or TURN BACK fuse blown Open circuit or high resistance existing between battery and switch Turn signal hazard relay faulty Combination switch turn signal hazard switch faulty Wirin...

Page 605: ...lown Fuel gauge unit faulty Printed plate in combination meter faulty Fuel meter faulty Wiring or grounding faulty Replace fuse to check for short Replace fuel gauge unit Replace printed plate Replace fuel meter Repair circuit ENGINE COOLANT TEMP ECT METER AND ECT SENSOR Trouble Possible Cause Correction Engine coolant temp me ter shows no operation or incorrect operation IG COIL fuse blown ECT me...

Page 606: ...ER AND WASHER FRONT WIPER AND WASHER Trouble Possible Cause Correction Wiper malfunctions or does not return to its origi nal position WIPER WASHER fuse blown Wiper motor faulty Combination switch wiper switch faulty Wiring or grounding faulty Replace fuse to check for short Replace wiper motor Replace switch Replace circuit Washer malfunctions Washer hose or nozzle clogged WIPER WASHER fuse blown...

Page 607: ...minal Switch Position Mating side front view of combination switch coupler Terminal Switch Position HEADLIGHT REMOVAL 1 Disconnect negative cable at battery 2 Remove front grille 3 Remove garnish 1 installed under the headlight 4 Remove headlight mounting bolts 5 Detach headlight assembly 2 from vehicle 6 Disconnect couplers from headlight assembly 7 Remove headlight assembly INSTALLATION Reverse ...

Page 608: ...ght surface Clearance a 10 m 32 8 ft b Adjust air pressure of all tires to a specified value respectively c Bounce vehicle body up and down by hand to stabilize suspen sion d Carry out with one driver aboard Driver s weight 75 kg 165 Ib Adjustment 1 Check to see if hot spot high intensity zone of each main low beam axis falls as illustrated Clearance H Approx 130 mm 5 15 in 2 If headlight aiming i...

Page 609: ...ecified replace Terminal Turn Signal SW Hazard SW REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH ASSEMBLY in Section 3C Mating side front view of combination switch coupler TURN SIGNAL HAZARD RELAY The turn signal hazard relay 1 is located on the fuse box 2 INSPECTION Connect battery and tester as shown left Unless a continued click sound is heard replace relay 1 Reference flashing cycle 60 ...

Page 610: ...EERING LOCK ASSEMBLY IGNITION SWITCH in section 3C COMBINATION METER REMOVAL 1 Disconnect negative cable at battery 2 Remove heater control knobs 1 and mounting bolts 3 Disconnect heater control lead wire couplers 2 4 Loosen steering column mounting nuts of upper side and lower steering column 5 Remove meter cluster 3 6 Pull out combination meter 4 and disconnect speedometer cable and combination ...

Page 611: ...ulb light up and pointer 2 moves to F side 7 If fuel meter shows no operation repair or replace defective parts FUEL SENDER GAUGE INSPECTION 1 Remove fuel tank referring to FUEL TANK REMOVAL in Sec tion 6C 2 Remove fuel gauge unit 1 from tank 3 Check resistance between terminal a and gauge unit ground in individual each float position below If the measured value is out of specification replace BOD...

Page 612: ...ion repair or replace defective parts ENGINE COOLANT TEMPERATURE ECT SENSOR FOR METER REMOVAL AND INSTALLATION Refer to ENGINE COOLANT TEMPERATURE SENSOR in sec tion 6E1 WARNING Make sure that engine coolant temperature is cold be fore removing any part of cooling system Also be sure to disconnect negative cable from battery terminal before removing any part 1 ECT sensor INSPECTION Warm up ECT sen...

Page 613: ...n 6A1 BRAKE AND PARKING BRAKE WARNING LIGHT INSPECTION BRAKE FLUID LEVEL SWITCH Check switch 1 for continuity If check result is not as specified replace switch PARKING BRAKE SWITCH Check switch 1 for continuity If check result is not as specified replace switch BODY ELECTRICAL SYSTEM 8 15 During Engine Running No continuity At Engine Stop Continuity OFF position float up No continuity ON position...

Page 614: ...wire coupler 3 Check for continuity between terminals at each switch position as shown below If check result is not as specified replace switch REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH ASSEMBLY in Section 3C Wiper SW Terminal Terminal N Q Washer SW OFF ON Mating side front view of combination switch coupler 8 16 BODY ELECTRICAL SYSTEM N P O S OFF INT LO HI ...

Page 615: ...itive lead to terminal O and negative lead to terminal R Check that the voltmeter indicates the battery voltage 10 14V 6 Connect terminal S and terminal N by a jumper wire Then move jumper wire end connected to terminal N to terminal R Observe the voltmeter voltage drops to 0V right after connect ing the jumper wire from terminal N to R Then the voltage rises to battery voltage 10 14 V within the ...

Page 616: ...nd its terminal to bracket 1 wiper ground If motor 2 rotates at a low revolution speed of 45 to 55 rpm it is proper As for high speed check connect battery terminal to terminal B and its terminal to bracket 1 wiper ground If motor 2 rotates at a high revolution speed of 67 to 83 rpm it is proper 2 Testing automatic stop action a Connect 12V battery terminal to terminal A of wiper mo tor 2 and term...

Page 617: ...NSPECTION Connect battery and terminals to pump and terminals respectively to check pumping rate Check for front washer pump Pumping Rate More than 1 0 l min 2 1 US pt min 1 76 Imp pt min Installation Reverse removal procedure for installation DOOR SWITCH INSPECTION Pull out door switch from body and check switch for continuity If found defective replace switch BODY ELECTRICAL SYSTEM 8 19 ...

Page 618: ...2 Front Door Glass and Window Regulator 9 2 Rear Door Glass and Window Regulator 9 6 Door Lock 9 9 Door 9 12 REAR QUARTER WINDOW 9 14 BACK DOOR 9 15 Back Door Balancer 9 15 Door Latch Striker 9 15 SEAT 9 17 Front Seat 9 17 Rear Seat 9 18 BODY DIMENSION 9 19 SIDE MOLDING 9 21 ...

Page 619: ...000 25010 to moving section 12 Door upper hinge 13 Door lower hinge 14 Window regulator handle snap 15 Glass bottom channel REMOVAL 1 Remove inside handle bezel 2 Remove door armrest 3 Remove window regulator handle 1 Pull off the snap with a cloth 2 in position to remove the regu lator handle 1 4 Remove door trim 5 Remove door sealing cover 6 Remove door outer weatherstrip Fully lower the window ...

Page 620: ...ews six places and take out the regulator through the hole A INSPECTION Check the window regulator gear for wear or damage Check the window regulator spring for weakened condition INSTALLATION Reverse the removal sequence to install the door window regulator and door glass However be careful of the following points 1 Apply SUZUKI SUPER GREASE A 99000 25010 to the slid ing parts BODY SERVICE 9 3 ...

Page 621: ...hown For 3 door model For 5 door model 3 When you feel hard to raise and lower the door glass it is pos sible that the glass is tilted toward the door sash If this is the case adjust the equalizer of the window regulator so that the measurements A and B are equal to each other 1 Equalizer screws 4 Securely seal the door sealing cover 1 with adhesive 2 9 4 BODY SERVICE ...

Page 622: ...weather strip securely fix its rear end with adhesive 1 Front door outer weather strip rear end 6 Install the door window regulator handle 1 so that it has a 45_ angle when the glass is fully closed as illustrated below BODY SERVICE 9 5 ...

Page 623: ...pply SUZUKI SUPER GREASE A 99000 25010 to moving sec tion 12 Door upper hinge 13 Door lower hinge 14 Window regulator handle snap 15 Glass bottom channel 16 Door center sash 17 Partition glass 3 Remove window regulator handle 1 Pull off the snap with a cloth 2 in position to remove the regu lator handle 1 4 Remove door trim 5 Remove door sealing cover 6 Remove door outer weatherstrip Fully lower t...

Page 624: ...om chan nel 1 Door glass 10 Detach the glass from the bottom channel 11 Loosen door window regulator attaching screws 1 four places and take out the regulator through the hole A INSPECTION Check the gear for wear or damage INSTALLATION Reverse the removal sequence to install the window regulator and door glass However be careful of the following points 1 Apply SUZUKI SUPER GREASE A 99000 25010 to ...

Page 625: ... into the bottom channel 2 4 After installing rear door outer weather strip and partition weath er strip securely fix their ends specified below with adhesive 1 Rear door outer weatherstrip front end 2 Rear door outer weatherstrip rear end 3 Partition weatherstrip rear end 5 Securely seal the door sealing cover 1 with adhesive 2 6 Install the door window regulator handle 1 so that it has a 45_ ang...

Page 626: ... key cylinder 3 Door inside handle 4 Door latch ass y 5 Door latch striker 6 Door rear sash 1 Outside handle 2 Inside handle bezel 3 Door inside handle 4 Door latch ass y 5 Door latch striker Rear door lock Front door lock BODY SERVICE 9 9 ...

Page 627: ...joint of control link remove the door inside handle and door latch ass y 1 Plain screw driver INSTALLATION Be careful of the following items to reverse the removal sequence to install the front door lock 1 Door outside opening rod When installing the opening rod 1 to the outside handle 2 turn the joint 3 to adjust the distance A to 0 to 2 mm as illus trated NOTE Do not push down the opening link 6...

Page 628: ...ing lever pin 3 Front Door Lock 4 Front door latch striker B 0 2 mm Rear Door Lock 4 Door latch ass y B 0 2 mm 3 Door lock rod pin Use the door lock rod pin 1 to securely fix the door lock rod as illustrated 4 Door latch striker Move the door latch striker 2 up and down so that its shaft 3 approximately aligns with the center of the groove C of the door latch 1 NOTE The striker should be placed le...

Page 629: ...ore and aft direction increase or decrease the number of spacers inserted between the body and the striker to adjust it The dimension D should be adjusted to 12 6 to 14 6 mm NOTE Apply oil or grease to the striker joints periodically 2 Shim 3 Door 4 Front side 5 Body D 12 6 14 6mm DOOR 1 Upper hinge 2 Lower hinge 3 Door 4 Body A Oil point REMOVAL 1 Remove the stopper pin upward by tapping with ham...

Page 630: ...g the hinge mounting bolts 1 Rags INSTALLATION Reverse the removal sequence to install the front door When the weatherstrip is hardened water leak may develop In this case replace it if possible After installing adjust the door latch striker position by referring to previous page so that the door is positioned correctly BODY SERVICE 9 13 ...

Page 631: ...trip is hardened water leak may develop In this case renew the weatherstrip if possible 1 Glass 2 Weatherstrip For 5 door model NOTE After installing the glass securely fix the weather strip up per front end A with adhesive 9 14 BODY SERVICE ...

Page 632: ...ndle balancer carefully Do not scar or scratch ex posed surface of its piston rod and never allow any paint or oil to stick to its surface Do not turn piston rod with balancer fully extended When discarding removed back door balancer damp er use a 2 to 3 mm 0 08 to 0 12 in drill to make a hole as shown The gas itself is harmless but it may issue out of the hole together with chips generated by the...

Page 633: ...To adjust the door latch and the striker with each other in the door up and down direction insert a proper number of shims below the bottom of the striker as illustrated 1 Shim 9 16 BODY SERVICE ...

Page 634: ...ning knob 9 Front seat frame 10 Front seat assembly bolt 11 Front seat adjuster bolt 12 Front seat back fixing screw 13 Front seat reclining bolt Tightening Torque REMOVAL AND INSTALLATION Refer to above figure when removing and installing or disassembling and assembling front seat Make sure to tighten each bolt as specified in above figure Right and left sides are symmetrical BODY SERVICE 9 17 ...

Page 635: ...ft rear seat back 5 Knob 6 Rear seat back lock assembly 7 Rear seat back lock striker 8 Rear seat back striker cover 9 Rear seat back hinge 10 Rear seat center hinge A B REMOVAL AND INSTALLATION Refer to above figure when removing and installing or disassembling and assembling rear seat 9 18 BODY SERVICE ...

Page 636: ...6 7 M m M Q O m M O O o P p R m 804 31 65 910 35 83 1123 44 21 552 21 73 1189 46 81 1050 41 34 790 31 10 8 9 10 11 12 13 14 15 16 17 S s T t U u V v S T S U S V T U T V U V 930 36 61 1176 46 30 1176 46 30 1172 46 14 987 38 86 725 28 54 891 35 08 818 32 20 487 19 17 387 15 24 T t DETAIL V v DETAIL o O DETAIL m M DETAIL BODY SERVICE 9 19 ...

Page 637: ...D d 840 33 07 1148 45 20 472 18 58 608 23 94 1162 45 75 780 30 71 970 38 19 853 33 58 790 31 10 544 21 42 524 20 63 29 30 31 32 33 34 35 36 37 38 39 40 41 D F E F G H I i I J I K I L J j J L J K K k K L L l 666 26 22 759 29 88 1195 47 05 1176 46 30 718 28 27 1260 49 61 643 25 31 1174 46 22 852 33 54 875 34 45 935 36 81 826 32 52 1179 46 42 G DETAIL H DETAIL I DETAIL 9 20 BODY SERVICE ...

Page 638: ...hly 2 Follow the above illustrated bonding positions to install the side moldings 3 If adequate adhesive force is unobtainable use urethane adhesive 1 Front fender molding 2 Front door molding 3 Quarter outer molding 4 Rear door molding Unit mm Unit mm BODY SERVICE 9 21 ...

Page 639: ...is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above procedures are not followed parts or system damage could result CONTENTS GENERAL DESCRIPTION 10 2 Seat belt with ELR 10 2 SEAT BELT 10 ...

Page 640: ...e For this rea son SUZUKI will supply only the spare buckle and ELR or webbing in a set part Before servicing or replacing seat belts refer to following precautionary items Seat belts should be normal relative to strap retractor and buckle portions Keep sharp edges and damaging objects away from belts Avoid bending or damaging any portion of belt buckle or latch plate Do not bleach or dye belt web...

Page 641: ...this section before starting to work and observe every precaution during work REMOVAL Remove front seat belts 1 Upper anchor 2 Lower anchor 3 Retractor assembly 4 Buckle 5 Anchor bolt 6 Retractor bolt 7 Setting washer 8 Spring washer 9 Spacer RESTRAINT SYSTEM 10 3 ...

Page 642: ...bbing even when tilted approx 15 toward the fore and aft or right and left directions Anchor bolt Anchor bolts should be torqued to specification Belt latch It should be secure when latched INSTALLATION Install in reverse order of removal noting the following Seat belt anchor bolts should have an unified fine thread 7 16 20 UNF Under no circumstances should any different sized or metric screw thre...

Page 643: ...ion during work REMOVAL Remove rear seat belts INSPECTION Check the rear seat belt in the same way as INSPECTION of FRONT SEAT BELT INSTALLATION Install the rear seat belt observing the same precautions as INSTALLATION of FRONT SEAT BELT Be sure to tighten seat belt anchor bolts to specified torque Tightening Torque for Anchor Bolt 35 N m 3 5 kg m 25 5 lb ft RESTRAINT SYSTEM 10 5 ...

Page 644: ...Prepared by Overseas Service Department 1st Ed October 1999 Printing 646 ...

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