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Suzuki RA410, Manual

The Suzuki RA410 user manual is a comprehensive guide for operating and maintaining your Suzuki RA410. Download the manual for free from manualshive.com to ensure you are getting the most out of your vehicle. Get all the information you need in one convenient place with the Suzuki RA410 manual.

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09924-17810
Flywheel holder

09916-84511
Forceps

09917-87010
Valve guide installer
attachment

09917-98221
Valve stem seal installer

09918-08210
Vacuum gauge hose joint

ENGINE MECHANICAL

6A4-81

REQUIRED SERVICE MATERIAL

MATERIAL

RECOMMENDED

SUZUKI PRODUCT

USE

Sealant

SUZUKI BOND NO. 1207C

(99000-31150)

Mating surfaces of cylinder block and oil pan.

Mating surfaces of cylinder block and timing chain cover.

Mating surfaces of camshaft housings (No.6).

Mating surfaces of crankcase

Summary of Contents for RA410

Page 1: ...nd the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Please observe all WARNINGS and CAU TIONS in SECTION 10B and Precautions Air Bag System Components and...

Page 2: ...l performance of the vehicle When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials lubricant sealants etc as specified in each de...

Page 3: ...nual Rack and Pinion Electrical Power Steering System If Equipped Steering Wheel and Column Front Suspension Rear Suspension Wheels and Tires DRIVE SHAFT AND PROPEL LER SHAFT Front Drive Shaft BRAKE S...

Page 4: ...ice 0A 10 Electrical Circuit Inspection Procedure 0A 11 Intermittent and Poor Connection 0A 14 Precaution for Installing Mobile Communication Equipment 0A 15 IDENTIFICATION INFORMATION 0A 15 Vehicle I...

Page 5: ...e 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...

Page 6: ...performance and lead to injury If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking pro cess remove the air bag system components before hand to avoid comp...

Page 7: ...slit 1 or use the workbench vise 2 to hold it securely at its lower mounting bracket 3 This is nec essary so that a free space is provided to allow the air bag to expand in the unlikely event of accid...

Page 8: ...select a place where the ambient temperature be low 65 C 150 F without high humidity and away from electric noise Never carry seat belt pretensioner by wire or connec tor of pretensioner When placing...

Page 9: ...harness can be identified easily as it is covered with a yellow protection tube Be very careful when handling it When an open in air bag wire harness damaged wire harness connector or terminal is fou...

Page 10: ...tting 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 use...

Page 11: ...sition 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...

Page 12: ...ing 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...

Page 13: ...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 speci...

Page 14: ...K 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 conta...

Page 15: ...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 ci...

Page 16: ...HORT 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 o...

Page 17: ...med 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 i...

Page 18: ...the antenna feeder more than 20 cm 7 9 in away 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 feede...

Page 19: ...RNING CAUTION label is found stained or damaged clean or replace it as necessary NOTE Air bag CAUTION WARNING labels are attached on the vehicle equipped with air bag system only Air bag label on sunv...

Page 20: ...ther 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 f...

Page 21: ...ure 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...

Page 22: ...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 E...

Page 23: ...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 Sequ...

Page 24: ...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 sp...

Page 25: ...section before perform ing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system in...

Page 26: ...10 000 km 6 000 miles or 8 months 1 5 Engine coolant R R 1 6 Exhaust system leakage damage tighteness I I I 2 IGNITION SYSTEM 2 1 Spark plugs When unleaded fuel is used R R R 2 2 Distributor cap and...

Page 27: ...first Miles 1 000 9 18 27 36 45 54 Months 12 24 36 48 60 72 6 CHASSIS AND BODY 6 1 Clutch pedal For manual transmission I I I 6 2 Tires wheel discs wear damage rotation I I I I I I 6 3 Drive shaft boo...

Page 28: ...al B C D Drive belt V rib belt I Every 15 000 km 9 000 miles or 12 months B C D Drive belt V rib belt R Every 45 000 km 27 000 miles or 36 months A C D E Engine oil and oil filter R Every 5 000 km 3 0...

Page 29: ...ferring to Water Pump Belt Removal and Installa tion in Section 6B 1 Water pump pulley WARNING Disconnect negative cable at battery before checking and replacing belt tension A C compressor drive belt...

Page 30: ...l Viscosity Chart Before draining engine oil check engine for oil leakage If any evi dence of leakage is found make sure to correct defective part be fore proceeding to the following work 1 Drain engi...

Page 31: ...c 9 Check oil filter and drain plug for oil leakage Engine oil capacity ITEM 1 5 Engine Coolant Change WARNING To help avoid danger of being burned do not remove ra diator cap while engine and radiato...

Page 32: ...cation 1 ITEM 1 6 Exhaust System Inspection WARNING To avoid danger of being burned do not touch exhaust system when it is still hot Any service on exhaust system should be performed when it is cool W...

Page 33: ...ove NOTE Dust and stains found within distributor can be cleaned by using a dry soft cloth 6 Install air cleaner case FUEL SYSTEM ITEM 3 1 Air Cleaner Filter Inspection 1 Unclamp air cleaner case clam...

Page 34: ...in a well ventilated area and away from any open flames such as gas hot water heaters ITEM 3 4 Fuel Tank Inspection Check fuel tank for damage cracks fuel leakage corrosion and tank bolts looseness I...

Page 35: ...same time check wheel cylinders for leakage Replace as necessary For the details refer to Section 5 3 Install brake drum and wheel ITEM 5 2 Brake Hoses and Pipes Inspection Perform this inspection wh...

Page 36: ...ing lever Check parking brake lever for proper operation and stroke and adjust it if necessary For checking and adjusting procedures refer to of Section 5 a Parking brake lever stroke 7 9 notches With...

Page 37: ...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 Inspec...

Page 38: ...tightness 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...

Page 39: ...el plug and tighten it to specified torque Change 1 Place the 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 t...

Page 40: ...nd 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 keep...

Page 41: ...er Transmission Check gear shift or select lever for smooth shifting to all positions and for good performance of transmis sion in any position With automatic transmission equipped vehicle also check...

Page 42: ...r 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 o...

Page 43: ...ailure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury Technical service wor...

Page 44: ...sides right and left of the instrument panel the hot air outlet at a place close to the feet of front passengers and the defroster air outlets at places right and left along the windshield glass The h...

Page 45: ...HEATER UNIT 1 Heater core 2 Blower motor assembly 3 Blower motor resistor 4 Temp door assembly 5 Mode door assembly 6 Mode lever 7 Temp lever assembly 8 Heater case 2 1 6 7 8 5 3 4 8 HEATER AND VENTI...

Page 46: ...k 7 Air inlet door 8 Evaporator case 1 8 6 7 5 4 3 2 HEATER CONTROL LEVER ASSEMBLY 1 Heater control lever assembly 2 Heater control panel 3 Blower fan switch assembly 4 Bulb 5 Fresh air control cable...

Page 47: ...emperature output Control cables broken or binding Temperature control lever faulty Control cable clamp position is faulty Air damper broken Air ducts clogged Heater core leaking or clogged Heater hos...

Page 48: ...proceed to next operation check if not replace Connect battery to blower motor as shown then check that the blower motor operates smoothly INSTALLATION 1 Reverse removal procedure for installation 2...

Page 49: ...ER ASSEMBLY REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Remove meter cluster hood ashtray center garnish inst...

Page 50: ...op at proper position 3 Enable air bag system if equipped with air bag Refer to ENAB LING AIR BAG SYSTEM in section 10B a c b f 2 1 Heater unit 2 Air inlet box 3 Mode control cable 4 Temperature contr...

Page 51: ...er unit 4 Remove instrument panel Refer to INSTRUMENTPANEL in BODY SERVICE section 1 5 Remove bolts 2 nuts 3 and screws 4 as shown 6 Remove heater unit 5 2 3 4 4 5 INSTALLATION Install heater unit by...

Page 52: ...to install ventialtion louver 2 1 2 Rag CAUTION When the heater unit is disassembled and reassembled locking force of the heater case lock may reduce In such a case tighten the heater case with a tap...

Page 53: ...WARNINGS and Service Precautions under On Vehicle Service in air bag system sec tion before performing service on or around the air bag system components or wiring Fail ure to follow WARNINGS could r...

Page 54: ...rge valve 1 Compressor label 2 Service valve HFC 134a CFC 12 REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM 1 Compressor 2 Magnet clutch 3 Condenser assembly 4 Receiver dryer 5 Dual pressure switch 6 Exp...

Page 55: ...Condenser assembly 4 Receiver dryer 5 Discharge hose 6 Suction hose 7 Receiver dryer outlet hose 8 Liquid pipe 9 Expansion valve 10 Ventilation air 11 Foot air 12 Defroster air 13 Demister air 14 Fre...

Page 56: ...enser cooling fan relay faulty Wiring or grounding faulty Radiator fan relay signal faulty Radiator and condenser cooling fan motor faulty Replace fuse and check short circuit to ground Check radiator...

Page 57: ...or thermal protector faulty Excessive charge of refrigerant Repair as necessary Check expansion valve Replace receiver dryer and evacua tion and charging Check magnetic clutch Check compressor thermal...

Page 58: ...leaks with a leak tester 2 No bubbles observed in signt glass No or insufficient charge of refrigerant in system Refer to the items 3 and 4 3 No temperature difference between compressor inlet and ou...

Page 59: ...y tighten nut TROUBLESHOOTING INFORMATION 1 Beginning on the next page the manifold gauge pressure val ues shown have been obtained under conditions listed below However keep in mind that the actual o...

Page 60: ...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 refrigeran...

Page 61: ...ure switch 5 ECT sensor 6 A C Evaporator thermistor 7 Radiator and condenser cooling fan relay 8 Radiator and condenser cooling fan motor 9 Compressor 10 Main relay 11 Ignition switch 1 2 3 5 4 6 11 1...

Page 62: ...MISSION 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 CAUTION ECM cannot be checked by itself It is...

Page 63: ...ion switch ON 10 14 volts Blower fan switch at Lo position with ignition switch ON 3 5 5 5 volts Blower fan switch at Me or Hi position with ignition switch ON 0 1 5 volts C21 A C switch input A C swi...

Page 64: ...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 R...

Page 65: ...8 mm pipe 13 N m 1 3 kg m 9 5 lb ft 14 5mm pipe 32 N m 3 2 kg m 23 0 lb ft A C CONDENSER ASSEMBLY REMOVAL 1 Disconnect negative cable at battery 2 Recover refrigerant from refrigeration system by usin...

Page 66: ...gerant from refrigeration system by using recovery and recycling equipment 2 Disconnect receiver outlet hose 1 and condenser outlet pipe 2 from receiver dryer 3 3 Loosen receiver dryer bracket bolt 4...

Page 67: ...ity proceed to next operation check If not replace 1 1 Radiator and condenser cooling fan motor Connect battery to radiator and condenser cooling fan motor 1 as shown then check that the radiator and...

Page 68: ...ag system if equipped 4 Remove heater control cable 1 main harness clamp 2 and disconnect evaporator thermistor coupler 3 1 3 2 5 Loosen suction hose 4 liquid pipe 5 bolt 6 6 Loosen cooling unit bolt...

Page 69: ...ith compressed air NOTE D 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...

Page 70: ...inuity at specified pressure as shown A Approx 200 KPa 2 0 kg cm2 B Approx 320 KPa 32 kg cm2 C Approx 230 KPa 2 3 kg cm2 D Approx 2800 KPa 28 kg cm2 Tightening torque for dual pressure switch 11 N m 1...

Page 71: ...ry and recycling equipment 4 Remove front bumper 5 Disconnect magnet clutch lead wire 1 and undo lead wire clamp 2 1 2 6 Disconnect suction and discharge hoses from compressor NOTE Cap open fittings i...

Page 72: ...and installation or for some other reason replenish 100cc oil When replenishing gas only oil replen ishment is not necessary When replacing compressor Compressor oil is sealed in each new compressor...

Page 73: ...rmature plate Tightening Torque c 14 N m 1 4 kg m b 23 N m 2 3 kg m a 14 N m 1 4 kg m 5 INSPECTION Check pressure plate and rotor for wear and oil soaked condi tions respectively Check clutch bearing...

Page 74: ...ol B remove armature plate Special Tool B 09991 06030 1 Armature plate 4 Remove lead wire clamp 5 Remove felt ring and shims from shaft 6 Using special tool C remove circlip Special Tool C 09900 06107...

Page 75: ...clutch squarely over clutch installation boss 2 Place special tool D onto clutch bearing Ensure that edge rests only on inner race of bearing 3 Install snap ring Special Tool D 09991 06010 CAUTION Be...

Page 76: ...NOTE Be careful not to remove cylinder from case 4 Remove O ring 1 Front head 2 Cylinder shaft 3 Cylinder 4 Case 5 O ring 5 Remove lip seal from front head 1 Front head 2 Bearing puller INSTALLATION...

Page 77: ...4 Apply A C oil to lip seal and O ring 5 Install front head assembly 1 Front head 2 O ring 6 Tighten front head bolt Tightening Torque a 14 N m 1 4 kg m 10 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft NOTE Be...

Page 78: ...r one set near evaporator air inlet read temperature indicated on each thermometer 1 Thermometer 1 7 Check for each pressure of low side and high side if it is within shaded range of left graph NOTE P...

Page 79: ...shown in graph at the left In this case cooling performance is satisfactory and proper 9 If crossing point is out of acceptable range diagnose trouble re ferring to following table 68 20 66 2 19 64 4...

Page 80: ...e opens too wide Thermister heat sensing tube of expansion valve improperly mounted poor contact poor insulation Compressor malfunction Insufficient compression Check expansion valve Check thermister...

Page 81: ...IAL TOOLS 09991 06020 Armature plate spanner 09991 06030 Armature plate remover 09991 06040 Lip type seal protector 09991 06050 Lip type seal installer 09900 06107 Snap ring pliers Opening type 09991...

Page 82: ...ECTRICAL POWER STEERING P S SYSTEM SECTION 3B1 STEERING WHEEL AND COLUMN SECTION 3C FRONT SUSPENSION SECTION 3D REAR SUSPENSION SECTION 3E WHEELS AND TIRES SECTION 3F CONTENTS DIAGNOSIS GENERAL DIAGNO...

Page 83: ...roken 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 Re...

Page 84: ...nts Disturbed front end alignment Rack and pinion adjustment Bind in steering column Inflate tires to proper pressure Check and correct Replace tie rod end or front suspension arm Check and adjust fro...

Page 85: ...nder 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 Fron...

Page 86: ...verloaded 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 moun...

Page 87: ...o 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 locati...

Page 88: ...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 K...

Page 89: ...rt 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 vehi...

Page 90: ...justed 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...

Page 91: ...em to be checked is the possibility of tire lead due to worn or improperly manufactured tires Lead is the deviation of the vehicle from a straight path on a level road without hand pressure on the ste...

Page 92: ...in length A NOTE If tie rod lengths were changed to adjust steering angle rein spect toe in Steering angle inside 445 35 outside 375 35 Reference Information Side slip For inspecting front wheel side...

Page 93: ...data apply to the right hand steering vehicle CONTENTS GENERAL DESCRIPTION 3B 1 DIAGNOSIS 3B 2 Diagnosis Table 3B 2 Steering Wheel Check 3B 2 Steering Rack Boot Check 3B 2 Tie Rod End Boot Check 3B 3...

Page 94: ...all 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...

Page 95: ...ll joint Inspect for play in rack end ball joint In either case if found defective replace ON VEHICLE SERVICE LUBRICATION When inner parts of the steering gear case were disas sembled they should be w...

Page 96: ...oil seal lip 8 Pinion bearing plug Fill SUZUKI SUPER GREASE E 99000 25050 to inside of pinion bearing 9 O ring 10 Steering pinion needle bearing 11 Rack damper screw Apply SUZUKI BOND No 1207C 99000 3...

Page 97: ...ve steering shaft lower joint bolt 2 3 Remove steering lower joint from steering pinion 4 Hoist vehicle and remove wheels 5 Disconnect both tie rod ends 1 from knuckles 2 using puller 2 1 6 Remove ste...

Page 98: ...tie rod thread 1 3 Loosen tie rod end lock nut and remove tie rod end 4 Remove boot wire 1 and clip 2 2 1 5 Remove boot from tie rod 6 Unbend bent part of tie rod lock washer 1 and remove tie rod 2 fr...

Page 99: ...eparate pinion assembly 1 from housing 1 2 10 Remove pinion assembly 11 Remove rack from gear case 1 Direction for rack removal is as shown CAUTION Inside of steering rack bushing is coated with speci...

Page 100: ...ull out pinion bearing 1 from gear case with special tools Special Tools A 09921 20200 B 09930 30102 A B 1 13 Remove oil seal 1 with special tool Special Tool A 09913 50121 A 1 3B 8 MANUAL RACK AND PI...

Page 101: ...il seal 1 for damage Inspect gear case O ring 2 for damage Replace any part found defective Steering Pinion Bearing Check rotation condition of bearing and inspect for wear If found defective replace...

Page 102: ...aring into gear case with special tool After press fitting make sure that bearing rollers are installed properly Special Tool B 09943 88211 B Apply grease to entire teeth surface of rack and its perip...

Page 103: ...25050 Install rack plunger 3 rack plunger spring 2 and rack damper screw 1 and adjust rotation torque of pinion as follows i Tighten rack damper screw 1 to specified torque Tightening Torque a 12 N m...

Page 104: ...housing 1 make sure that rack side mount 2 is positioned as shown a 0 9 1 9 mm 0 04 0 07 in a Position boot properly in grooves of gear case and tie rod and clamp it with wire 1 and clip 2 Wire 1 sho...

Page 105: ...or installation reverse removal procedure observing following instructions Tighten gear case mounting bolts 1 to specified torque Tightening Torque a 25 N m 2 5 kg m 18 0 lb ft 1 a Install pipe gasket...

Page 106: ...E Removed split pin 4 should be replaced with new one 2 1 4 3 a Tighten tie rod end lock nut 1 to specified torque Tightening Torque a 45 N m 4 5 kg m 32 5 lb ft 1 a Tighten wheel nut 1 to specified t...

Page 107: ...ERIALS 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 plunge...

Page 108: ...battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CONTENTS GENERAL DESCRIPTION 3B1 2 Components 3B1 2 Wiring diagram 3B1 3 DIAGNOSIS 3B1 4 On bo...

Page 109: ...the vehicle speed runs the motor so as to assist operation of the steering wheel P S control module diagnoses troubles which may occur in the area including the following components when the ignition...

Page 110: ...upler 9 Diagnosis output terminal for P S system 10 Ground terminal 11 P S control module 12 P S control module body ground 13 Motor and clutch 14 Torque sensor 15 Connector A 16 Connector B 17 Connec...

Page 111: ...ion indicator lamp which alert the driver to the occurrence of the trouble The trouble area is shown as Diag nostic Trouble Code DTC and it can be read using analog type voltmeter For detail refer to...

Page 112: ...left during test driving See WARNING 1 Check if any trouble symptom exists 2 Inspect and repair basic parts referring to DIAGNOSIS CHART in SECTION 3 3 If the trouble cannot be repaired in Step 3 2 i...

Page 113: ...rmittent times a day a month other________________ Conditions for Occurrence of Problem Vehicle at stop ignition switch ON When starting at initial start only at every start Other_______________ Vehic...

Page 114: ...osition and disconnect voltmeter probes from monitor coupler 2 3 4 1 DTC CLEARANCE 1 Remove glove box 2 Turn ignition switch to ON position 3 Using service wire short diagnosis output terminal 1 to gr...

Page 115: ...DTC 21 is set High Low TIME sec DTC VOLTMETER DEFLECTION PATTERN DIAGNOSTIC ITEM DIAGNOSIS 12 Normal This code appears when none of the other codes are identified 11 13 14 Torque sensor 15 16 21 23 V...

Page 116: ...2 C3 C4 C5 W Y B Bl R 7 8 STEP ACTION YES NO 1 Was SYSTEM CHECK FLOW TABLE performed Go to STEP 2 Go to SYSTEM CHECK FLOW TABLE in this section 2 Is DTC 14 or 16 indicated too Go to flow table corre s...

Page 117: ...column hole cover 2 Check proper connection for 5 pin C connec tor to P S control module 3 If OK turn ignition switch ON 4 Check voltage between C4 BI wire terminal of 5 pin C connector and body grou...

Page 118: ...g column hole cover 2 Check proper connection for 5 pin C connec tor to P S control module 3 If OK turn ignition switch ON 4 Measure voltage between C5 R wire terminal of 5 pin C connector and body gr...

Page 119: ...ing column lower cover 3 Disconnect 8 pin A connector from P S control module 4 Check proper connection to P S control module at terminal A4 V wire 5 If OK connect voltmeter between A4 V wire terminal...

Page 120: ...ck DTC with engine running Is DTC 22 indicated Go to STEP 3 It is nothing abnormal for DTC 22 System is in normal condition 3 1 Check proper connection to P S control module and ECM at each Br wire te...

Page 121: ...on for 4 pin B connector to P S control module 3 If OK start engine 4 Check voltage between B1 terminal and body ground and B2 terminal and body ground with B connector connected to P S control module...

Page 122: ...and body ground with B connector connected to P S control module Is it 0 V Go to STEP 3 Repair poor connec tion high resistance open or short to power circuit or ground in B3 circuit 3 1 Check voltag...

Page 123: ...ove steering column lower cover 2 Check P S fuse and proper connection to P S control module at A2 B R wire terminal 3 If OK check voltage between A2 terminal and body ground with A connector connecte...

Page 124: ...from it Voltage Check 1 Remove steering column lower cover with ignition switch OFF position 2 Check voltage at each terminal with couplers 2 connected P S control module Each voltage should be as sp...

Page 125: ...position for vehicle to run straight B2 Motor output 1 5 7V Engine idling and steering wheel held at position for vehicle to run straight B3 Clutch output 2 0V B4 Clutch output 1 10 14V Engine idling...

Page 126: ...USE INSPECTION Steering wheel feels heavy Perform IN SPECTION OF STEERING FORCE on next page before diagnosis Steering wheel installed improperly twisted Poor performance of torque sensor Poor perform...

Page 127: ...cification inspect as follows and replace if found defective Tie rod end ball stud for wear Lower ball joint for wear Steering shaft joint for wear Steering pinion or rack gear for wear or breakage Ea...

Page 128: ...SPECTION 1 Remove steering column hole cover 2 Turn ignition switch to ON position 3 Check voltage between terminals of torque sensor connector with connecting it to P S control module and not running...

Page 129: ...terminal of motor and clutch coupler and body ground If check result is not as specified above replace steering col umn assembly B3 B4 B1 B2 1 STEERING COLUMN ASSEMBLY Refer to STEERING WHEEL AND COLU...

Page 130: ...replaced use the correct part number fastener for that ap plication If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fasteners that a...

Page 131: ...tion The driver air bag inflator module is one of the supplemental restraint air bag system components and is mounted to the center of the steering wheel During certain frontal crashes the air bag sys...

Page 132: ...er to DISPOSAL under SERVICE PRECAUTIONS in SECTION 10B STEERING WHEEL AND COLUMN 3C 3 DIAGNOSIS For maintenance service of the steering wheel and column refer to SECTION 0B For diagnosis of the steer...

Page 133: ...ir bag inflator module 3 from steering wheel 5 Disconnect yellow connector 1 of driver air bag inflator mod ule and horn connector 2 in order a d shown in the figure 1 d a d b c INSPECTION WARNING Nev...

Page 134: ...6 5 lb ft 6 Connect negative cable at battery 7 Enable air bag system Refer to ENABLING AIR BAG SYSTEM under SERVICE PRECAUTIONS in SECTION 10B 1 a 1 a STEERING WHEEL REMOVAL 1 For vehicle without ai...

Page 135: ...steering shaft nut 3 Make alignment marks 1 on steering wheel and shaft for a guide during reinstallation 1 4 Remove steering wheel 1 with special tool Special Tool A 09944 36011 CAUTION Do not hamme...

Page 136: ...re prerequisite for installation of steering wheel If steering wheel has been installed without these conditions contact coil will break when steering wheel is turned For vehicle without air bag syste...

Page 137: ...t coil became unable to turn any further it stopped turn it back clockwise about two and a half rotations and align center mark 1 with alignment mark 1 COMBINATION SWITCH FOR VEHICLE WITHOUT AIR BAG S...

Page 138: ...ag system disconnect connector from air bag harness 8 Disconnect horn connector from instrument panel harness 9 Remove combination switch contact coil and combination switch assembly 3 from steering c...

Page 139: ...2 and lower cover 3 and then tighten steering column cover screws 1 3 2 1 1 Standard screw Tapping screw CAUTION When installing lower cover 3 and upper cover 2 be careful so that combination switch c...

Page 140: ...e with air bag system Disable air bag system Refer to DISABLING AIR BAG SYS TEM under SERVICE PRECAUTIONS in SECTION 10B 3 If it is necessary to remove steering wheel and or combination switch assembl...

Page 141: ...screw g Disconnect connectors 1 from combination switch 2 h If equipped with air bag system disconnect connector from air bag harness i Disconnect horn connectors from instrument panel harness 2 4 Di...

Page 142: ...column as sembly into steering column and shaft If column or shaft is defective replace as an assembly A C C B INSPECTION NOTE Vehicles involved in accidents resulting in body damage where steering co...

Page 143: ...r shaft 1 A B 2 1 3 Install steering column and tighten steering column mounting nuts A B C by hand 4 Connect all connectors disconnected in REMOVAL Ignition switch Combination switch P S control modu...

Page 144: ...ightening Torque b 25 N m 2 5 kg m 18 0 lb ft 9 Install steering joint cover 1 A a C a C a B a 2 1 3 2 10 Install steering column hole cover 1 11 If steering wheel is removed install steering wheel Re...

Page 145: ...haft 2 in the center of hole 3 in column 4 2 Turn ignition key to ACC or ON position and install steering lock assembly 5 onto column 4 3 Now turn ignition key to LOCK position and pull it out 4 Align...

Page 146: ...tch have got out of its centered position it needs to be centered again Also turning steering wheel more than about two and a half turns will break contact coil 4 5 1 4 2 3 6 6 INSTALLATION 1 Be sure...

Page 147: ...or break age If anything is found faulty replace as steering column assembly 1 1 2 3 Take measurement a b as shown If it is shorter than specified length replace column assembly with new one Length a...

Page 148: ...AL TOOL 09944 36011 Steering wheel remover STEERING WHEEL AND COLUMN 3C 19 REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Grease SUZUKI GREASE CE T 99000 25290 To apply to contact p...

Page 149: ...ck 3D 5 Front Suspension Fasteners Check 3D 5 Wheel Disc Nut And Bearing Check 3D 5 ON VEHICLE SERVICE 3D 7 Strut Assembly 3D 7 Stabilizer Bar and or Bushing 3D 10 Wheel Hub and Steering Knuckle 3D 12...

Page 150: ...2 Stabilizer bar 3 Steering knuckle 5 Suspension control arm 8 Tie rod 9 Brake disc 2 9 3 5 8 3D 2 FRONT SUSPENSION...

Page 151: ...6 1 Strut assembly 4 Wheel 5 Suspension control arm 6 Vehicle body 7 Drive shaft 8 Tie rod 9 Brake disc 1 4 8 7 5 9 FRONT SUSPENSION 3D 3...

Page 152: ...esistance both when pushed and rebounding Also note how many times vehicle body rebounces before com ing to stop after hands are off Do the same for strut on the other side Compare strut resistance an...

Page 153: ...and nut fastening suspension parts for tighteness Tighten loose one if any to specified torque referring to P 3D 7 WHEEL DISC NUT AND BEARING CHECK Inspect each wheel disc for dents distortion and cra...

Page 154: ...By rotating wheel actually check wheel bearing for noise and smooth rotation If defective replace bearing 3D 6 FRONT SUSPENSION...

Page 155: ...t bolts 2 FRONT SUSPENSION 3D 7 9 23 N m 2 3 kg m ON VEHICLE SERVICE STRUT ASSEMBLY 7 6 5 4 3 2 1 1 Strut assembly 2 Coil spring 3 Bump stopper 4 Coil spring seat 5 Coil spring upper seat 6 Strut bear...

Page 156: ...spring seat is released WARNING Use a commercially available spring compressor and follow the operation procedure described in the Instruction Manual supplied with that spring com pressor 2 Remove str...

Page 157: ...N m 5 0 kg m 36 5 lb ft a A B C INSTALLATION 1 Install strut assembly by reversing REMOVAL Steps 1 6 In sert bolts in such direction as shown 2 Tighten all fasteners to specified torque Tightening To...

Page 158: ...N m 6 8 kg m 7 45 N m 4 5 kg m 6 68 N m 6 8 kg m Tightening Torque Do not reuse REMOVAL 1 Remove stabilizer bar nut 1 and washer 2 1 2 CAUTION Never reuse stabilizer bar nut 1 2 Remove stabilizer bar...

Page 159: ...Install sta bilizer bar mount bracket to outside of stabilizer bar at that mark 1 Install mount bracket 1 so that its oblong hole side 2 comes to the rear Tighten stabilizer bar mounting bracket bolt...

Page 160: ...ake pedal and hold it there Remove drive shaft nut 1 4 Remove caliper carrier bolts CAUTION Never reuse drive shaft nut 1 5 Remove caliper 1 with carrier NOTE Hang removed caliper with a wire hook or...

Page 161: ...all joint bolt 1 11 Remove strut bracket bolts from strut bracket and then steer ing knuckle 2 1 DISASSEMBLY 1 Uncaulk and remove dust cover 1 2 Remove circlip 3 Using hydraulic press 1 and special to...

Page 162: ...e to use a new bolt for replacement ASSEMBL Y 1 Press fit wheel bearing 1 by using special tool Special Tool A 09913 75520 A 1 2 Install circlip 1 1 3 Drive in dust cover so that dimensions a and b be...

Page 163: ...2 and then install steering knuckle Special Tool A 09913 70122 A 2 1 Tighten suspension arm ball joint bolt 1 to specified torque Tightening Torque a 60 N m 6 0 kg m 43 5 lb ft Tighten strut bracket n...

Page 164: ...torque Tightening Torque a 175 N m 17 5 kg m 127 0 lb ft Caulk drive shaft nut 1 as shown CAUTION Be careful while caulking nut so that no crack will oc cur in caulked part of nut Cracked nut must be...

Page 165: ...collar of bushing 1 as shown 2 Set collar cut section to special tool and remove bushing Special Tool A 09943 77910 ASSEMBLY Press fit bushing by using special tool and press Special Tool A 09943 779...

Page 166: ...joint bolt 1 from the direction as shown Tightening Torque a 60 N m 6 0 kg m 43 5 lb ft 1 a 3 Install wheel and tighten wheel nuts to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft a...

Page 167: ...hing remover 09943 17912 Front wheel hub remover 09942 15510 Sliding hammer 09913 75520 Bearing installer 09913 75810 Bearing installer 09945 26010 Socket wrench 17 mm 1 2 FRONT SUSPENSION 3D 19 REQUI...

Page 168: ...re proper retention of this part 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...

Page 169: ...Rear bump 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 63 N m 6 3 kg m 85 N m 8 5 kg m 17...

Page 170: ...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...

Page 171: ...spect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced Check wheel nuts for tightness and as necessary retigten to specification Tightening Torque a 8...

Page 172: ...for proper installing direction of nuts 4 bolt 5 and washer 6 Tighten nuts temporaliry at this step 5 3 4 1 6 2 FORWARD 1 Rear axle side Body side 2 Lower hoist 3 Tighten lateral rod nuts 1 to specif...

Page 173: ...is step 2 Remove floor jack from rear axle 1 and lower hoist 3 Tighten nuts to specified torque Tightening Torque a 63 N m 6 3 kg m 46 0 lb ft b 25 N m 2 5 kg m 18 5 lb ft Inside 4 3 4 a 1 2 b 5 COIL...

Page 174: ...d large pitch end with paint marking down and make sure that spring end contact to stepped part 2 of spring seat 3 as shown LARGE SMALL Upper side 1 3 2 2 Install shock absorber 1 lower side to rear a...

Page 175: ...fied torque Tightening Torque a 25 N m 2 5 kg m 18 5 lb ft b 65 N m 6 5 kg m 47 0 lb ft 1 a 2 b BUMP STOPPER REMOVAL 1 Hoist vehicle and remove rear wheel 2 Remove bump stopper using flat tip screwdri...

Page 176: ...e at left 2 Install coil spring For details refer to COIL SPRING INSTALLA TION in this section Vehicle body side TRAILING ARM REMOVAL 1 Hoist vehicle and remove rear wheel 2 Support rear axle 1 using...

Page 177: ...emove trailing arm 2 2 1 INSTALLATION 1 Install trailing arm 1 to vehicle body and rear axle referring to figure for proper installing direction of bolts 2 Tighten front nut 3 center nut 4 and rear nu...

Page 178: ...ng Torque for wheel nuts a 85 N m 8 5 kg m 61 5 lb ft 7 Lower hoist Be sure that vehicle is off hoist and in non loaded condition FORWARD 2 3 2 8 Tighten front center and rear trailing arm nuts 1 shoc...

Page 179: ...hose 2 CAUTION Do not allow brake fluid to get on painted surfaces 2 1 5 Disconnect brake pipe flare nuts 1 from wheel cylinders 2 right left and put bleeder plug cap 3 onto brake pipe 4 to prevent f...

Page 180: ...ar trailing arm nut 2 from trailing arm but don t remove bolts right left 2 1 14 While supporting rear axle at both ends right left remove center and rear trailing arm bolts right left and then remove...

Page 181: ...ct to stepped part 2 of lower seat 3 as shown in left figure SMALL LARGE Upper side 1 3 2 1 4 Install shock absorber 1 lower sides right left to rear axle Tighten shock absorber lower nuts 2 temporali...

Page 182: ...d bleed brake system For bleeding operation see SECTION 5 in this manual 2 1 12 Install wheel and tighten wheel nuts 1 to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 1 a 13 Upon co...

Page 183: ...to ensure that brake drum is free from dragging and proper braking is obtained 18 Perform brake test foot brake and parking brake 2 b 1 a 3 c WHEEL BEARING AND WHEEL STUD REMOVAL 1 Remove rear brake...

Page 184: ...e by replaced bolt 2 Press fit wheel bearing 1 with it s seal side facing back plate side using special tools and hydraulic press Special Tool A 09951 76010 B 09924 84510 004 A 1 B 1 Wheel bearing 3 I...

Page 185: ...Brake reservoir tank Water tight sealant SEALING COMPOUND 366E 99000 31090 Join seam of rear axle and brake back plate SPECIAL TOOLS 09913 76010 Rear wheel bearing installer 09942 15510 Sliding hamme...

Page 186: ...ce 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 balancin...

Page 187: ...r leak through welds have elongated bolt holes if lug nuts won t stay tight or if they are heavily rusted Wheels with greater runout than shown in figure below may cause objectional vibrations Replace...

Page 188: ...at the assembly plant This means that the radially stiffest part of the tire or high spot is matched to the smallest radius or low spot of the wheel This is done to provide the smoothest possible rid...

Page 189: ...o 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 th...

Page 190: ...surface and brake disc mounting surface by scraping and wire brushing Installing wheels without good metal to metal contact at mounting surfaces can cause wheel nuts to loosen which can later allow a...

Page 191: ...not 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 BALA...

Page 192: ...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 manufactu...

Page 193: ...4A 1 SECTION 4A FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION 4A 2 Component 4A 2 DIAGNOSIS 4A 3 Diagnosis table 4A 3 ON VEHICLE SERVICE 4A 4 Drive shaft assembly 4A 4 REQUIRED SERVICE MATERIALS 4A 1...

Page 194: ...RH Constant velocity ball joint 2 Boot 3 Drive shaft RH 4 Boot 5 Differential side joint RH Constant velocity tripod joint 6 Differential side joint LH Constant velocity DOJ 7 Boot 8 Drive shaft LH 9...

Page 195: ...spect drive shaft boot for tear If even a small tear is noted replace with new one FRONT DRIVE SHAFT 4A 3 DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction Abnormal Noise Worn or breakage...

Page 196: ...3 2 4 6 Drain transmission fluid 7 By using large size lever 1 pull out drive shaft joint 2 so as to release snap ring fitting of joint spline at differential side 1 2 8 Disconnect front suspension co...

Page 197: ...ing de greased do not wash it if it is to be reused 3 Remove boot band then pull out differential side boot from shaft 4 Undo band of dynamic damper then pull out damper through shaft 5 Undo boot band...

Page 198: ...ix cage by using special tool A Special Tool A 09900 06107 4 Draw away cage 1 by using bearing puller 2 and remove boot 3 from shaft NOTE Do not disassemble wheel side joint outboard joint If any malc...

Page 199: ...1 Wash disassembled parts except boots After washing dry parts completely by blowing air 2 Clean boots with cloth DO NOT wash boots in degreaser such as gasoline or kerosene etc Washing in degreser c...

Page 200: ...by washing solu tion do not wash joint boots and tripod joint ex cept its housing Degreasing of those parts with cloth is allowed To ensure full performance of joint as designed be sure to distinguis...

Page 201: ...ll wheel side boot 1 on shaft fill up boot inside with grease and then fasten boot 2 with band 5 Driver in the cage 1 by using a pipe 2 whose inner diameter is 23 mm 0 906 in or more and outer diamete...

Page 202: ...2 6 41 in A T vehicle CAUTION To prevent any problem caused by washing solu tion do not wash joint boots Degreasing of those parts with cloth is allowed To ensure full performance of joint as designed...

Page 203: ...lling drive shaft Do not hit joint boot with hammer 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...

Page 204: ...MMENDED SUZUKI PRODUCT USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips Sealant SUZUKI BOND NO 1215 99000 31110 Oil drain and filler plug for manual transmission SPECIAL TOOLS 09913...

Page 205: ...dal Free Height Adjustment 5 5 Brake Pedal Play Inspection 5 5 Stop Light Switch Adjustment 5 5 Excessive Pedal Travel Check 5 5 Front Brake Pad Inspection 5 6 Brake Disc Inspection 5 6 Parking Brake...

Page 206: ...UBSTANDARD OR CONTAMINATED BRAKE FLUID Improper brake fluid mineral oil or water in the fluid may cause the brake fluid to boil or the rubber compo nents in the hydraulic system to deteriorate If prim...

Page 207: ...ctioning 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 approxi...

Page 208: ...spindle Check per instructions If not within speci fications replace or machine disc Check per instructions If not within speci fications replace or machine disc Check runout Repair or replace drum as...

Page 209: ...that clearance between end of thread and brake pedal is as specified Then adjust stop light switch assembly position and lock it by turning clockwise Clearance a 0 5 1 5 mm 0 02 0 06 in a EXCESSIVE P...

Page 210: ...USTMENT INSPECTION Hold center or parking brake lever grip and pull it up with 20 to 25 kg 44 to 55f lbs force With parking brake lever pulled up as above count ratchet notches in A as shown in figure...

Page 211: ...adjustment 1 2 INSPECT BOOSTER OPERATION There are two ways to perform this inspection with and without a tester Ordinarily it is possible to roughly determine its condition without using a tester NO...

Page 212: ...the same load and make sure that pedal travel doesn t change 2 Start engine while depressing brake pedal If pedal travel in creases a little operation is satisfactory But no change in pedal travel in...

Page 213: ...for leak age Correct leaky points and then refill to specified level CAUTION Do not use shock absorber fluid or any other fluid which contains mineral oil Do not use a container which has been used f...

Page 214: ...er 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 an...

Page 215: ...kg m 6 5 lb ft Rear 8 0 N m 0 8 kg m 6 0 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 reser...

Page 216: ...ke pedal with brake pads removed 4 Remove brake pads 3 2 5 12 BRAKES FRONT BRAKE 1 Brake caliper carrier 2 Boot 3 Caliper 4 Disc brake piston 5 Piston seal Apply fluid Brake power steering or automati...

Page 217: ...r hard particles of sandpaper will be deposited in lining and may damage disc When pad lin ing requires correction replace it with a new one INSTALLATION 1 Set brake pad springs 1 and shim 2 and insta...

Page 218: ...caliper pin bolt and remove caliper from caliper carrier DISASSEMBLY 1 Remove piston with air blown into flexible hose bolt installation hole CAUTION Clean around caliper with brake fluid before disa...

Page 219: ...everse order of disassembly observing follow ing instructions CAUTION Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir Never use other fluid or...

Page 220: ...ittle but do not take it all out Insert piston into 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 k...

Page 221: ...ake flex ible hose and not to depress brake pedal 4 Pull brake disc off by using 8 mm bolts 1 2 pcs INSPECTION Using micrometer measure thickness of brake disc Brake disc thickness Standard 17 0 mm 0...

Page 222: ...ing caliper carrier bolts to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 4 Tighten wheel nuts temporarilly and lower lift 5 Tighten front wheel nuts to specified torque Tightening...

Page 223: ...return upper spring 6 Shoe hold down pin 7 Brake strut 8 Wheel cylinder Apply brake fluid to piston cup 9 Bleeder plug 10 Bleeder pug cap 11 Parking lever spring 12 Parking brake shoe lever 13 Brake D...

Page 224: ...tap it lightly at about 3 locations using care not to damage seat face of cap 3 Uncalk spindle nut remove spindle nut 4 Release parking brake lever 1 to cancel rear brake 5 Loosen adjusting nut 3 for...

Page 225: ...in Limit 2 6 mm 0 10 in a 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 qui...

Page 226: ...ft 8 Upon completion of all jobs depress brake pedal with about 20 30 kg load three to five times so as to obtain proper drum to shoe clearance Adjust parking brake cable 9 Check to make sure that br...

Page 227: ...e lever 2 along shoe rim CAUTION Use a new push nut 1 INSTALLATION Install parts in reverse order of removal Install shoe hold down springs 2 by pushing them down in place and turning hold down pins 1...

Page 228: ...back plate 2 to specified torque Tightening Torque a 10 N m 1 0 kg m 7 5 lb ft 3 Tighten flare nut 3 of brake pipe to specified torque Tightening Torque b 16 N m 1 6 kg m 11 5 lb ft 4 Install bleeder...

Page 229: ...L 1 Remove brake drum refer to BRAKE DRUM REMOVAL 2 Remove brake shoe refer to BRAKE SHOE REMOVAL 3 Remove wheel cylinder refer to WHEEL CYLINDER RE MOVAL 4 Remove parking brake cable securing clip 1...

Page 230: ...ke pipe flare nut to specified torque Refer to WHEEL CYL INDER INSTALLATION of this section 5 For procedure hereafter refer to WHEEL CYLINDER INSTAL LATION of this section 1 3 2 1 1 3 5 26 BRAKES MAST...

Page 231: ...N m 1 3 kg m 7 RH steering vehicle Tightening Torque Do not reuse 2 1 14 N m 1 4 kg m 13 12 11 10 14 8 6 5 9 7 Secondary piston Apply brake fluid to contact surface of cup 8 Sleeve cup Confirm instal...

Page 232: ...X line 5 Perform air bleeding referring to AIR BLEEDING OF BRAKE SYSTEM and check for fluid leakage A Special Tool A 09922 89810 1 3 2 1 MASTER CYLINDER ASSEMBLY REMOVAL 1 Clean outside of master cyli...

Page 233: ...pect all disassembled parts for wear or damage and replace parts if necessary NOTE Wash disassembled parts with brake fluid Do not reuse piston assembly Inspect master cylinder bore for scoring or cor...

Page 234: ...cap 1 push it in as far as groove in cylinder 2 and check that claw of stopper cap is caught in cylinder groove securely Be sure to use a new stopper cap RH steering vehicle 1 Apply brake fluid to ins...

Page 235: ...p O ring is the same as that of smaller one of cap O ring 2 3 1 6 Install sleeve assembly with aligning protrusion 1 of sleeve and dent 2 of cylinder body 1 2 7 Install cup 1 and washer 2 such a direc...

Page 236: ...STEERING VE HICLE 1 Install radiator cap test with special tool to master cylinder port 1 Special Tool A 09952 46010 2 Apply air and confirm that pressure is not applied A 1 3 Set master cylinder on v...

Page 237: ...After installation bleed air from system Refer to AIR BLEED ING OF BRAKE SYSTEM 6 Perform brake test and check each installed part for fluid leak age b b a a b c b d 2 1 BRAKE BOOSTER REMOVAL 1 Remov...

Page 238: ...Connect brake pipes and tighten flare nuts to specified torque Tightening torque for brake flare nut 16 N m 1 6 kg m 11 5 lb ft 5 Install intake minifold LH steering vehicle 6 Connect reservoir lead w...

Page 239: ...rovide specified clearance a between piston rod 1 end and master cylinder pis ton 2 Before measuring clearance push piston rod several times so as to make sure reaction disc is in place Keep inside of...

Page 240: ...sn t contact any part of suspension both in extreme right and extreme left turn conditions If it does at any point remove and correct Fill and maintain brake fluid level in reser voir Bleed brake syst...

Page 241: ...N FOR INSTALLATION Never reuse protector nut once removed Be sure to use a new one Install clamps properly referring to figure below and tighten bolts When installing hose make sure that it has no twi...

Page 242: ...on adjust cable Refer to PARKING BRAKE INSPECTION AND ADJUSTMENT of this section Then check brake drum for dragging and brake system for proper performance After removing vehicle from hoist brake test...

Page 243: ...N m 1 3 kg m 4 b 2 5 1 6 Tightening Torque REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Brake fluid Indicated on reservoir tank cap or described in owner s manual of vehicle DO...

Page 244: ...er 09942 15510 Sliding hammer 09943 17912 Brake drum remover Front wheel hup remover 09952 16020 Booster piston rod adjuster 09900 20606 Dial gauge 09900 20701 Magnetic stand 09951 18220 Secondary cup...

Page 245: ...ssure relief procedure 6 4 Fuel leakage check procedure 6 4 ENGINE DIAGNOSIS 6 5 On board diagnostic system 6 5 Precaution in diagnosing troubles 6 5 Engine diagnostic flow table 6 6 Engine diagnosis...

Page 246: ...ng 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 batter...

Page 247: ...s 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 v...

Page 248: ...fuel pressure in lines Fuel system line is now safe for servicing 5 Upon completion of servicing install fuel pump relay 1 to fuse relay box 2 CAUTION This work must not be done when engine is hot If...

Page 249: ...ion control system which controls A F mixture ignition timing emission etc suitably to engine conditions by ECM PCM ECM PCM has an On Board Diagnostic system which detects a malfunction in this system...

Page 250: ...tion 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 Reche...

Page 251: ...pplied A C Electric load P S Other Other OTHERS VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather Temperature Frequency Road Fair Cloudy Rain Snow Always Other Hot Wa...

Page 252: ...Engine coolant level leakage Fuel level leakage A T fluid level leakage Air cleaner element dirt clogging Battery electrolyte level corrosion of terminal Water pump belt and or cooling fan belt tensio...

Page 253: ...5 Go to Step 7 5 Check engine idle speed IAC duty referring to B 5 IAC SYSTEM CHECK in SECTION 6E1 Is check result as specified Go to Step 6 Go to ENGINE DIAGNOSIS TABLE in this section 6 Check ignit...

Page 254: ...rm that no malfunction DTC a normal code is indicated ENGINE DIAGNOSIS TABLE Condition Possible Cause Reference Item Hard starting Engine cranks OK Engine and emission control system out of order Faul...

Page 255: ...roper engine idling or engine fails to idle Ignition system out of order Faulty spark plug Leaky or disconnected high tension cord Worn distributor terminals Cracked cap in distributor with leakage in...

Page 256: ...le Diag Flow Table B 5 in SECTION 6E1 Fuel injector in SECTION 6E1 TP sensor ECT sensor or MAP sensor in SECTION 6E1 Inspection of ECM PCM and its circuit in SECTION 6E1 Previously outlined Surges Eng...

Page 257: ...formance Dragging brakes Slipping clutch Blown cylinder head gasket Faulty radiator fan control system Thermostat in SECTION 6B Water pump in SECTION 6B Radiator in SECTION 6B Engine oil and oil filte...

Page 258: ...chanical 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 sp...

Page 259: ...eck for absence of filler neck restrictor PCV 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 Idl...

Page 260: ...tarted at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the sys tem may be activated by reserve energy in...

Page 261: ...d with its D O H C Double Overhead Camshaft valve mechanism ar ranged for V type valve configuration and 16 valves IN 2 and EX 2 one cylinder Both overhead camshafts are mounted over the cylin der hea...

Page 262: ...ENGINE MECHANICAL 6A4 3...

Page 263: ...block drive wheels 3 Remove air cleaner assembly and resonator Refer to AIR CLEANER ASSEMBLY AND RESONATOR in this section 4 Remove all spark plugs 5 Disconnect RADIO DOME fuse 1 from fuse box WARNIN...

Page 264: ...ine at least 250 r min by using fully charged battery 9 Carry out steps 6 through 8 on each cylinder to obtain four readings 10 After checking connect ignition coil coupler securely and install spark...

Page 265: ...stopped disconnect pressure regulator vacuum hose from intake manifold and connect 3 way joint hoses and special tool vacuum gauge and joint between intake manifold and vacuum hose disconnected Speci...

Page 266: ...Section 9 and oil pressure switch 1 from cylinder block 1 2 Install special tool Oil pressure gauge to vacated threaded hole Special Tool A 09915 77310 B 09915 78211 3 Start engine and warm it up to n...

Page 267: ...h to speci fied torque NOTE If sealing tape edge is bulged out from screw threads of switch cut it off Tightening Torque a 12 N m 1 2 kg m 9 0 lb ft 2 a 1 7 Start engine and check oil pressure switch...

Page 268: ...es to be checked in this case and if not adjust it by turning crankshaft Check valve lashes 4 In the same manner as 2 3 check valve lashes at valves and 5 In the same manner as 2 3 again check valve l...

Page 269: ...shim to be installed A B C 0 20 mm A Thickness of new shim to be installed mm B Removed shim thickness mm C Valve clearance as measured mm 6 Select new shim from the following thickness and install i...

Page 270: ...valves reverse removal proce dure for installation 1 a AIR CLEANER ELEMENT REMOVAL 1 Open air cleaner case by unhooking its clamps 2 Remove air cleaner element from case INSPECT Check air cleaner ele...

Page 271: ...breather hose 3 from air cleaner assembly 1 3 Remove air cleaner assembly 1 resonator 2 and their hoses together by removing bolts and loosening clamps shown in fig ure 3 INSTALLATION Reverse removal...

Page 272: ...inder head cover gas ket 2 and O rings 3 1 2 3 INSTALLATION 1 Install O rings 2 and cylinder head cover gasket 1 to cylinder head cover 3 NOTE Be sure to check each of these parts for deterioration or...

Page 273: ...No 1 bracket 1 5 Connect breather hose and PCV valve hose then clamp them securely 6 Install cylinder head upper cover and air cleaner No 2 bracket 7 Install air cleaner assembly and resonator and cla...

Page 274: ...5 17 16 Tightening Torque Do not reuse REMOVAL 1 Relieve fuel pressure according to procedure described in p 6 4 2 Disconnect negative cable at battery 3 Drain cooling system WARNING To help avoid dan...

Page 275: ...ake surge tank Canister purge hose from purge valve Engine cooling water coolant hoses inlet and outlet from water inlet pipe and thermostat case PCV valve hose from intake surge tank A T vacuum hose...

Page 276: ...m 1 0 kg m 7 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft Check to ensure that all removed parts are back in place Rein stall any necessary parts which have not been reinstalled Adjust accelerator cable play...

Page 277: ...2 Oil pump strainer 3 Seal 4 Drain plug gasket 5 Drain plug 6 Oil pan bolt and nut 7 Strainer bolt 1 6 11 N m 1 1 kg m 5 50 N m 5 0 kg m 3 Tightening Torque REMOVAL 1 Drain engine oil 2 Remove clutch...

Page 278: ...CLEANING Clean mating surfaces of oil pan and cylinder block Remove oil old sealant and dusts from mating surfaces and oil pan inside Clean oil pump strainer screen ENGINE MECHANICAL 6A4 19...

Page 279: ...orque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft After fitting oil pan to cylinder block run in securing bolts and start tightening at the center move wrench outward tightening one bolt at a time T...

Page 280: ...eing burned do not service exhaust system while it is still hot Service should be performed after system cools down REMOVAL 1 Disconnect negative cable at battery 2 Remove front bumper refer to Sectio...

Page 281: ...fore installing pipe gasket check it for deterioration or dam age and replace as necessary Tighten pipe fasteners to specified torque Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft 4 Install exhaust m...

Page 282: ...ng Torque Do not reuse REMOVAL 1 Remove front bumper 2 Disconnect negative cable at battery 3 Remove water pump generator belt 1 and A C compressor drive belt 2 1 2 4 Remove crankshaft pulley 1 with c...

Page 283: ...A 09911 97010 A 2 Install crankshaft pulley Tighten bolt to specified torque Tightening Torque a 100 N m 10 0 kg m 72 5 lb ft 3 Install and adjust water pump generator belt referring to Sec tion 6H 4...

Page 284: ...lt 4 Oil seal 5 Timing chain cover bolt 6 mm 6 Timing chain cover bolt 8 mm 7 Center bolt 2 1 3 100 N m 10 0 kg m 5 11 N m 1 1 kg m Tightening Torque Do not reuse 7 REMOVAL 1 Drain coolant and engine...

Page 285: ...LINDER HEAD COVER in this section 7 Hold engine by using lifting device as shown in figure 8 Remove engien mounting 9 Remove generator adjusting arm 10 Remove bolts and then timing chain cover CLEAN C...

Page 286: ...Before installing timing chain cover check that pin is se curely fitted Use new center bolt Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft b 23 N m 2 3 kg m 16 5 lb ft 3 Install generator adjusting arm...

Page 287: ...n bolt to specified torque Tightening Torque a 100 N m 10 0 kg m 72 5 lb ft 9 Connect oil pressure switch connector 10 Perform steps 3 6 of CRANKSHAFT PULLEY AND OIL SEAL INSTALLATION for procedure he...

Page 288: ...oat of engine oil 3 Inner rotor Apply thin coat of engine oil 4 Timing chain cover Apply SUZUKI BOND No 1207C 99000 31150 to mating surfaces 5 Pin 6 Oil seal Apply thin coat of engine oil 7 Relief val...

Page 289: ...for excessive wear or damage MEASUREMENT Radial clearance Check radial clearance between outer rotor and case using thickness gauge If clearance exceeds its limit replace outer rotor or case Limit on...

Page 290: ...il seal lip portion and inside surfaces of oil pump case and plate 3 Install outer and inner rotors to pump case 4 Install rotor plate Tighten 7 screws securely After installing plate check to be sure...

Page 291: ...g m Tightening Torque 2 1 REMOVAL 1 Remove timing chain cover Refer to item TIMING CHAIN COVER in this section for remov al 2 Turn crankshaft until match marks 1 on camshaft timing sprockets are in ma...

Page 292: ...removed never turn intake cam shaft exhaust camshaft and crankshaft independent ly more than such an extent as shown If turned interference may occur between piston and valves and valves themselves a...

Page 293: ...ks on cylinder head 2 as shown in figure 2 Set key 3 and align it with timing mark on cylinder block 4 as shown in figure by turning crankshaft 4 CAUTION After timing chain is removed never turn intak...

Page 294: ...tall timing chain guide No 1 2 and timing chain tensioner 1 as shown in figure Tightening Torque a 9 N m 0 9 kg m 6 5 lb ft Apply engine oil to timing chain guide No 1 and timing chain tensioner a 2 1...

Page 295: ...rk on cylinder head 3 Key 4 Timing mark on cylinder block 4 11 Install timing chain cover Refer to item TIMING CHAIN COVER in this section for installation 12 Install cylinder head cover Refer to item...

Page 296: ...pan as previously outlined 2 Remove timing chain cover Refer to TIMING CHAIN COVER in this section 3 Remove timing chain Refer to TIMING CHAIN AND CHAIN TENSIONER in this section 4 Loosen camshaft hou...

Page 297: ...replacing housings Check clearance by using gaging plastic Checking procedure is as follows 1 Clean housings and camshaft journals 2 Remove all tappets with shims 3 Install camshafts to cylinder head...

Page 298: ...Replace camshaft or cylinder head assembly whichever the differ ence from specification is greater Wear of tappet and shim Check adjuster for pitting scratches or damage If any malcondition is found r...

Page 299: ...learance If clearance exceeds limit replace tappet or cylinder head 6A4 40 ENGINE MECHANICAL Item Standard Limit Tappet O D 26 959 26 975 mm 1 0614 1 0620 in Cylinder head bore 27 000 27 021 mm 1 0630...

Page 300: ...pply oil to sliding surface of each camshaft and camshaft jour nal then install them as shown in figure 3 Install camshaft housing pins 1 as shown in figure 1 4 Check position of camshaft housings Emb...

Page 301: ...at a time and evenly among bolts and repeat tightening sequence two or three times before they are tight ened to specified torque Tightening Torque 11 N m 1 1 kg m 8 0 lb ft 7 Install timing chain wit...

Page 302: ...an Refer to item OIL PAN AND OIL PUMP STRAINER in this sec tion for removal 3 Remove cylinder head cover Refer to item CYLINDER HEAD COVER in this section for re moval 4 Remove timing chain cover Refe...

Page 303: ...d valve spring 5 Remove valve from combustion chamber side 6 Remove valve stem oil seal 1 from valve guide and then valve spring seat 2 NOTE Do not reuse oil seal once disassembled Be sure to use new...

Page 304: ...emove all carbon from valves Inspect each valve for wear burn or distortion at its face and stem end as necessary replace it Measure thickness of valve head If measured thickness ex ceeds limit replac...

Page 305: ...l 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 fa...

Page 306: ...ce is the same as for ex haust valve seats But note that the first cutting angle is 30 for intake valve seat Seat width for intake valve seat 1 80 2 20 mm 0 0709 0 0866 in 3 VALVE LAPPING Lap valve on...

Page 307: ...off high spots Should this fail to reduce thickness gauge readings to within limit replace cylinder head Leakage of combustion gases from this gasketed joint is often due to warped gasketed surface s...

Page 308: ...of valve spring and square Valve springs found to exhibit a larger clearance than limit given below must be replaced Valve spring squareness limit 2 0 mm 0 079 in ENGINE MECHANICAL 6A4 49 Item Standa...

Page 309: ...h 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 11 mm 0 43 in from cylinder head Speci...

Page 310: ...ping 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 valv...

Page 311: ...side facing up toward cylinder head side 2 Check to make sure that oil jet venturi plug is installed and if it is that it is not clogged When installing it be sure to tighten to specified torque Tight...

Page 312: ...ue Tightening Torque 60 N m 6 0 kg m 43 5 lb ft 1 Camshaft pulley side 2 Distributor side 5 Install camshafts camshaft housings distributor timing chain tensioner tensioner link tensioner adjuster spr...

Page 313: ...m 3 3 kg m 7 8 6 5 4 3 2 1 REMOVAL 1 Remove cylinder head from cylinder block as previously out lined 2 Drain engine oil 3 Remove oil pan and oil pump strainer as previously outlined 4 Mark cylinder n...

Page 314: ...pression 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...

Page 315: ...ylinder bore dia limit 68 070 mm 2 6799 in Taper and out of round limit 0 10 mm 0 0039 in NOTE If any one of four cylinders has to be rebored rebore all four to the same next oversize This is necessar...

Page 316: ...ation replace piston Ring groove clearance Top ring 0 03 0 07 mm 0 0012 0 0027 in 2nd ring 0 02 0 06 mm 0 0008 0 0023 in Piston Pin Check piston pin connecting rod small end bore and piston bore for w...

Page 317: ...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...

Page 318: ...fective condition must be replaced 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 p...

Page 319: ...paint from crank pulley side represents inner diameter of No 1 cylinder the second paint of No 2 cylinder the third paint of No 3 cylinder and the fourth paint of No 4 cylinder c Stamped number on pi...

Page 320: ...kness 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 1 1st ring 2 2nd ri...

Page 321: ...to bore Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore Special Tool A 09916 77310 5 Install bearing cap 1 Point arrow mark on cap 2 to crankshaft...

Page 322: ...or are still hot Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon 4 Remove stabilizer bar Refer to Section 3D 5 Remove right hand stabilizer bracket 6 Re...

Page 323: ...Gear select cable 5 from transmission A T 12 Disconnect the following hoses Canister purge hose from EVAP canister purge valve 6 Brake booster hose from surge tank 7 Radiator outlet hose from inlet pi...

Page 324: ...1 Back up light switch M T 22 A C compressor switch 20 MAP sensor 6 Ground wire from cylinder block 13 ECT sensor 17 IAT sensor 3 TP sensor 4 and IAC valve wires at the coupler 5 Shift switch A T 10 H...

Page 325: ...age will be caused during removal and installation of en gine assembly 16 Install lifting device 17 Check to ensure all hoses electric wires and cables are dis connected from engine 18 Remove bolts i...

Page 326: ...m 70 N m 7 0 kg m Tightening Torque 2 Install engine assembly together with transmission to vehicle RR MTG RH MTG LH MTG M T A T 50 N m 5 0 kg m 50 N m 5 0 kg m 55 N m 5 5 kg m 55 N m 5 5 kg m Tighten...

Page 327: ...battery and it s tray 8 Install front bumper and engine hood Refer to Section 9 9 Install drive shafts Refer to Section 4A 10 Install right hand stabilizer bracket and stabilizer bar Refer to Section...

Page 328: ...haft Apply engine oil to crankshaft journals 4 Main bearing Apply engine oil to bearing inside surfaces 5 Thrust bearing Apply engine oil 6 Crankshaft timing sprocket key 7 Rear oil seal Apply engine...

Page 329: ...oner link timing chain and crank timing sprocket 7 Remove cylinder head assembly with intake manifold and ex haust manifold 8 Remove pistons and connecting rods 9 Loosen lower crankcase bolts in such...

Page 330: ...replace thrust bearing with new standard one or oversize one to obtain standard thrust play Out of round and taper uneven wear of journals An unevenly worn crankshaft journal shows up as a difference...

Page 331: ...lf Main bearing clearance Check clearance by using gaging plastic 1 according to following procedure 1 Remove lower crankcase 2 Clean bearings and main journals 3 Place a piece of gaging plastic to fu...

Page 332: ...by using following procedure As shown in the figure crank web 1 of No 2 cylinder has five stamped numerals Three kinds of numerals 1 2 and 3 represent following journal diameters The first second thi...

Page 333: ...ring cap bore diameter 3 There are five kinds of bearings differing in thickness To distin guish them they are painted in following colors at the position as indicated in figure Each color indicates f...

Page 334: ...to be installed by referring to numerals stamped on new crankshaft or numerals stamped on the inside of new lower crankcase 1 Gaging plastic 2 Scale Rear Oil Seal Carefully inspect oil seal 1 for wea...

Page 335: ...icrometer measure piston diameter 1 19 mm 0 75 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 02...

Page 336: ...t each part goes back to where it came from when installing 1 Install main bearings to cylinder block Upper half of bearing 2 has an oil groove 3 Install it to cylin der block 1 and the other half wit...

Page 337: ...to 58 N m 5 8 kg m 42 0 lb ft to 24 N m 2 4 kg m 17 5 lb ft NOTE After tightening lower crankcase bolts check to be sure that crankshaft rotates smoothly when turned by hand 10 1 10 1 20 11 11 20 6 I...

Page 338: ...usly outlined 11 Install oil pump strainer and oil pan as previously outlined 12 Install clutch to flywheel for M T vehicle For clutch installa tion refer to Section 7C CLUTCH section 13 Install trans...

Page 339: ...wrench 09915 67310 Vacuum gauge 09915 77310 Oil pressure gauge 09915 78211 Oil pressure gauge attachment 1 09916 14510 Valve lifter 2 09916 14910 Valve lifter attachment 09916 34542 Reamer handle 0991...

Page 340: ...08210 Vacuum gauge hose joint ENGINE MECHANICAL 6A4 81 REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Sealant SUZUKI BOND NO 1207C 99000 31150 Mating surfaces of cylinder block and...

Page 341: ...AINTENANCE 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 Cooli...

Page 342: ...stat closed Throttle body Heater unit A T oil cooler Water intake pipe 2 When coolant is warmed up to normal temperature and the thermostat opens coolant passes through the radia tor core to be cooled...

Page 343: ...n cooling system D Defective cooling fan motor D Faulty fan motor control circuit D Plugged radiator D Faulty radiator cap D Improper ignition timing D Dragging brakes D Slipping clutch Adjust or repl...

Page 344: ...t temperature lower than 36 C 33 F NOTE D 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 D Even in a ma...

Page 345: ...and are unnecessary expense D When installing reservoir cap align arrow marks on reser voir and cap WARNING To help avoid danger of being burned D do not remove reservoir tank cap while coolant is boi...

Page 346: ...press down while 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 u...

Page 347: ...r of cap lines is parallel to radiator 1 2 3 4 4 FULL LOW 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...

Page 348: ...olant 3 After draining coolant be sure to tighten drain plug securely 4 Fill cooling system Refer to Item COOLANT of MAINTE NANCE 1 COOLING WATER PIPES OR HOSES REMOVAL 1 Drain cooling system 2 To rem...

Page 349: ...deterioration or any other damage 1 2 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 tempe...

Page 350: ...2 and generator pivot bolts 3 When servicing car equipped with A C remove compressor drive belt before removing water pump belt 1 4 Slacken belt by displacing generator and then remove it INSTALLATION...

Page 351: ...radiator inlet and outlet hoses and reservoir tank hose from radiator 8 Disconnect radiator fan wire harness at connector 9 Detach receiver dryer 1 from radiator 1 10 Hang A C condenser with wire hoo...

Page 352: ...ferring to COOLANT item of MAINTENANCE D Refer to the figure at REMOVAL for tightening torque D After installation check each joint for leakage WATER PUMP e d a c Tightening Torque N m kg m lb ft a Wa...

Page 353: ...ssure switch 1 connector and remove clamp 8 Remove water pump assembly by removing 4 bolts INSPECTION NOTE Do not disassemble water pump If any repair is required on pump replace it as assembly 1 Rota...

Page 354: ...s nuts to specified torque 6 Install water pump belt refer to WATER PUMP BELT INSTAL LATION 7 Install A C compressor belt if equipped 8 Fill coolant 9 Install front bumper 10 Connect negative cable at...

Page 355: ...S could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at lea...

Page 356: ...1 0 7 5 b Fuel tank bolt 23 2 3 17 0 c Fuel filler hose clamp 1 5 0 15 1 0 6C 2 ENGINE FUEL GENERAL DESCRIPTION FUEL SYSTEM The main components of the fuel system are fuel tank fuel pump assembly with...

Page 357: ...reduce the chance of personal injury cover the fitting to be disconnected with a shop cloth Be sure to put that cloth in an ap proved container when disconnection is completed Note that fuel hose con...

Page 358: ...isconnect fuel pipe joint and fuel hose from fuel pipe at the front and rear of each fuel pipe For quick joint 2 disconnect it as follows a Remove mud dust and or foreign material between pipe 3 and j...

Page 359: ...er 1 to vehicle 5 With engine OFF and ignition switch ON check for fuel leaks CAUTION When connecting joint clean outside surfaces of pipe where joint is to be inserted push joint into pipe till joint...

Page 360: ...AUTION Never drain or store fuel in an open container due to possibility of fire or explosion 7 Disconnect fuel pipe joint and fuel hoses from pipes For quick joint disconnect it as follows a Remove m...

Page 361: ...is used for purging fuel tank 1 After removing fuel tank remove all hoses pipes fuel pump as sembly from fuel tank 2 Drain all remaining fuel from tank 3 Move tank to flushing area 4 Fill tank with w...

Page 362: ...ck 3 as shown in figure and clamp them securely Tightening Torque a 1 5 N m 0 15 kg m 1 0 lb ft a a 4 Connect fuel hose 1 fuel return hose 1 and vapor hose 2 to each pipe as shown in figure and clamp...

Page 363: ...4 from pipe unlock joint by inserting special tool between pipe and joint lock first Special Tool A 09919 47020 WARNING Refer to the WARNING at the beginning of ON VEHICLE SERVICE in this section A 4...

Page 364: ...level sensor securely CAUTION While removing fuel level gauge do not contact resis tor plate 1 or deform arm 2 It may cause fuel level gauge to fail When removing grommet from fuel tube or bracket su...

Page 365: ...de surface of pipe where joint is to be inserted push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely or fuel leak may occur 4 2 4 Install fuel tank 1 to v...

Page 366: ...c Module SDM CONTENTS GENERAL DESCRIPTION 6E1 3 System components 6E1 3 System flow chart 6E1 5 System wiring diagram 6E1 6 DIAGNOSIS 6E1 8 On board diagnostic system 6E1 8 Precaution in diagnosing tr...

Page 367: ...1 60 Air Intake System 6E1 61 Throttle body 6E1 61 IAC Valve 6E1 63 Fuel Delivery System 6E1 64 Fuel pressure inspection 6E1 64 Fuel cut operation 6E1 65 Fuel pump relay 6E1 65 Fuel pump 6E1 65 Fuel p...

Page 368: ...ator fuel injectors etc Electronic control system includes ECM PCM vari ous sensors and controlled devices Emission control system includes EGR EVAP and PCV systems SYSTEM COMPONENTS INFORMATION SENSO...

Page 369: ...4 Diagnostic monitor terminal 38 Combination meter 38 1 Malfunction indicator lamp CHECK ENGINE light 38 2 Speedometer 39 VSS in transmission 40 Ignition switch 41 Starter 42 Main fuse 1 Air cleaner 2...

Page 370: ...R HO2S IF EQUIPPED IAT SENSOR ECT SENSOR TP SENSOR MAP SENSOR CMP SENSOR ENGINE AND EMISSION CONTROL SYSTEM 6E1 5 SYSTEM FLOW CHART SIGNAL FROM SENSOR SWITCH AND CONTROL MODULE FUEL PUMP RELAY f f f F...

Page 371: ...F ECM PCM CONNECTOR VIEWED FROM HARNESS SIDE C13 C12 C11 C26 C25 C24 C10 C9 C8 C23 C22 C21 C7 C6 C5 C4 C3 C2 C1 A11 A2 A1 B8 B7 B6 B5 B4 B3 B2 B1 A10 A9 A8 A7 A6 A5 A4 A3 C20 C19 C18 C17 C16 C15 C14 B...

Page 372: ...nal ECT sensor A C evaporator temp sensor thermister Knock sensor TP sensor Heated oxygen sensor Map sensor CMP sensor CMP sensor Not used A C compressor magnet clutch Ground Not used IAT sensor Not u...

Page 373: ...while engine is running malfunction indica tor lamp CHECK ENGINE light turns OFF When ECM PCM detects a trouble which has occurred in the areas it monitors malfunction indicator lamp CHECK EN GINE li...

Page 374: ...2 With ignition switch at OFF position connect a jumper wire from diagnosis switch terminal 1 to ground terminal 2 in monitor connector 3 3 With ignition switch at ON position but engine not running r...

Page 375: ...ied time below to erase diagnostic trouble code stored in ECM PCM memory and reconnect it Time required to erase DTC 6E1 10 ENGINE AND EMISSION CONTROL SYSTEM Ambient temperature Time to cut power to...

Page 376: ...ed Go to DTC No 14 HEATED OXYGEN SENSOR CIRCUIT in this section 15 Camshaft position sensor Go to DTC No 15 CAMSHAFT POSI TION SENSOR CIRCUIT in this section 16 Vehicle speed sensor Go to DTC No 16 VE...

Page 377: ...OFF WIRING DIAGRAM 1 Ignition switch 2 Malfunction indicator lamp CHECK ENGINE light 3 Main relay 4 Fuse relay box 5 Monitor connector 6 ECM PCM 7 ECM PCM connector TERMINAL ARRANGEMENT OF ECM PCM CON...

Page 378: ...Go to Step 2 Go to ENGINE DIAG NOSIS FLOW TABLE in SECTION 6 2 Diagnosis switch terminal circuit check 1 Check for continuity from B9 terminal of ECM PCM connector to ground Is there continuity P B wi...

Page 379: ...2 Measure voltage from A2 terminal of ECM PCM connector to ground Is voltage within 10 14V Go to step 3 B W wire open or short 3 Main relay circuit check 1 With ignition switch at OFF position remove...

Page 380: ...l of ECM PCM connector to ground Is each voltage within 10 14V Go to Step 7 B R wire open 7 ECM PCM ground circuit check 1 Check for continuity from A13 terminal of ECM PCM connector to ground from C1...

Page 381: ...position disconnect MAP sensor connector 2 Turn ignition switch to ON position without run ning engine 3 Measure voltage from terminal c of MAP sen sor connector to ground Is voltage within 4 5V Go to...

Page 382: ...tep 6 6 1 Perform MAP SENSOR INSPECTION in this section Is voltage within specified value Poor connection of MAP sensor connector termi nal If OK substitute a known good ECM PCM and recheck Faulty MAP...

Page 383: ...TABLE in SECTION 6 Go to Step 2 Go to ENGINE DIAGNO SIS FLOW TABLE in SECTION 6 2 1 With ignition switch at OFF position discon nect TP sensor connector 2 Turn ignition switch to ON position without...

Page 384: ...TP sensor 5 1 Perform TP SENSOR INSPECTION in this section Is resistance within specified value Poor connection of TP sensor connector termi nal If OK substitute a known good ECM PCM and re check Faul...

Page 385: ...rminal connections are poor NOTE Before diagnosing trouble according to flow table given below check to make sure that the following system and parts other than electronic fuel injection system are in...

Page 386: ...ctors and oxygen sensor con nector 3 Check R and Or wires for open or short Are they in good condition Go to Step 4 Repair or replace 4 1 Substitute a known good oxygen sensor Refer to OXYGEN SENSOR R...

Page 387: ...in SECTION 6F1 Is resistance within specified value Go to Step 3 Faulty CMP sensor 3 1 With ignition switch at OFF position disconnect ECM PCM electrical connectors 3 Measure resistance from terminal...

Page 388: ...ENGINE AND EMISSION CONTROL SYSTEM 6E1 23 Blank...

Page 389: ...Did you perform ENGINE DIAGNOSIS FLOW TABLE in SECTION 6 Go to Step 2 Go to ENGINE DIAGNO SIS FLOW TABLE in SECTION 6 2 Does speedometer indicate vehicle speed V wire open or short Poor connection of...

Page 390: ...SECTION 8 3 Disconnect P S control module connector if equipped 4 Turn ignition switch to ON position without run ning engine 5 Measure voltage from terminal c of VSS con nector to ground Is voltage w...

Page 391: ...dy ground 3 Is it about 2 V Knock sensor and its circuit are in good condition Intermittent trouble or faulty ECM PCM Recheck referring to INTER MITTENT TROUBLE in SEC TION 0A Go to step 3 3 1 Stop en...

Page 392: ...ENGINE AND EMISSION CONTROL SYSTEM 6E1 27 Fig for Step 3 2 3 1...

Page 393: ...Turn ignition switch to ON position without running engine 3 Measure voltage from terminal b of IAT sensor connector to ground Is voltage within 4 5V Go to Step 3 Lg B wire open or short Poor connecti...

Page 394: ...SSION CONTROL SYSTEM 6E1 29 NOTE Upon completion of inspection and repair work perform DTC CONFIRMATION PROCEDURE in this sec tion and confirm that the trouble has been corrected Fig for Step 2 Fig fo...

Page 395: ...ctor 1 2 Turn ignition switch to ON position without run ning engine 3 Measure voltage from terminal c of ECT sen sor connector to ground Is voltage within 4 5V Go to Step 3 Lg wire open or short Poor...

Page 396: ...EMISSION CONTROL SYSTEM 6E1 31 NOTE Upon completion of inspection and repair work perform DTC CONFIRMATION PROCEDURE in this sec tion and confirm that the trouble has been corrected Fig for Step 2 Fig...

Page 397: ...ON position for 5 seconds or more 3 Check DTC Refer to DTC CHECK in this section DTC NO 14 1 Clear DTC Refer to DTC CLEARANCE in this section 2 Perform HO2S output signal check referring to Step 2 of...

Page 398: ...tch at OFF posi tion remove fuel pump relay fuse relay box 2 Using service wire connect be tween two terminals 3 Is fuel pump heard to operate when terminals are connected Go to step 3 P wire open poo...

Page 399: ...6E1 34 ENGINE AND EMISSION CONTROL SYSTEM Fig for Step 2...

Page 400: ...of 4 injectors make operating sound Go to step 4 Go to step 3 3 1 Check connector connection and wire harness of fuel injector not making operating sound and fuel injector itself 2 Are all above OK Su...

Page 401: ...ed for 1 minute after fuel pump is stopped in step 1 Go to step 3 Go to step 4 3 1 Start engine and warm it up to normal op erating temperature 2 Keep it running at specified idle speed 3 Is fuel pres...

Page 402: ...pressure regu lator Shortage of fuel or fuel pump or its circuit defective Refer to TABLE B 1 FUEL PUMP CIR CUIT INSPECTION 9 1 Operate fuel pump 2 With fuel return hose blocked by pinch ing it check...

Page 403: ...ferring to DTC in this section 2 Was DTC No 12 displayed when diagnosis switch terminal is grounded Go to step 2 Go back to Flow Table corresponding to that DTC 2 1 Warm up engine to normal operating...

Page 404: ...to step 5 Faulty IAC valve 5 Check R B R W R B R Y and B R wire for open and short Are they in good condition Go to step 6 Repair or replace 6 Check TP sensor for adjusting properly by referring TP S...

Page 405: ...d condition Go to step 2 2 1 Check vacuum hose EGR valve and EGR back pressure transducer refer ring to EGR PRESSURE TRANS DUCER AND EGR VALVE of EGR SYSTEM in this section 2 Is it in good condition G...

Page 406: ...ON of EVAPORATE EMISSION CON TROL SYSTEM in this section 2 Is it in good condition EVAP canister purge system is in good condition Check EVAP canister tank pressure control valve and fuel filler cap G...

Page 407: ...rol system for operation referring to SYSTEM INSPECTION of RADIATOR FAN CONTROL SYSTEM in this section 2 Is it in good condition Radiator fan control system is in good condition Go to step 2 2 1 Check...

Page 408: ...Ignition switch ON Heated blower fan OFF Ignition switch ON Heater blower fan ON 10 14 V 0 5 V Go to step 2 P Bl wire open or short Poor C20 terminal connection After repair go to step 2 2 1 Check vol...

Page 409: ...nce between A4 terminal and C14 terminal 3 Is it within specification Reference value Refer to characteristic curve below At 0 C 6 3 6 9 k At 25 C 1 8 2 2 k Go to step 2 Faulty A C evaporator thermist...

Page 410: ...below 2 Is check result satisfactory 0 V 10 14 V While engine running A C switch OFF While engine running A C switch ON A C control system circuits are in good condition P B wire open or short Poor A1...

Page 411: ...22 A21 TERMINAL POSITION WIRE COLOR CIRCUIT NORMAL VOLTAGE CONDITION A1 B R Power source 10 14V Ignition switch ON A2 B W Ignition switch signal 10 14V Ignition switch ON A3 Lg ECT sensor About 2 9 V...

Page 412: ...ge B6 R Bl IAC valve step motor 1 0 1 V Ignition switch ON B7 W Bl 10 14 V Shift lever in L 2 D range and vehicle stopped B7 W Bl Shift solenoid No 2 below 1 5 V Shift lever in P N R range B8 W R 10 1...

Page 413: ...R W Electric load rear defogger 0 1 V Rear defogger switch ON C19 R Y Electric load small light 10 14 V Small light OFF C19 R Y Electric load small light 0 1 V Small light ON C20 P Bl Electric load bl...

Page 414: ...ystem referring to DISABLING AIR BAG SYSTEM in SECTION 10B CAUTION As ECM PCM consists of precision parts be careful not to expose it to excessive shock 3 Open glove box then while pressing glove box...

Page 415: ...d IAC duty check check for following conditions Lead wires and hoses of engine emission control systems are connected securely Accelerator cable has some play that is it is not tight Valve lash is che...

Page 416: ...CHECK in this section 3 2 6 4 1 5 NOTE IAC duty can be checked roughly by using voltmeter IAC duty to voltage relation is as follows OFF DUTY METER is such duty meter that indicates approx 100 when te...

Page 417: ...t into consideration when performing above check If check result is not satisfactory in above step 3 or 4 check MAP sensor and its circuit according to flow table of diagnostic trouble code No 11 NOTE...

Page 418: ...decrease when vacuum is applied up to 400 mmHg by using vacuum pump 2 Output voltage Vin voltage 3 5 4 5V ambient temp 20 305C 68 865F If check result is not satisfactory replace MAP sensor Vin Vout G...

Page 419: ...voltage as specified below is ob tained TP sensor output voltage when throttle is completely closed 0 50 0 15 V 5 Tighten TP sensor screw to specified torque Tightening Torque a 2 5 N m 0 25 kg m 1 8...

Page 420: ...ove ECT sensor 1 from water outlet pipe 2 INSPECTION Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating water gradually If measured r...

Page 421: ...trouble code No 17 INSTALLATION Reverse removal procedure noting the followings Tighten knock sensor to specified torque Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft Connect connector of knock sens...

Page 422: ...k 2 0 3 0 0 25 0 40 0 32 20 68 40 104 60 140 80 176 C F TEMPERATURE RESISTANCE HEATED OXYGEN SENSOR OXYGEN SENSOR INSPECTION Inspect oxygen sensor and its circuit referring to flow table of diag nosti...

Page 423: ...h exhaust system when system is hot Oxygen sensor should be re moved when system is cool INSTALLATION Reverse removal procedure noting the followings Tighten oxygen sensor to specified torque Tighteni...

Page 424: ...te deflection between 0 1 V and 4 14 V a few times while tire is turned one revolution If check result is not satisfactory proceed to flow table of diag nostic trouble code NO 16 in this section REMOV...

Page 425: ...s as in table below If check results are as specified proceed to next operation check If not replace A D B C C B A D 4 Check that there is continuity between terminals A and B when battery is connecte...

Page 426: ...ring to SECTION 6B 3 Remove air cleaner inlet pipe 1 air cleaner assembly 2 and resonator 3 3 2 1 4 Disconnect accelerator cable from throttle body 5 Disconnect connectors of MAP sensor 1 TP sensor 2...

Page 427: ...ottle body gasket 1 to in take manifold NOTE Use new gasket 1 2 Install throttle body to intake manifold and tighten bolts 3 Connect water hoses 1 and vacuum hose 2 4 Connect connectors of MAPsensor 3...

Page 428: ...E B 5 IAC SYSTEM CHECK INSPECTION Check resistance between following terminals of IAC valve If found faulty replace throttle body assembly A C D F B E A B C D E F ENGINE AND EMISSION CONTROL SYSTEM 6E...

Page 429: ...s and then check fuel pressure 5 Start engine 6 Measure fuel pressure at idling If measured pressure doesn t satisfy specification refer to TABLE B 4 IAC SYSTEM CHECK and check each possibly de fectiv...

Page 430: ...reduced to less than about 2500 r min rpm FUEL PUMP RELAY INSPECTION 1 Disconnect negative cable at battery 2 Disconnect fuel pump relay 1 3 Perform steps 3 4 of MAIN RELAY for procedure of ECM PCM P...

Page 431: ...ove fuel pump assembly from fuel tank INSPECTION Check suction filter for evidence of dirt and contamination If present clean and check for presence of dirt in fuel tank INSTALLATION Install fuel pump...

Page 432: ...of fuel may be released when fuel re turn hose is disconnected Cover the hose to be dis connected with a shop cloth 4 2 1 3 INSTALLATION For installation reverse removal procedure and note following...

Page 433: ...REMOVAL 1 Relieve fuel pressure referring to SECTION 6 2 Disconnect connectors from each injector 3 Remove air cleaner inlet pipe 1 air cleaner assembly 2 and resonator 3 3 2 1 4 Remove delivery pipe...

Page 434: ...ashing out when injecting 5 Put graduated cylinder 2 under injector as shown in the figure 6 Remove fuel pump relay 7 To operate fuel pump and apply fuel pressure to injector use wire harness 3 as thi...

Page 435: ...o intake manifold 3 1 3 Apply thin coat of fuel to O rings 1 and then install injectors 2 into delivery pipe and intake manifold Make sure that injectors rotate smoothly If not probable cause is incor...

Page 436: ...RADIATOR FAN CONTROL SYSTEM CHECK ENGINE COOLANT TEMPERATURE METER INSPEC TION AND ENGINE COOLANT TEMPERATURE SENSOR IN SPECTION in SECTION 8B RADIATOR FAN CONTROL RELAY INSPECTION 1 Disconnect negat...

Page 437: ...B during deceleration If EGR valve fails to operate properly check vacuum hoses EGR valve EGR back pressure transducer 2 and EGR sole noid vacuum valve A B 2 1 3 Keep engine running at idle speed and...

Page 438: ...EGR VALVE INSPECTION 1 Disconnect vacuum hose from EGR back pressure transducer 2 Connect vacuum pump gauge 1 to its hose 3 Check that EGR valve diaphragm 2 moves smoothly and that it is held at the s...

Page 439: ...above replace EGR solenoid vacuum valve 6 Connect solenoid vacuum valve connector securely 7 Connect vacuum hoses securely 1 EVAPORATIVE EMISSION CONTROL SYS TEM SYSTEM INSPECTION NOTE Before inspect...

Page 440: ...ion of flow through purge port 2 and air port 3 3 If operation differs from above description EVAP canister must be replaced 4 Connect hoses to EVAP canister WARNING DO NOT SUCK nozzles of EVAP canist...

Page 441: ...pump assembly 1 installed on fuel tank referring to SECTION 6C 2 Air should pass through valve 2 smoothly from fuel vapor line hose 3 A to B when blown hard 3 Also when vacuum pump 4 is connected to...

Page 442: ...N 1 Disconnect PCV valve 1 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 c...

Page 443: ...ck sensor 23 2 3 17 0 SPECIAL TOOLS 1 09912 58441 Pressure gauge 2 09912 58431 Pressure hose 3 09912 58450 Attachment 09912 58412 Fuel pressure gauge set 1 Tool body washer 2 Body plug 3 Body attachme...

Page 444: ...efore performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative E...

Page 445: ...from ECM or PCM 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 Hig...

Page 446: ...WIRING 1 To ignition switch 2 IG METER fuse 3 Ignition coil 4 Noise suppressor 5 Distributor 5 1 CMP sensor 6 Spark plug 7 Igniter 8 ECM or PCM 9 Monitor coupler B Y 1 2 4 B 3 7 8 5 6 5 1 9 W B Y R P...

Page 447: ...med Go to Step 2 Go to Engine Diag nostic Flow Table in 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...

Page 448: ...eplace 10 Ignition Trigger Signal Circuit Check 1 Check ignition trigger signal Y R wire circuit for open short and poor connection Are circuits in good condition Go to Step 11 Repair or replace 11 Ig...

Page 449: ...f each spark plug sparks 7 If no spark is emitted inspect high tension cords spark plugs ignition coil distributor igniter and other related parts ON VEHICLE SERVICE HIGH TENSION CORDS REMOVAL 1 Remov...

Page 450: ...MOVAL 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 Ins...

Page 451: ...fully charged REMOVAL 1 Remove ignition coil igniter assembly 1 from vehicle 2 Remove igniter 2 from bracket 2 1 INSPECTION 1 Arrange 2 new 1 5V batteries 1 in series check that total volt age is abou...

Page 452: ...r crack and their terminals for corrosion and wear Replace as necessary Signal Rotor Air Gap 1 Remove distributor cap and rotor 2 Using thickness gauge measure air gap 3 between signal ro tor tooth 1...

Page 453: ...cap 1 IGNITION TIMING NOTE Before starting engine place transmission gear shift lever in Neutral shift select lever to P range for A T model and set parking brake INSPECTION AND ADJUSTMENT 1 Set timin...

Page 454: ...usting initial ignition timing discon nect service wire from monitor coupler and release ignition tim ing fixation 7 With engine idling test switch terminal ungrounded vehicle stopped check that ignit...

Page 455: ...ip the cap of high tension cord when disconnect ing it 1 2 4 Remove distributor cap screws and cap 5 Remove distributor flange bolts 6 Pull out distributor housing assembly 6F1 12 IGNITION SYSTEM DIST...

Page 456: ...set 4 Therefore if the dogs can not be fitted into the slots turn distrib utor shaft by 180 and try again 4 3 1 2 2 Lightly install flange bolt and prepare for ignition timing adjust ment 3 Check to m...

Page 457: ...mbly 6G 6 Inspection 6G 7 Armature 6G 7 Field coil 6G 9 Brush 6G 9 Brush holder and spring 6G 9 Drive lever 6G 9 Pinion and over running clutch 6G 10 Front housing bush 6G 10 Armature shaft bush 6G 10...

Page 458: ...e below 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 m...

Page 459: ...e 99000 25010 to joint of magnetic switch and over running clutch 7 Magnetic switch Apply lithium grease 99000 25010 to plunger 8 Rear bracket 9 Brush spring 10 Brush holder 11 Brush 12 Washer 13 Arma...

Page 460: ...wn Battery voltage too low due to battery deteriora tion Poor contact in battery terminal connection Loose grounding cable connection Fuse set loose or blown off Poor contacting action of ignition swi...

Page 461: ...otor running but not cranking engine Worn pinion tip Poor sliding of over running clutch Over running clutch slipping Worn teeth of ring gear Replace over running clutch Replace Replace Replace flywhe...

Page 462: ...cables at battery 2 Remove battery and battery tray 3 Disconnect battery cable and magnetic switch lead wire 1 from starting motor terminals 4 Remove 2 starting motor mounting bolts 2 5 Remove starti...

Page 463: ...NSPECTION ARMATURE Inspect commutator 1 for dirt or burn Correct with sandpaper or lathe if necessary 1 Check commutator 1 for uneven wear with armature supported on V blocks 2 If deflection of dial g...

Page 464: ...sulator depth A Standard 0 4 0 6 mm 0 015 0 023 in Limit 0 2 mm 0 0078 in 1 Insulator 2 Commutator segments A Insulator depth Ground Test Check commutator 1 and armature core 2 If there is continuity...

Page 465: ...brush holder is sluggish check brush holder for distortion and sliding faces for contamination Clean or correct as necessary Check for continuity across insulated brush holder positive side and groun...

Page 466: ...othly in reverse direction Replace if necessary Inspect spline teeth 1 for wear or damage Replace if necessary Inspect pinion for smooth movement 1 FRONT HOUSING BUSH Inspect bush for wear or damage R...

Page 467: ...Hold in Coil Open Circuit Test Check for continuity across magnetic switch S terminal 1 and coil case If no continuity exists the coil is open and should be re placed 1 ASSEMBLY Reverse disassembly pr...

Page 468: ...ct field coil lead 2 from M terminal 3 3 2 1 HOLD IN TEST While connected as above with plunger out disconnect negative lead from M terminal 1 Check that plunger and pinion remain out If plunger and p...

Page 469: ...53A maximum 6 000 rpm minimum Around at 20 C Load characteristic 9 0V 150A 2 8 N m 0 28 kg m 2 0 lb ft minimum 2 100 rpm minimum 68 F Locked rotor current 5 0V 370 A maximum 7 N m 0 7 kg m 5 0 lb ft m...

Page 470: ...NOSIS 6H 3 ON VEHICLE SERVICE 6H 5 Jump Starting in Case of Emergency 6H 5 Removal 6H 6 Handling 6H 6 Installation 6H 6 GENERATOR GENERAL DESCRIPTION 6H 7 DIAGNOSIS 6H 8 ON VEHICLE SERVICE 6H 11 Remov...

Page 471: ...aches normal op erating temperature with engine speed of 2000 to 3000 rpm Make sure all electric switches are off before storing the ve hicle Recharge the battery twice a month to prevent it from dis...

Page 472: ...G of the electrolyte is indicative of the state of charge DIAGNOSIS VISUAL INSPECTION Check for obvious damage such as cracked or broken case or cover that could permit loss of electrolyte If obvious...

Page 473: ...ATURE CORRECTED STAGE OF CHARGE GRAPH Suppose your S G reading is 1 28 and the battery temperature is 5 C 23 F Locate the intersection of the 5 C line and the 1 28 S G line The intersection is within...

Page 474: ...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 Di...

Page 475: ...wed 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 sho...

Page 476: ...Ignition terminal L Lamp terminal 7 8 9 5 10 4 3 6 2 1 CHARGING SYSTEM 6H 7 GENERATOR GENERAL DESCRIPTION The generator is a small and high performance type with an IC regulator incorporated The inte...

Page 477: ...E When connecting a charger or a booster battery to ve hicle battery refer to this section describing battery charging B Generator output Battery terminal E Ground F Field coil terminal IG Ignition te...

Page 478: ...voltmeter and ammeter as shown in left figure Voltmeter Set between generator B terminal 3 and ground Ammeter Set between generator B terminal and battery terminal NOTE Use fully charged battery 6 Mea...

Page 479: ...tor 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...

Page 480: ...connect negative cable 1 at battery 2 1 2 2 Disconnect B terminal wire 1 and coupler 2 from generator 3 3 Remove adjusting bolt 4 and loosen generator pivot bolt 5 4 Remove generator with bracket 6 1...

Page 481: ...1 Rear end frame 12 Regulator 13 Brush holder 14 Brush 15 Rectifier 16 Insulator 17 Rear end cover 5 8 7 N m 0 87 kg m Tightening Torque 1 113 N m 11 3 kg m 2 0 N m 0 2 kg m 2 0 N m 0 2 kg m 4 5 N m 0...

Page 482: ...3 4 1 5 Remove brush holder cover 1 from brush holder 2 1 2 6 Remove rectifier holder 1 1 7 Hold shaft by using hexagonal box wrench 1 and remove pulley nut and then pull out pulley 2 CAUTION To hold...

Page 483: ...g ro tor and rear end frame 1 2 3 11 If required use bearing puller 1 to remove end housing bear ing 2 and bearing cover 3 CAUTION Care must be exercised so as not to distort cooling fan blade while a...

Page 484: ...lip rings for roughness or scoring If rough or scored re place rotor Using a vernier caliper measure the slip ring diameter Standard diameter 14 4 mm 0 567 in Minimum diameter 12 8 mm 0 504 in If the...

Page 485: ...er to each rectifier terminal 2 2 Reverse the polarity of the tester probes and repeat step 1 3 Check that one shows continuity and the other shows no conti nuity If there is continuity replace the re...

Page 486: ...move the brush and spring 2 Run the wire of a new brush through the hole in the brush holder and insert the spring and brush into the brush holder 3 Solder the brush wire to the brush holder at specif...

Page 487: ...0 87 kg m 6 5 lb ft b 2 6 N m 0 26 kg m 2 0 lb ft 2 a 1 3 b 6 Place drive end frame 1 on pulley and then install rotor 2 to drive end frame 2 1 7 Install rear end frame 1 to drive end frame 2 8 Tighte...

Page 488: ...1 together with the brush holder 2 horizontally on the rear end frame 3 13 Install the 5 screws until there is a clearance of approx 1 mm 0 04 in between the brush holder and connector Tightening Torq...

Page 489: ...5 0 kg m 36 5 lb ft c 7 N m 0 7 kg m 5 0 lb ft c a b 6H 20 CHARGING SYSTEM SPECIFICATIONS Rated voltage 12 V Permissible ambient 30 to 90 C Nominal output 65 A at 13 5 V temperature 22 to 194 F Permis...

Page 490: ...TS 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 A...

Page 491: ...ontrol device added to the exhaust system to lower the levels of Hydrocarbon HC Carbon Monoxide CO and Oxides of Nitrogen NOx pollutants in the exhaust gas 2 1 Exhaust manifold cover 2 Gasket 3 Exhaus...

Page 492: ...and out of position Check exhaust system for leakage loose connection dent and damage If bolts or nuts are loosened tighten them to specified torque Refer to page 6K 2 for torque data Check nearby bod...

Page 493: ...n or damage Replace 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...

Page 494: ...activation of the system or could render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignitio...

Page 495: ...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 1...

Page 496: ...nizer 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 L...

Page 497: ...gear shift fork 12 High speed gear shift fork 13 Low speed gear shift fork 14 Reverse gear shift arm 15 Reverse gear shaft lever bolt Apply thread lock cement 99000 32110 to joint seam of T M right ca...

Page 498: ...broken synchronizer spring Distorted shift shaft or shift fork Replace Replace Hard shifting Inadequate lubricant Improper clutch pedal free travel Distorted or broken clutch disc Damaged clutch pres...

Page 499: ...level filler plug 2 Torque drain and level filler plugs as specified below A Sealant 99000 31110 Tightening Torque a 21 N m 2 1 kg m 15 5 lb ft NOTE It is recommended to use API GL 4 75W 90 gear oil W...

Page 500: ...differential side oil seal 1 with spring side in ward using plate 2 and special tool with hammer up to the posi tion below Distance a 1 0 1 5 mm 0 04 0 06 in Diameter b 56 mm 1 38 in Right side 60 mm...

Page 501: ...ift control lever 2 Gear shift lever boot 3 Gear shift control cable Apply lithium grease 99000 25010 to joint seam of shift cable lever and gear shift control lever 4 Gear select control cable 5 Gear...

Page 502: ...knob is aligned with lever 3 Install control lever assembly and related parts as they were For positioning control lever loosely install 4 gear shift control cable guide nuts adjust position and then...

Page 503: ...ts 9 Support engine with engine support jack 1 as shown in left figure 10 Remove upper side 2 transmission to engine bolts 1 11 Remove front wheels right left 12 Drain transmission oil 13 Remove clutc...

Page 504: ...n Do not hit drive shaft joint with hammer installing it into differential gear Use specified torque as given below Push in left side drive shaft joint fully so as to engage snap ring of shaft with di...

Page 505: ...gear Use new circlips on shaft for installation Don t reuse cir clips DISASSEMBLY 1 Remove select lever assembly 1 from gear shift guide case 2 2 Remove 3 gear shift locating bolts 1 with washers then...

Page 506: ...and hammer and re move circlip 3 Special Tool B 09922 85811 10 Remove gear shift fork 1 sleeve hub assembly 2 syn chronizer ring and 5th gear all together 1 2 11 Remove counter shaft nut 1 as follows...

Page 507: ...with washer then take off re verse idler gear 4 19 Pull out 5th reverse gear shift guide shaft 5 together with 5th reverse gear shift shaft 6 NOTE When removing 5th reverse gear shift shaft and guide...

Page 508: ...Remove differential gear assembly 3 from right case 2 3 4 Remove input shaft oil seal 1 using special tools combination of bearing remover and sliding shaft Special Tool A 09930 30102 B 09923 74510 5...

Page 509: ...differential right side oil seal 1 to right case 2 facing its spring side inward using plate 3 and special tool with ham mer up to the position below Apply grease to its lip Distance a 1 0 1 5 mm 0 0...

Page 510: ...al Tools A 09930 30102 B 09941 64511 3 Remove differential side left oil seal using screwdriver 2 A B 1 REASSEMBLY 1 Press fit differential left side oil seal 1 to left case 2 facing its spring side i...

Page 511: ...press work in the middle way and take out 5th gear spacer to prevent it from being compressed and then continue to remove bearing with gear 5 1 3 2 4 3 Take out 4th gear needle bearing and high speed...

Page 512: ...s 1 and make sure that they are free from any obstruction 2 Input shaft 2 1 4 Fit high speed synchronizer sleeve 1 to hub 2 insert 3 keys 3 in it and then set springs 4 as shown in left figure NOTE No...

Page 513: ...needle bearing 2 apply oil to bearing then install synchronizer ring 3 and 4th gear 4 NOTE Confirm that circlip is installed in groove securely 9 Press fit left bearing 1 and 5th gear spacer 2 using...

Page 514: ...er 1 to 1st gear 2 and drive out low speed synchro nizer sleeve hub assembly 3 with gear using press 6 Disassemble synchronizer sleeve hub assembly 7 Take out needle bearing from shaft 3 2 1 INSPECTIO...

Page 515: ...istinguish the difference properly Width b 8 2 mm 0 32 in c 8 8 mm 0 35 in Needle bearings for 1st and 2nd gear are identical 6 Drive in low speed sleeve hub assembly 1 using special tool and hammer N...

Page 516: ...o that countershaft will not be compressed excessively Special Tool A 09913 80112 2 1 9 Press fit 4th gear 1 using the same procedure as the above 10 Install left bearing cone 2 using special tool and...

Page 517: ...le component parts using special tool and hammer Special Tool A 09922 85811 4 5 mm 2 Replace or correct parts as required and assemble shafts mak ing sure that component parts are in proper order as s...

Page 518: ...TMENT 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 Mak...

Page 519: ...l tool and copper hammer Special Tools A 09951 76010 2 1 5 Hold differential assembly with soft jawed vise 1 install final gear 2 and then tighten it with 8 bolts 3 to specified torque CAUTION Use of...

Page 520: ...at the same time 3 Place reverse gear shift lever fasten it with 2 bolts after applying thread lock cement A Thread lock cement 99000 32110 Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft NOTE When ins...

Page 521: ...en them to specification If vinyl tape has not been removed remove it from input shaft 4 c B 2 1 3 b A 9 Check locating spring for deterioration and replace with new one as necessary 10 Install steel...

Page 522: ...fication quickly 3 4 1 a 2 3 6 4 5 1 14 Place left case plate 1 inserting its end in groove of 5th re verse gear shift guide shaft 2 and then tighten it with new screws NOTE After tightening screws ma...

Page 523: ...stall 5th gear to counter shaft 1 facing machined boss A in ward 17 Apply oil to 5th gear bearing and set bearing A Machined boss Inside B No machining Outside 18 Install counter shaft nut as follows...

Page 524: ...lock cement 99000 32110 Tightening Torque a 9 N m 0 9 kg m 6 5 lb ft 24 Fit hub plate 2 and fix it with circlip 25 Install circlip 3 to the end of 5th reverse gear shift guide shaft Make sure circlip...

Page 525: ...31110 Tightening Torque b 23 N m 2 3 kg m 17 0 lb ft 30 Install washer and 5th to reverse interlock guide bolt 3 ap plied with sealant and then tighten it to specified torque A Sealant 99000 31110 Tig...

Page 526: ...lever filler plug Mating surface of transmission case Gear shift interlock bolt Thread lock cement THREAD LOCK 1322 99000 32110 Control lever knob Reverse gear shift lever bolts Oil gutter bolt Left c...

Page 527: ...achment 09924 74590 Oil seal installer 09925 68210 Bearing outer race installer 09925 88210 Bearing puller attachment 09930 30102 Sliding shaft 09940 53111 Bearing installer 09951 16060 Bush remover 0...

Page 528: ...clutch 7B 49 Forward clutch 7B 52 Output shaft 7B 55 Counter shaft 7B 56 Second brake 7B 57 Differential assembly 7B 58 Input shaft 7B 60 Planetary gear 7B 60 Planetary ring gear 7B 60 Parking lock p...

Page 529: ...es manually by means of the select lever installed on the compartment floor In the D or 2 range the gear ratio is changed for the 1st 2nd or 3rd speed D range only automatically by power train control...

Page 530: ...verter 3 Oil pump 4 Input shaft 5 Forward clutch assembly 6 Direct clutch assembly 7 First reverse brake 7 1 First reverse brake piston assembly 7 2 First reverse brake discs plates 8 Rear planetary g...

Page 531: ...m 8 N m 0 8 kg m 13 N m 1 3 kg m 7 N m 0 7 kg m 7 N m 0 7 kg m Tightening Torque 1 Transmission case assembly 2 Rear cover 3 Lower cover 4 Side bearing housing 5 Vacuum diaphragm 6 Oil filler tube lev...

Page 532: ...ear change 2 range Forward 1st 2nd 3rd automatic gear change L range Forward 1st 2nd 3rd reduction and fixed at 1st gear G Engine type K10A Gear change 1st low gear 2 659 change device Gear 2nd second...

Page 533: ...enoid B by sending electric signals to them so as to attain automatic gear shift between the 1st and 2nd gears and the 2nd and 3rd gears Equipped as PCM sensed parameters are the throttle position sen...

Page 534: ...e Function Forward clutch The forward clutch connects the input shaft and internal gear of the front planetary gear unit Direct clutch The direct clutch connects the input shaft and the sun gear commo...

Page 535: ...ON TABLE OF COMPONENT OPERATION Element Gear position Forward clutch 2nd brake Direct clutch 1st reverse brake One way clutch P R f f N 3rd gear f f 2nd gear f f 1st gear D and 2 range f f 1st gear L...

Page 536: ...e points in D 2 and L ranges vary depending on throttle opening as given below km h Shift Throttle opening 1 2 2 3 3 2 2 1 Full open 41 75 70 35 Full close 10 16 9 8 OPERATION OF SHIFT SOLENOIDS Range...

Page 537: ...ft unknown but also a secondary failure could be induced In addition time would be wasted Failures which might occur in the automatic transmission can be classified into the following categories 1 Imp...

Page 538: ...ace O ring Tighten plug Replace O ring CON Low fluid pressure Low fluid level Clogged oil pump screen Leak in oil pressure circuit Pressure regulator valve malfunction Adjust fluid level Wash screen O...

Page 539: ...ressure leakage to direct clutch due to worn or damaged oil pump cover seal ring Direct clutch slippage 2 3 shift valve stuck shift solenoid B stuck Foreign matter caught in direct clutch piston check...

Page 540: ...ecified level NOISE Abnormal noise in P and N ranges Low A T fluid level Wear in oil pump Fill A T fluid to specified level Replace Noise from differential Missing tooth of differential gear Seizure o...

Page 541: ...tachometer Read engine rpm quickly when it has become constant stall speed 6 Release accelerator pedal immediately after stall speed is checked 7 In the same way check stall speed at R 2 and L range 8...

Page 542: ...10 2 Install tachometer 3 Apply parking brake and block vehicle wheels 4 With selector lever shifted to P range start engine 5 Depress brake pedal fully 6 Shift select lever to D range and check fluid...

Page 543: ...Defective vacuum hose Pressure leakage from fluid pressure circuit Defective oil pump Clogged oil strainer Fluid pressure is lower than standard value in D range only Leakage from D range fluid press...

Page 544: ...om N to D range and measure time from that moment till shock is felt 4 Similarly measure time lag by shifting select lever from N to R range Time lag N D Less than 1 0 sec Time lag N R Less than 1 4 s...

Page 545: ...CM defective or disconnection or poor connection in PCM electric circuit No upshift from 2nd to 3rd 2 3 shift valve defective Shift solenoid B defective PCM defective or disconnection or poor connecti...

Page 546: ...alfunction indicator lamp CHECK ENGINE light doesn t flash just remains ON even with grounding diagnosis switch terminal DIAGNOSTIC TROUBLE CODE DTC CHECK 1 Check malfunction indicator lamp CHECK ENGI...

Page 547: ...epeatedly no other DTC is stored in PCM memory If any other DTCs are in PCM memory this code is output first followed by output of these DTCs starting from the smallest code number in the increasing o...

Page 548: ...ere continuity between S1 terminal and engine ground Go to Step 3 Go to Step 5 3 Check continuity between S1 terminal of PCM coupler and body ground Is there continuity W R wire shorted to ground Go t...

Page 549: ...tween S2 terminal of PCM coupler and body ground Is there continuity W Bl wire shorted to ground Go to Step 4 4 Check continuity between B terminal of trans mission side and engine ground Is there con...

Page 550: ...range 10 14 V other than P range 0 1 V R and ground R range 10 14 V other than R range 0 1 V N and ground N range 10 14 V other than N range 0 1 V D and ground D range 10 14 V other than D range 0 1...

Page 551: ...g m 29 lb ft 4 Remove fluid level gauge from fluid filler tube and add new fluid from fluid filler tube Use DEXRON IIE or equivalent automatic transmission fluid NOTE Draining or refilling volume of f...

Page 552: ...AUTOMATIC TRANSMISSION 7B 25...

Page 553: ...7B 26 AUTOMATIC TRANSMISSION...

Page 554: ...l strainer 1 to lower valve body 2 Tightening Torque a 8 N m 0 8 kg m 5 mm bolt b 3 N m 0 3 kg m 6 mm bolt 6 Reinstall oil pan and refill transmission fluid 7 Upon completion of installation warm up t...

Page 555: ...1 terminal 1 and body about 20 Between solenoid B 2 terminal 2 and body about 16 VACUUM DIAPHRAGM AND PIPING INSPECTION D Check pipe of vacuum diaphragm 2 for looseness coming off or breakage D Check...

Page 556: ...LECT CABLE REMOVAL 1 Remove console box 2 Disconnect select cable from selector lever and then from floor bracket 3 Disconnect select cable from transmission 4 Disconnect select cable from dash panel...

Page 557: ...shift to P range Vehicle should not move D Turn ignition switch START with select lever shifted to P and N range Starting motor should not operate D Turn ignition switch ON with select lever shifted t...

Page 558: ...nge switch connector SELECT LEVER REMOVAL 1 Remove select knob screw and then select knob 1 NOTE Knob and push button must not be disassembled 2 Remove console box and select indicator assembly 2 3 Re...

Page 559: ...ump 4 Second brake band 5 Direct clutch 6 Forward clutch 7 Front planetary gear 8 Planetary sun gear 9 One way clutch 10 Rear planetary gear 11 1st reverse brake 12 Output shaft 13 Reduction drive gea...

Page 560: ...d as cleaning solvent D Do not use wiping cloths or rags to clean or dry parts D All fluid passages should be blown out and checked to make sure that they are not obstructed D Keep face and eyes away...

Page 561: ...ar and burn Replace Oil seal and gasket Scratched or hardened seal ring Wear on outer circumference and side of seal ring Piston seal ring oil seal and gaskets Replace Replace Replace Gears Scratch an...

Page 562: ...er WARNING Be sure to keep transmission with torque converter hori zontal or facing up throughout the work Should it be tilted with torque converter down converter may fall off and cause personal inju...

Page 563: ...been removed from the transmission the stator roller clutch can be checked by insert ing a finger into the splined inner race of the roller clutch and trying to turn the race in both directions The i...

Page 564: ...acket 1 3 Remove select cable bracket 1 4 Disconnect fluid filler tube 5 Drive out spring pin 1 by using special tool and remove select lever 2 Special Tool A 09922 89810 6 Remove shift range switch 3...

Page 565: ...h a plastic hammer Oil pan may get deformed D Do not pry against mating surface of oil pan with a screwdriver 12 Remove magnet from oil pan and remove sealing material at tached on mating surface of o...

Page 566: ...20 NOTE Use care not to lose oil pump thrust washer 2 and bearing race 3 16 Holding anchor bolt 1 loosen anchor nut 2 and then remove anchor bolt CAUTION Remove sealing material on anchor end bolt and...

Page 567: ...0 Remove front planetary gear 1 21 Remove sun gear input drum 1 22 Remove snap ring 1 and then remove one way clutch 3 and rear planetary carrier 3 as an assembly NOTE Use care not to damage transmiss...

Page 568: ...on plates 25 Remove side bearing housing 1 mounting bolts and then re move housing 1 26 Remove lower cover mounting bolts and then remove lower cover 1 CAUTION D Remove sealing material attached on ma...

Page 569: ...er 1 D Remove sealing material attached on mating surface of side cover 1 completely D Use care so that none of sealing material remains in side Special Tool D 09912 34510 29 Remove shims 1 from side...

Page 570: ...D Do not push down return spring 4 more than neces sary Special Tool E 09926 98320 F 09941 84510 G 09926 98370 34 Remove 1st reverse brake piston NOTE Blow air into oil hole 1 gradually while holding...

Page 571: ...air gradually while trying to receive it with paper CLUTCH AND BRAKE PARTS DIAGNOSIS SYMPTOMS Clutch Discs and Brake Band Dry and inspect them for pitting flaking wear glazing cracking charring and ch...

Page 572: ...d and Direct Clutch Discs D Stuck or leak in check ball in clutch piston D Damaged clutch piston seals D Worn or broken seal rings D Obstruction in solenoid valves or shift valves D Disconnected speed...

Page 573: ...uter rotor 2 Inner rotor 3 Oil seal 4 Oil pump cover 5 Oil pump cover seal ring 6 Cover seal A Grease 99000 25030 A 9 N m 0 9 kg m Tightening Torque SUB ASSEMBLY SERVICE OIL PUMP DISASSEMBLY 1 Remove...

Page 574: ...TION D Check each component part for damage and abnormal wear D Measure side clearance of outer rotor and inner rotor 2 at 3 posi tions each Side clearance Standard 0 02 0 05 mm 0 0008 0 0018 in D Mea...

Page 575: ...then apply grease to its lip portion Special Tool A 09913 85210 Grease SUZUKI SUPER GREASE C 99000 25030 D Install inner rotor 1 and outer rotor 2 into housing by aligning their punch marks 3 D Insta...

Page 576: ...7B 49 1 Thrust washer 2 Direct clutch drum 3 Oil seal ring 4 Oil seal ring 5 Direct clutch piston 6 Plate 7 Separator plate 8 Friction plate 9 Retaining plate 10 Snap ring 11 Clutch return spring 12 S...

Page 577: ...al tool and press 1 push down spring retainer and remove snap ring 2 CAUTION Do not push down spring retainer more than necessary Special Tool A 09926 98350 3 Using air gun 1 blow air into oil passage...

Page 578: ...ure that O ring fits securely to 4 lugs of spring seat Install separator plates and friction plates in correct order and cushion plate in proper direction Measure clearance between retaining plate 1 a...

Page 579: ...ISSION 1 Race 2 Bearing 3 Ring 4 Input shaft 5 Oil seal ring 6 Oil seal ring 7 Piston 8 Cushion plate 9 Separator plate 10 Friction plate 11 Retaining plate 12 Snap ring 13 Piston return spring 14 Sna...

Page 580: ...input shaft 1 2 Using special tool push down spring retainer and remove snap ring CAUTION Do not push down spring retainer more than necessary Special Tool A 09926 98350 3 Blow air 1 into oil hole 2...

Page 581: ...ted Install cushion plates in proper direction Install friction plates and separator plates in correct order Check to make sure that C ring fits securely to 4 lugs of spring seat Measure clearance bet...

Page 582: ...output shaft from reduction gear 2 3 Remove snap ring 1 and then pull off bearing 2 toward the front ASSEMBLY Assemble parts in reverse order of disassembly noting following points Apply A T fluid to...

Page 583: ...driven gear 2 3 Using special tool remove bearing from counter shaft 1 Special Tool A 09941 84510 ASSEMBLY Assemble parts in reverse order of disassembly noting following points Apply A T fluid to pre...

Page 584: ...d brake band Check second brake band 1 visually for damage wear discolor ation etc and replace it if not in good condition CAUTION When using a new second brake band immerse it in A T fluid for longer...

Page 585: ...aring 13 Side beaning shim Selection 14 Speedometer sensor rotor A Apply thread lock cement THREAD LOCK CEMENT SUPER 1333B 99000 32020 5 7 5 7 11 13 11 12 14 10 90 N m 9 0 kg m A Tightening Torque 2 D...

Page 586: ...nent parts Special Tool C 09922 85811 ASSEMBLY Asselmbly in reverse order of disassembly nothing the following Assembly differntial gear 2 and measure thrust play of differential gear as follows Diffe...

Page 587: ...ied ones is prohibited Tightening Torque a 90 N m 9 0 kg m 65 0 lb ft INPUT SHAFT Inspection Visually check splines for damage and wear Visually check seal ring for breakage and wear PLANETARY GEAR In...

Page 588: ...AUTOMATIC TRANSMISSION 7B 61 PARKING LOCK PAWL Inspection Check parking lock pawl for damage BEARING Inspection While turning bearing by hand check if it turns smoothly without making abnormal noise...

Page 589: ...n function check each part carefully before installation Clean all parts with compressed air Never use wiping cloths or rags Before assembling new clutch discs and brake band soak them in automatic tr...

Page 590: ...nd set them in case 3 Install manual shaft 1 and tighten lock bolt 2 to specified torque Tightening Torque a 7 N m 0 7 kg m 5 0 lb ft 4 Set manual plate 1 to manual shaft 2 fix it by width across flat...

Page 591: ...m spring retainer 7 Inspect 1st reverse brake as follows Using thickness gauge 1 measure clearance between sep arator plate 2 and friction plate 3 Clearance between separator plate and retaining plate...

Page 592: ...on plates 3 as shown in left figure and then retaining plate 4 one way clutch outer race 5 separator plate 6 and snap ring 7 in that order 11 Assemble rear planetary carrier one way clutch 1 one way c...

Page 593: ...ance measured here is referred to as b Standard value for clearance b a a 0 2 mm a a 0 0078 in Example Supposing thickness a of shim on counter side is 0 8 mm 0 031 in acceptable range for clearance b...

Page 594: ...o shim set it in case and tighten side cover 1 bolts to specified torque Tightening torque for side cover bolt 19 N m 1 9 kg m 13 5 lb ft 19 Set differential assembly in case and apply even amount of...

Page 595: ...l bearing surface with dummy 3 as shown in figure Calculate clearance L4 between case side and side bearing housing side L4 L1 L2 Clearance L4 0 0 2 mm 0 0 0078 in If clearance is not within range of...

Page 596: ...Special Tool D 09916 14510 E 09916 48210 28 Assemble direct clutch assembly 1 and forward clutch and in put shaft 2 29 Install needle bearing 1 to front side of front internal gear 2 and race incorpo...

Page 597: ...32 Install sun gear input drum 1 to direct clutch drum 2 by matching their splines 33 Set assembled clutch assembly in case CAUTION Check bearing of sun gear input drum and seal ring 1 of output shaf...

Page 598: ...in left figure Measure L2 from top surface of oil pump thrust washer 1 Measure depth g which is from top surface of case gasket to installation surface of direct clutch drum bearing as shown in left f...

Page 599: ...on Tightening torque for oil pump mounting bolt 13 N m 1 3 kg m 9 5 lb ft C SUZUKI BOND 1216 99000 31160 39 Adjust brake band as follows Loosen anchor end nut 1 as far as tip end and apply sealant to...

Page 600: ...of case 42 Tighten valve body 1 and oil strainer 2 mounting bolts to specified torque Tightening torque for valve body and oil strainer mounting bolt 3 N m 0 3 kg m 5 mm bolt 2 2 lb ft 8 N m 0 8 kg m...

Page 601: ...31160 CAUTION Remove old gasket on mating surface of oil pan com pletely Use care so that no sealant will remain inside 45 Install oil cooler Align projection 1 of oil cooler at the position as shown...

Page 602: ...f oil pump Using 12 mm bolt 1 as shown in figure will facilitate instal lation 2 After installing torque converter check to make sure that dis tance j is within specification Distance j More than 23 7...

Page 603: ...PRODUCT USE Automatic transmission fluid An equivalent of DEXRONr IIE D Automatic transmission D Parts lubrication when installing Sealant SUZUKI BOND N0 1215 99000 31110 D Side and bottom cover case...

Page 604: ...emover 4 5 mm 09925 37810 Oil pressure gauge set 09925 88210 Bearing puller attachment 09926 98320 Spring compressor No 1 set 09926 98350 Spring compressor No 4 09926 98370 Spring compressor No 1 atta...

Page 605: ...ION 7C 2 DIAGNOSIS 7C 3 ON VEHICLE SERVICE 7C 4 Maintenance Service 7C 4 Clutch Pedal 7C 4 Clutch Cable 7C 5 UNIT REPAIR OVERHAUL 7C 6 Clutch Cover Clutch Disc and Flywheel 7C 6 Clutch release system...

Page 606: ...pressure plate against the flywheel with the disc in between when the clutch release bearing is held back This is the en gaged condition of the clutch Depressing the clutch pedal causes the release b...

Page 607: ...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...

Page 608: ...5 5 N m 0 6 kg m 4 5 lb ft 4 a 3 1 2 a 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 w...

Page 609: ...ect clutch cable and replace it for any of the following condi tions Excessive cable friction Frayed cable Bent or kinked cable Broken boots Worn end INSTALLATION Reverse removal procedure for install...

Page 610: ...9 Clutch release shaft No 2 bush 10 Clutch release shaft seal Apply lithium grease 99000 25010 to inside 1 2 10 9 8 7 6 3 23 N m 2 3 kg m 5 4 Tightening Torque DISMOUNTING REMOUNTING Refer to SECTION...

Page 611: ...it at any of holes replace disc assembly Rivet head depth Standard 1 35 1 95 mm 0 05 0 08 in Service limit 0 5 mm 0 02 in Clutch Cover 1 Check diaphragm spring 1 for abnormal wear or damage 2 Inspect...

Page 612: ...install clutch cover 1 and bolts Then tighten bolts to specification NOTE While tightening clutch cover bolts compress clutch disc with special tool by hand so that disc centered Tighten cover bolts l...

Page 613: ...pring 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 1 and return spring 2 2 6 Install ta...

Page 614: ...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 appli...

Page 615: ...e 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 3 4 B 2 A 1 9 Set release arm 1 to rel...

Page 616: ...aft bushes and seal Release shaft arm SUZUKI SUPER GREASE I 99000 25210 Input shaft spline front end SPECIAL TOOLS 09917 58010 Bearing remover 09922 46010 Bush remover 09923 36330 Clutch center guide...

Page 617: ...ice work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the sys tem may be activated by...

Page 618: ...ation Meter 8 16 Speed Meter Sensor 8 17 Fuel Meter Fuel Level Sensor Gauge Unit 8 17 Engine Coolant Temperature Meter and Sensor For Meter 8 18 Oil Pressure Warning Light 8 19 Brake and Parking Brake...

Page 619: ...ecting 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...

Page 620: ...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 Us...

Page 621: ...to the 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 wi...

Page 622: ...B 11 To parking brake switch R B 12 To alternator W Bl 13 To oil pressure switch Y B 14 Blank 15 To air bag controller if equipped Y B 16 Blank Coupler L 1 To combination switch turn L G R 2 To combin...

Page 623: ...circuit or high resistance existing between Combination switch turn sig nal hazard warning switch and light on one side Wiring or grounding faulty Check bulb Check bulb Check relay Repair circuit Rep...

Page 624: ...itch faulty Check adjust or replace switch SPEEDOMETER AND VSS Trouble Possible Cause Correction Speedometer shows no op eration or incorrect opera tion IG METER and RADIO DOME fuse blown VSS faulty P...

Page 625: ...k oil pressure switch Repair circuit Oil pressure warning light stay on Oil pressure switch faulty Check oil pressure swtich BRAKE AND PARKING BRAKE WARNING LIGHT Trouble Possible Cause Correction Bra...

Page 626: ...Repair circuit POWER WINDOW CONTROL SYSTEM IF EQUIPPED Trouble Possible Cause Correction All power windows do not operate POWER WINDOW fuse blown Ignition main switch faulty Power window main switch f...

Page 627: ...unding Replace Check switch Check switch Repair HORN Trouble Possible Cause Correction Horn does not operate HORN HAZARD fuse blown Horn switch faulty Horn relay faulty if equipped Horn faulty Check f...

Page 628: ...STALLATION Refer to COMBINATION SWITCH STEERING COLUMN AND STEERING SHAFT LOWER JOINT in Section 3C INSPECTION 1 Disconnect negative cable at battery 2 Remove column cover and disconnect couplers from...

Page 629: ...from headlight assembly 6 Remove headlight assembly INSTALLATION Reverse removal procedure for installation BULB REPLACEMENT WARNING To avoid danger of being burned don t touch when the bulb is hot 1...

Page 630: ...and 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 C...

Page 631: ...lead wire coupler 3 Check continuity at each switch position shown below by using a circuit tester Terminal Turn Signal SW Hazard SW HAZARD RELAY The turn signal hazard relay 1 is located near the fus...

Page 632: ...nect negative cable at battery 2 Loosen steering column mounting screws and nuts Refer to Section 3C 3 Remove ashtray cover cigarette lighter socket assembly and then remove instrument center garnish...

Page 633: ...nals by using an ohmmeter 8 If inspection result in step 2 5 and or 7 is not as specified re place fuel meter 2 1 B O A B C D E FUEL LEVER SENSOR GAUGE UNIT INSPECTION 1 Remove fuel pump assembly 1 re...

Page 634: ...inspection result in step 2 5 and or 7 is not as specified re place ECT meter 1 B O Y Bl 2 A E C D B ENGINE COOLANT TEMPERATURE SENSOR FOR METER REMOVAL AND INSTALLATION Refer to ENGINE COOLANT TEMPE...

Page 635: ...circuit tester If found defective replace switch PARKING BRAKE SWITCH Check swtich for continuity by using a circuit tester If found defective replace switch REAR WINDOW DEFOGGER IF EQUIPPED DEFOGGER...

Page 636: ...voltage is zero wire must be damaged between its center and ground At center 4 6 V Good 9 11 V Broken wire 0 2 V Broken wire 2 Locating damage in wire a Touch voltmeter positive lead to heat wire pos...

Page 637: ...minutes later remove masking tapes 1 previous ly applied 5 Leave repaired heat wire as it is for at least 24 hours before op erating defogger again 2 3 4 WIPERS AND WASHERS COMPONENTS 1 2 9 3 8 7 6 4...

Page 638: ...battery 2 Disconnect combination switch lead wire coupler 3 Turn the front wiper switch to INT position 4 Connect battery positive terminal to terminal B3 and bat tery negative terminal to terminal H...

Page 639: ...per ground If motor rotates at a low revolution speed of 44 to 52 rpm it is proper As for high speed check connect battery terminal to terminal B and its terminal to bracket wiper ground If mo tor rot...

Page 640: ...ely to check pumping rate Check for both front and rear washer pump Pumping Rate Front more than 1 0 l min 2 1 US pt min 1 76 Imp pt min Rear more than 1 0 l min 2 1 US pt min 1 76 Imp pt min INSTALLA...

Page 641: ...or stop c Next connect terminal B and terminal C with a jumper wire and connect terminal D to battery terminal Observe the wiper motor turns once again then stops at a given position d Repeat these st...

Page 642: ...tester If found defective replace switch IGNITION KEY REMAINDER LIGHT REMAINDER WARNING BUZZER BUZZER UNIT REMOVAL 1 Remove combination meter Refer to COMBINATION METER in this section 2 Remove buzze...

Page 643: ...ose parts beforehand Refer to Section 10B NOTE Fasteners are important attaching parts in that they could affect the performance of vital compo nents and systems and or could result in major repair ex...

Page 644: ...bottom rubber 7 3 Glass bottom channel 8 Front door glass run 9 Front door glass sash 10 Front window regulator assembly 11 1 Front door outside handle assembly 11 2 Front door latch assembly 11 3 Doo...

Page 645: ...own in figure turn door trim 90 counterclockwise to remove it And disconnect power window switch lead wire at coupler if equipped 6 Remove door inside pull handle bracket 1 7 Remove door sealing cover...

Page 646: ...ass fitted position of bottom channel 1 is as shown in figure 1 113 6 mm 4 5 in Adjust equalizer 1 of window regular so that measurement A and B are equal B A 1 Secure door sealing cover with adhesive...

Page 647: ...1 1 INSPECTION 1 Check regulator sliding and rotating parts for greasing 1 2 Check rollers 2 for wear and damage 1 1 1 1 2 INSTALLATION Reverse removal procedure to install window regulator noting th...

Page 648: ...of the adhesive in any way hinders its inherent adhesive property Therefore before the work make sure to read carefully the instruction and description given by the maker of the adhesive to be used a...

Page 649: ...head lining Refer to HEAD LINING in this section 7 Remove or cut windshield molding until windshield edge comes out Remove or cut stopper 8 Drill hole with eyeletter 1 through adhesive and let piano s...

Page 650: ...ion glass 1 against body 1 so that clearance a between upper end of glass 1 and body 2 is about 6 mm 0 236 in and clear ances a between each side end right left of glass 1 and body 2 are even Upper cl...

Page 651: ...mm 1 18 1 97 in 7 Install new spacer 1 to glass 2 as shown in figure 2 8 Using new brush apply sufficient amount of primer for glass along glass surface to be adhered to body NOTE Be sure to refer to...

Page 652: ...e c Approx 10 5 mm 0 41 in d Approx 17 mm 0 67 in Press glass 2 against body quickly after adhesive 1 is ap plied Use of rubber sucker grip is helpful to hold and carry glass 2 after adhesive is appli...

Page 653: ...e following Sudden closing of door before adhesive is completely set may cause glass to become loose or to come off Therefore if door is opened or closed before adhesive is completely set make sure to...

Page 654: ...REAR DOOR GLASS 1 Rear door inside handle 2 Window regulator handle 3 Door inside lock knob 4 Rear door weatherstrip 5 Rear door sash 6 Rear window glass 7 Rear door glass run 8 1 Glass bottom rubber...

Page 655: ...outer weatherstrip 1 1 CAUTION Using a tape wrapped putty knife or tape wrapped screwdriver pry off weatherstrip Use of an un wrapped tool will cause damage to painting 8 Detach rear part of glass ru...

Page 656: ...ss referring to steps 1 to 8 of REAR DOOR GLASS REMOVAL in this section 2 Disconnect power window motor lead wire at coupler and clamp if equipped 3 Remove door window regular mounting screws 1 and ta...

Page 657: ...2 Pass string through outer groove of weatherstrip 1 groove where back door panel 3 fits in so that weatherstrip 1 can be installed to back door 3 Apply soap water to outer edge of back door panel 3 a...

Page 658: ...TE When replacing door coat replacement door inside with wax for proper anticorrosion treatment Refer to UNDERCOATING ANTI CORROSION COMPOUND APPLICATION AREA in this section Adjust door latch striker...

Page 659: ...n this sec tion REMOVAL 1 Disconnect washer hose joint 1 1 2 Remove high mount stop lamp 1 if equipped 1 BODY SERVICE 9 17 BACK DOOR ASSEMBLY 1 Back door panel assembly 2 Back door window glass 3 Weat...

Page 660: ...ck door balancer damper use a 2 to 3 mm 0 08 to 0 12 in drill 2 to make a hole as shown Handle balancer carefully Do not scar or scratch exposed surface of its piston rod and never allow any paint or...

Page 661: ...e and latch or repair hood lock system ADJUSTMENT Fore and aft and right and left adjustment Loosen four mounting bolts 1 for adjustment Hood lock adjustment When installing hood lock hold hood lock a...

Page 662: ...cket 3 us ing care not to damage painted surface 1 2 1 3 2 Attach new pad 1 cutting appropriately size temporarily and adjust height with a knife so that fender becomes flush with side body 3 Reverse...

Page 663: ...BODY SERVICE 9 21 BUMPERS Front bumper Rear bumper...

Page 664: ...control arm installation hole j j Headlight installation hole k k Jig hole 7 b c d h j g f i k i k g j h f d c b a e MEASUREMENT POSITION LENGTH mm in MEASUREMENT POSITION LENGTH mm in a b 604 23 78 d...

Page 665: ...lamp upper installation hole i i Combination lamp lower installation hole j Tail end member trim installation hole k Rear bumper installation hole a b c b d a g e f e f g h i k j i h MEASUREMENT POSI...

Page 666: ...m Side sil scuff installation hole n Rear seat belt installation hole o Door switch installation hole p Parking brake rear installation hole l n f e d a c b g k m o j i h f l i n o m k h g d c b p MEA...

Page 667: ...sion control arm installaion hole h h Bump stopper installation hole i i Jig hole 16 Unit mm in a a 312 12 28 312 12 28 b b 49 5 1 75 330 4 13 01 323 12 72 323 12 72 453 17 83 453 17 83 d e d e f f 40...

Page 668: ...ion control arm installation hole h Bump stopper installation hole i Jig hole 16 a o e e f f g h i b c d MEASUREMENT POSITION LENGTH mm in MEASUREMENT POSITION LENGTH mm in o e 1252 42 29 d e 816 32 1...

Page 669: ...ide trims 4 and bolt cover 6 8 Remove air bag harness from instrument pannel section if equipped Refer to Section 10B 9 Remove ground wire from dash side 10 Remove instrument pannel mounting bolts 7 1...

Page 670: ...m 25 5 lb ft b 23 N m 2 3 kg m 16 5 lb ft b b a a REMOVAL AND INSTALLATION Refer to above figure when removing and installing or disassembling and assembling front seat Make sure to tighten each bolt...

Page 671: ...BODY SERVICE 9 29 REAR SEAT Tightening Torque a 35 N m 3 5 kg m 25 5 lb ft a REMOVAL AND INSTALLATION Refer to above figure when removing and installing or disassembling and assembling rear seat...

Page 672: ...sion barrier The sealer is applied to the door and hood hem areas and between panels Correct and re seal the originally sealed joints if damaged Reseal the attaching joints of a new replacement panel...

Page 673: ...l conditioner to the bare metal exposed to open air As for method of use of the metal conditioner follow directions on the con tainer 4 Apply primer surfacer to the part completely dry before starting...

Page 674: ...a VIEW M DETAIL Y Smooth out sealant with a brush in one direction Wipe off excess sealant after application Smooth out sealant with a brush in one direction VIEW B VIEW A DETAIL X Smooth out sealant...

Page 675: ...covers completely end of flange Make sure that the sealant covers completely end of flange between C and E Smooth out sealant with a brush in one direction Smooth out sealant with a brush in one direc...

Page 676: ...A VIEW EE Wipe off excess sealant after application Wipe off excess sealant after application Do not sealant to this area Be free from protrude of sealant outside from this line PANEL DOOR OUTER PANEL...

Page 677: ...Do not sealant to this area Be free from protrude of sealant outside from this line Wipe off excess sealant after application Wipe off excess sealant after application Wipe off excess sealant after a...

Page 678: ...SERVICE Apply sealant to pointed area VIEW K SECT I I SECT H H SECT A A VIEW C SECT C C DETAIL Z Between F and H Smooth out sealant with a brush in one direction Smooth out sealant with a brush in one...

Page 679: ...UND APPLICATION AREA A Apply rustproof wax hot wax 50 mm or more B Apply rustproof wax high viscosity wax 50 mm or more A A A A A A A B A A Do not fill drain hole SECT A A SECT G G SECT B B SECT D D S...

Page 680: ...A Apply undercoating PVC 300 mm or more B Do not apply undercoating A B A A B A B B A B A A Apply undercoating in the arrow direction A A B SECT D D DETAIL W SECT D D SECT A A SECT B B SECT C C VIEW Y...

Page 681: ...re range is 60 to 705C Reference Plastic parts employ not only ABS Acrylonitrile Butadiene Sty rene plastic but also polypropylene vinyl or the like plastic Burn ing test method to identify ABS plasti...

Page 682: ...l lowings points Door latch striker Move door latch striker 1 up or down so its center aligns with the center of groove A on the door as shown NOTE Striker 1 should be moved vertically and placed leve...

Page 683: ...noting points mentioned in FRONT DOOR LOCK ASSEMBLY 3 1 2 BACK DOOR ASSEMBLY REMOVAL 1 Remove back door trim 2 Disconnect key cylinder rod 1 3 Remove lock assembly 2 and key cylinder assembly 3 2 3 1...

Page 684: ...s If key codes are not available from records or tags key code can be obtained from the right hand door lock cylinder if lock has not been replaced Lock cylinders supplied by the factory as service pa...

Page 685: ...ffs 2 center pillar inner lower rims 3 and rear side sill scuffs 4 4 Remove console box and parking brake lever cover 5 Remove floor carpet 5 5 4 3 1 2 INSTALLATION Reverse removal procedure to instal...

Page 686: ...emove inner trims covering head lining 3 and door opening trims 4 6 Remove crips 5 7 Remove head lining 6 NOTE Adhesive 7 is used to attach head lining 4 3 4 4 4 4 5 5 1 3 2 2 2 3 3 3 3 7 6 INSTALLATI...

Page 687: ...ilure to follow procedures could result in possible activation of the air bag system personal injury or otherwise unneeded air bag system repairs CAUTION When fasteners are removed always reinstall th...

Page 688: ...he following items is detected as exceeding each set value speed at which the webbing is pulled out of the retractor acceleration or deceleration of the vehicle speed and inclination Seat belt with A...

Page 689: ...T BELT PRETENSIONER IF EQUIPPED Some seat belts of the driver and front passenger seats are provided with a pretensioner as an optional function unit The pretensioner is incorporated in retractor asse...

Page 690: ...EM FOR VEHICLE WITH AIR BAG SYSTEM Refer to DISABLING AIR BAG SYSTEM of SERVICE PRECAUTIONS under ON VEHICLE SERVICE in SEC TION 10B ENABLING AIR BAG SYSTEM FOR VEHICLE WITH AIR BAG SYSTEM Refer to EN...

Page 691: ...his 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 Tightening Torque a 35 N m 3 5...

Page 692: ...ht 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 Sea...

Page 693: ...attery 2 Disable air bag system Refer to DISABLING AIR BAG SYS TEM of SERVICE PRECAUTIONS under ON VEHICLE SER VICE in SECTION10B 3 Remove center pillar lower trim 4 Disconnect Yellow connector 1 for...

Page 694: ...ew one as an assembly Pretensioner has activated There is a crack in seat belt pretensioner retractor assem bly Wire harness or connector 2 is damaged Seat belt pretensioner retractor assembly is dama...

Page 695: ...erve every precaution during work REMOVAL Remove rear seat belts INSPECTION Check the rear seat belt in the same way as INSPECTION of FRONT SEAT BELT WITHOUT PRETENSIONER INSTALLATION Install the rear...

Page 696: ...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 conditions are not followed part...

Page 697: ...ystem activation command outputted 10B 38 DTC 61 AIR BAG warning lamp circuit failure 10B 39 DTC 71 Internal SDM fault 10B 40 Repairs and inspections required after an accident 10B 41 Accident with de...

Page 698: ...ith an impact larger than a certain set value to supplement protection offered by the driver and front passenger seat belts The air bag system is designed to activate only in severe frontal collisions...

Page 699: ...module 7 SDM 8 Seat belt pretensioner retractor assembly CONNECTOR B C CONNECTOR D CONNECTOR F G CONNECTOR A CONNECTOR E 1 1 Air bag harness 2 Ground for air bag system 3 AIR BAG monitor coupler 4 Con...

Page 700: ...eat belt pretensioner 16 Passenger seat belt pretensioner WIRE HARNESS COLOR B Black B Y Black Yellow B W Black White Bl Blue Bl R Blue Red Bl O Blue Orange Bl Y Blue Yellow G Green G O Green Orange G...

Page 701: ...ance You should be familiar with proper use of a scan tool such as Air Bag Driver Passenger Load Tool Connector Test Adapter Kit and the Digital Multimeter WARNING To avoid deployment when troubleshoo...

Page 702: ...odule when it is connected to the air bag harness connector for passenger air bag inflator mod ule driver and passenger seat belt pretensioner when it is con nected to air bag harness connector for dr...

Page 703: ...rminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal included in the connector test adapter kit special tool If contact tension is not enough...

Page 704: ...t be the starting point of any air bag system diagnosis The AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE checks for proper AIR BAG warning lamp op eration through AIR BAG warning lamp and whether air ba...

Page 705: ...to DIAGNOS TIC TROUBLE CODE DTC CHECK 2 Is DTC 12 indicated NOTE See NOTE 1 below Air bag system is in good condi tion NOTE See NOTE 2 below An intermittent trouble has oc curred at some place Check...

Page 706: ...ition and disconnect service wire from AIR BAG monitor coupler 2 1 3 2 DIAGNOSTIC TROUBLE CODE DTC CLEARANCE 1 Turn ignition switch ON and wait about 6 seconds or more 2 Using service wire repeat shor...

Page 707: ...E DIAGNOSIS NO MODE DIAGNOSIS 12 Normal 15 Resistance high 16 Passenger air Resistance low 18 bag circuit Short to ground 19 Short to power circuit 21 Resistance high Diagnose trouble according to DIA...

Page 708: ...st If a code not listed on the table is displayed then the SDM is faulty Current DTC and history DTC can be identified by lighting and flashing of AIR BAG warning lamp as follows Current DTC is set Ab...

Page 709: ...ed digital multi meter Refer to SPECIAL TOOLS in this section along with a correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to...

Page 710: ...d SDM A connector open B Y wire between ignition switch and AIR BAG fuse open or short to ground 3 1 Disconnect 16 pin connector from com bination meter Refer to COMBINATION METER in SECTION 8 2 Check...

Page 711: ...i tion switch ON 3 Is it 8 V or more Substitute a known good SDM and recheck Go to Step 4 4 1 Remove combination meter Refer to COM BINATION METER in SECTION 8 2 Check proper connection to combination...

Page 712: ...2 76010 NOTE Upon completion of inspection and repair work perform following items 1 Reconnect all air bag system components ensure all components are properly mounted 2 Repeat AIR BAG DIAGNOSTIC SYST...

Page 713: ...SDM A connector 2 Measure resistance between A15 terminal of SDM A connector and body ground 3 Is resistance 1 or more Substitute a known good SDM and recheck Repair short from V wire circuit to groun...

Page 714: ...ctor 2 Check for proper connection at V wire A15 terminal of SDM A connector and terminal on AIR BAG monitor coupler 1 terminals 3 If OK then measure resistance between V wire circuit terminals 4 Is r...

Page 715: ...his section If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC WILL SET WHEN DTC 15 The comb...

Page 716: ...IR BAG INFLATOR MOD ULE in this section 2 1 With ignition switch OFF disconnect SDM A connector 2 Check proper connection to SDM at termi nals A7 and A8 3 If OK then measure resistance between A7 and...

Page 717: ...2 1 With ignition switch OFF disconnect SDM A connector 2 Check proper connection to SDM at ter minals A7 and A8 3 If OK then measure resistance between A7 and A8 terminals with connected Special Tool...

Page 718: ...tion switch OFF disconnect Spe cial Tool B and SDM A connector 2 Measure resistance between A7 termi nals and body ground 3 Is resistance 1 k or more Go to Step 3 Repair short from Bl R wire circuit t...

Page 719: ...isconnect Special Tool B and SDM A connector 2 Measure voltage from A7 terminal to body ground 3 With ignition switch ON is voltage 1 V or less Go to Step 3 Repair short from Bl R wire circuit to powe...

Page 720: ...re is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC WILL SET WHEN DTC 21 The combined resistance of...

Page 721: ...coil B con nector located near the base of the steering col umn 2 Remove driver air bag inflator module from steering wheel Refer to DRIVER AIR BAG IN FLATOR MODULE in SECTION 3C 3 Check proper conne...

Page 722: ...nnect contact coil B con nector located near the base of the steering col umn 2 Remove driver air bag inflator module from steering wheel Refer to DRIVER AIR BAG IN FLATOR MODULE in SECTION 3C 3 Check...

Page 723: ...the base of the steering column 2 Remove driver air bag inflator module from steering wheel Refer to DRIVER AIR BAG IN FLATOR MODULE in SECTION 3C 3 Check proper connection to driver air bag inflator...

Page 724: ...located near the base of the steering col umn 2 Remove driver air bag inflator module from steering wheel Refer to DRIVER AIR BAG IN FLATOR MODULE in SECTION 3C 3 Check proper connection to driver air...

Page 725: ...l Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section If there is open circuit in the air bag wire harness connector o...

Page 726: ...n SECTION 6H 2 1 With ignition switch OFF reconnect SDM A connector 2 With ignition switch ON is DTC 31 current Substitute a known good SDM and recheck Check Charging System and repair as necessary Re...

Page 727: ...body ground 4 Is voltage 8 V or more Repair poor connec tion high resistance in R or B Y circuit of air bag harness or AIR BAG fuse Possibly faulty points are as follows Check each of them and repair...

Page 728: ...this section along with a correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this sect...

Page 729: ...ION 10 2 1 With ignition switch OFF disconnect SDM A connector 2 Check proper connection to SDM at ter minals A11 and A12 or A5 and A6 3 If OK then measure resistance between A11 and A12 terminals or...

Page 730: ...or 2 Check proper connection to SDM at ter minals A11 and A12 or A5 and A6 3 If OK then measure resistance between A11 and A12 terminals or A5 and A6 terminals with connected Special Tool B 4 Is resis...

Page 731: ...elt preten sioner retractor assem bly Refer to SECTION 10 2 1 With ignition switch OFF disconnect Special Tool B and SDM A connec tor 2 Measure resistance between A11 or A6 and A17 terminals 3 Is resi...

Page 732: ...tensioner retractor assembly Refer to SECTION 10 2 1 With ignition switch OFF disconnect Special Tool B and SDM A connector 2 Measure voltage from A12 or A5 terminal to body ground 3 With ignition swi...

Page 733: ...TABLE STEP ACTION YES NO 1 1 Ignition switch OFF 2 Has air bag deployed Replace components and perform inspections as di rected in REPAIRS AND IN SPECTIONS REQUIRED AF TER AN ACCIDENT in this section...

Page 734: ...nnection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness co...

Page 735: ...rk perform following items 1 Reconnect all air bag system components ensure all components are properly mounted 2 Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected...

Page 736: ...and combination switch assembly Air bag wire harness Proper operation of the air bag system requires that any repairs to the vehicle structure return it to its original production configuration CAUTI...

Page 737: ...h crack peeled paint etc Check that SDM cannot be installed properly due to a cause in itself There is a gap between SDM and SDM plate or it cannot be fixed securely Check that connector or lead wire...

Page 738: ...TENTS AND POOR CONNECTIONS in this section Check wire harness clamps for tightness If any faulty condition is found correct or replace Seat belt pretensioner Check for dents cracks damage or fitness C...

Page 739: ...ay result in extended diag nostic time incorrect diagnosis and incorrect parts replacements Never use air bag component parts from another vehicle If the vehicle will be exposed to temperatures over 9...

Page 740: ...ts stopper from both right and left sides and disconnect Yellow connector 4 of passenger air bag infla tor module a Release locking of lock lever b After unlocked disconnect connector NOTE With AIR BA...

Page 741: ...is not rigidly attached to the vehicle Otherwise personal injury may result CAUTION After detecting one time of such collision as to meet de ployment conditions the SDM must not be used Refer to AIR B...

Page 742: ...or modules driver and passenger wipe it offimmediately with a dry cloth If air bag inflator module was dropped from a height of 90 cm 3 ft or more it should be replaced with a new one as an assem bly...

Page 743: ...lso when the seat belt pretensioners activate gas is generated and the seat belt 1 is retracted into the retractor assembly 2 quickly Note therefore that if they activate accidentally the seat belt pr...

Page 744: ...PRETENSIONERS WARNING The air bag inflator module and seat belt pretension er immediately after deployment activation is very hot Wait for at least 30 minutes to cool it off before pro ceeding the wo...

Page 745: ...spose of the live undeployed air bag inflator modules and the live inactivated seat belt pretensioners When disposal is necessary be sure to deploy activate the air bag and seat belt pretensioner acco...

Page 746: ...ect a tester whatever type it may be Never repair or disassemble SDM 3 If SDM has been dropped or if there are cracks dents or other defects in the case or plate replace it with a new one Check SDM 3...

Page 747: ...ag Inflator module was dropped from a height or 90 cm 3 ft or more it should be replaced Check air bag inflator module appearance visually for following symptoms and if any one of them is applicable r...

Page 748: ...efer to ENABLING AIR BAG SYSTEM of SERVICE PRECAUTIONS in this section 2 3 1 a 4 DRIVER AIR BAG INFLATOR MODULE Refer to DRIVER AIR BAG INFLATOR MODULE in SECTION 3C for removal inspection and install...

Page 749: ...utions must be observed for this work Failure to observe any of them may result in personal injury The procedure should be followed strictly as described here Be sure to read SERVICE PRECAUTIONS in th...

Page 750: ...elt pretension er s from vehicle referring to SECTION 3C 10B and 10 WARNING Always carry live air bag inflator module with trim cover away from you When storing a live air bag inflator module or when...

Page 751: ...e 1 is to be deployed A paved outdoor location where there is no activ ity is preferred If an outdoor location is not available a space on the shop floor where there is no activity and sufficient ven...

Page 752: ...seat belt pretensioner a Pull out the webbing 2 fully as shown in the figure and cut it at the root of the pretensioner retractor assembly 1 as shown in the figure b Clear a space on the ground about...

Page 753: ...sioner to the deployment harness connector and lock connec tor with lock lever 11 Notify all people in the immediate area that you intend to deploy activate the air bag inflator module or seat belt pr...

Page 754: ...4 Disconnect the deployment harness from power source 12V vehicle battery 2 and short 3 the two deployment harness leads together by fully seating one banana plug into the other 15 In the unlikely eve...

Page 755: ...proce dures 20 Ensure that the deployment harness has been disconnected from the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the other...

Page 756: ...e connector Yellow connector For seat belt pretensioner Remove both side driver and passenger side center pillar low er trim 1 and disconnect seat belt pretensioner connectors Yellow connectors 4 Conf...

Page 757: ...ner acti vates the rapid gas expansion will create a substantial report Wear suitable ear protection Notify all people in the immediate area that you intend to deploy the air bag inflator module or to...

Page 758: ...teps 2 through 19 to deploy activate air bag infla tor modules and seat belt pretensioners which has not been deployed activated if any 21 In the unlikely event that the air bag inflator module and th...

Page 759: ...retensioner im mediately after deployment activation is very hot Wait for 30 minutes to cool it off before handling it Never apply water oil etc to deployed air bag inflator module and the activated s...

Page 760: ...he specified digital multimeter Otherwise air bag deployment or personal injury may result 09932 75010 Air bag driver passenger load tool 09932 76010 Connector test adapter kit 09932 75030 Air bag dep...

Page 761: ...Prepared by Overseas Service Department 1st Ed May 1998 Printed in Japan Printing May 1999 610...

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