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Suzuki Samurai 1986, Service Manual

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Summary of Contents for Samurai 1986

Page 1: ......

Page 2: ...on approval The right is reserved to make changes at any time without notice And used as the main subject of description is the vehicle of standard specifications among others Therefore note that illu...

Page 3: ...FUEL FILTER EMISSION CONTROL SYSTEM ENGINE COOLING SYSTEM CAR HEATER IGNITION SYSTEM CRANKING SYSTEM CHARGING SYSTEM CLUTCH GEAR SHIFTING CONTROL TRANSMISSION TRANSFER GEAR BOX PROPELLER SHAFTS DIFFER...

Page 4: ...trument panel left side Refer to below figure for detailed VIN cord information and its location 5 1 C G 4 100001 Sequential Number Assembly Plant Model Year G 1986 H 1987 J 1988 Check Digit Body Type...

Page 5: ...ont or rear car end off the floor by jacking be sure to put the jack against differential portion of axle housing NOTE Don t get on the car get under it or service it in this state Fig O 3 Front Side...

Page 6: ...cularly important for engine overhauling 7 Have on hand liquid packing SUZUKI BOND No 1215 99000 31110 for ready use This packing dope is an essential item to assure leak free water and oil work mansh...

Page 7: ...en as practical and do each job properly as prescribed NOTE Engine cylinders are identified by numbers See Fig O 9 Counting from the front end the cylinders are referred to as No 1 No 2 No 3 and No 4...

Page 8: ...ecial tools assure three things 1 improved workmanship 2 speedy execution of jobs for which they are meant and 3 protection of parts and components against damage Here are the special tools pres cribe...

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Page 16: ...ill be marked with punch mark strength identification on the nut face Fig O 10 shows the different strength markings When replacing metric fasteners be careful to use bolts and nuts of the same streng...

Page 17: ...tightening torque chart for the applicable torque for each fastener When a fastener of greater strength than the original one is used however use the torque specified for the original fastener NOTE l...

Page 18: ...SECTION 1 PERIODIC MAINTENANCE SERVICE CONTENTS 1 1 MAINTENANCE SCHEDULE 1 2 ENGINE AND EMISSION CONTROL 1 5 1 3 CHASSIS AND BODY 1 17 1 1 2 1 1...

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Page 21: ...hoke system Carburetor shafts I L Every 7 500 miles 12 000 km or 6 months E Distributor cap and Ignition wiring 2 I Every 15 000 miles 24 000 km or 12 months ABCD Brake discs and pads Front I Every 7...

Page 22: ...tive battery lead to battery REPLACEMENT 1 Disconnect negative battery lead at battery 2 Loosen alternator adjusting bolt and pivot bolts 3 Replace water pump belt 4 Adjust belt tension to specificati...

Page 23: ...p belt tension to specifica tion 16 Connect negative battery lead to battery 3 VALVE LASH INSPECTION 1 Remove cylinder head cover 2 Inspect intake and exhaust valve lash and adjust as necessary 1 V ma...

Page 24: ...ter and drain plug for oil leakage 5 COOLING SYSTEM HOSES AND CONNECTIONS INSPECTION 1 Visually inspect cooling system hoses for any evidence of leakage and cracks Examine them for damage and check co...

Page 25: ...UTION To tighten the oil filter properly it is important to accurately identify the 1 position at which the filter 0 ring first contacts the mounting surface 5 Tighten the filter 3 4 turn from the poi...

Page 26: ...nd 4 2 liters heater 8 9 7 4 US Imp pt Reservoir tank 0 6 liters 1 3 1 1 US Imp pt I Total 4 8 liters 10 1 8 4US lmp pt WARNING To avoid danger of being burned do not touch exhaust system when system...

Page 27: ...t to specification Tightening 45 torque 55 N m 4 5 for oxygen sensor 5 5 kg m 33 0 39 5 lb ft 4 Connect oxygen sensor wire at the coupler securely and clamp its wire 5 Connect negative cable to batter...

Page 28: ...age Correct faulty condition if any 13 EXHAUST GAS RECIRCULATION EGR SYSTEM INSPECTION NOTE l Before checking confirm that altitude is not higher than 1 220 m 4 088 ftt atmospheric pressure is below 6...

Page 29: ...ecessary Refer to SECTION 5 for checking procedure A CHECK ENGINE CHECK ENGINE ligh t 3 Turn off CHECK ENGINE light cancel or check switch on steering holder bracket 4 Stop engine 15 WIRING HARNESS AN...

Page 30: ...essary any compo nent which is found to be in malcondition as described above 18 IGNITION WIRING REPLACEMENT 1 Disconnect high tension cords from spark plugs ignition coil and distributor 2 Connect ne...

Page 31: ...nk After releasing reinstall the cap 3 Disconnect inlet and outlet hoses from fuel filter located at the front part of fuel tank inside the right hand side of chassis 4 Remove fuel filter with clamp 5...

Page 32: ...le speed 28 IDLE MIXTURE INSPECTION 1 Warm up engine to normal operating tem perature 2 Remove seal rubber of duty check coupler and connect positive terminal of duty meter to Blue Red wire and negati...

Page 33: ...arking brake and block drive wheels 5 Start engine and warm it up to normal operating temperature stop engine 6 Be sure to check the following before idle mixutre adjustment l Fuel level is within rou...

Page 34: ...rry out air purge operation 33 BRAKE FLUID INSPECTION AND CHANGE INSPECTION 1 Check around master cylinder and reservoir for fluid leakage If found leaky correct 2 Check fluid level If fluid level is...

Page 35: ...for proper operation by moving free wheeling hub knob to LOCK and FREE positions The same check on both right and left wheels For checking procedure refer to MAINTE NANCE SERVICE p 17 29 of SECTION 1...

Page 36: ...above inspec tion replace absorbers 2 1 Shock absorber 2 Leaf spring WARNING When handling rear shock absorber in which high pressure gas is sealed make sure to observe the following precautions 1 Do...

Page 37: ...pecified oil as given in the below table Change Oil change procedure is as follows Place the car level and drain oil by removing drain plug Pour specified amount of specified oil as in the below table...

Page 38: ...igh ten them as necessary Repair or replace defective parts if any Refer to MAINTENANCE SERVICE on p 18 18 for particular check points 4 Inspect steering gear box for evidence of oil leakage If leakag...

Page 39: ...abnormal condition 3 Gearshift Lever Transmission and Transfer Check gearshift lever for smooth shifting to all positions and for good performance of transmission and transfer in any position 4 Brake...

Page 40: ...UST AND MUFFLER CLUTCH 2 9 TRANSMISSION DIFFERENTIALS 2 11 PROPELLER SHAFTS 2 12 BRAKES 2 12 SUSPENSION STEERING SYSTEM AND TIRES STARTING MOTOR 2 11 ALTERNATOR FUEL METER 2 19 2 14 SPEEDOMETER 2 19 2...

Page 41: ...ce or this switch open circuited 7 Loose or blown fuse Set right or replace 8 Improper ignition timing Adjust 9 Defective ignition coil Replace Faulty intake and exhaust systems 1 Carburetor out of ad...

Page 42: ...e as necessary 7 Leaky cylinder head gasket Replace Improperly timed ignition 1 Improper ignition timing 2 Defective spark plug 3 Worn distributor terminals 4 Leaks loose connection or disconnection o...

Page 43: ...t trying to resulting in leakage make the car move as 4 Leaky high tension cords Replace from a stop sign 5 Ignition timing out of adjustment Adjust as prescribed Abnormal condition in fuel system 1 I...

Page 44: ...5 Cracked rotor or cap in distributor Replace Emission control 1 Malfunctioning bowl vent solenoid valve 2 Malfunctioning throttle position switch wide open switch 3 Malfunctioning high altitude switc...

Page 45: ...Leaky carburetor and intake manifold gaskets Replace Abnormal detonation Abnormal condition in ignition system 1 Spark plugs tending to overheat Change plug heat value 2 Improper ignition timing Adjus...

Page 46: ...sh Others 1 Dragging brakes Repair or replace 2 Slipping clutch Adjust or replace 3 Blown cylinder head gasket Replace Engine noise Crankshaft noise Note Before check 1 Worn down bearings resulting in...

Page 47: ...heck and repair or air cleaner replace Abnormal condition in engine 1 Low compression Previously outlined 2 Poor valve seating Repair or replace 3 Improper valve clearance Adjust Emission control 1 Ai...

Page 48: ...g some fuel Replace 4 Broken or otherwise defective gasket Replace 5 Loose float chamber securing screws Retighten 2 3 EXHAUST AND MUFFLER Condition Poor muffling per formance Possible cause 1 Loose e...

Page 49: ...Cracked clutch disc 5 Pressure plate and diaphragm spring rattling 1 Clutch facings soaked with oil 2 Excessively worn clutch facings 3 Rivet heads showing out of the facing 4 Weakened torsion spring...

Page 50: ...oper mesh of drive pinion and ring gear 3 Improper tooth contact in the mesh between drive pinion and ring gear 4 Insufficient or wrong kind of gear oil 5 Ring gear wobbling when turning or ring gear...

Page 51: ...brake shoe linings Replace 7 Defective wheel cylinders Repair or replace 8 Malfunctioning caliper assembly Repair or replace Brake Pull Brakes not 1 Shoe linings wet with water or Replace working in...

Page 52: ...nt 5 Weakened or broken return springs in the brake Repair master cylinder Clean Check for soft hoses or damaged tubes and replace with new hoses and or new double walled steel brake tubing Check and...

Page 53: ...ster or bump on tire Replace tire 12 Disturbed front wheel alignment Check front wheel alignment Steering wheel pulling to one side car pulls 1 Unevenly worn wheel tires 2 Brake dragging in one road w...

Page 54: ...all studs 2 Bind in steering column 3 Lack of lubricant steering gear box 4 Disturbed front end alignment 5 Steering gear box adjustment 6 Tires not adequatley inflated Replace tie rod end Repair or r...

Page 55: ...lace Replace Tighten stabilizer bar bolts or replace bushes Replace shock absorbers or tighten mounting Replace Check loading STARTING MOTOR Condition Starter runs but pinion will not mesh into ring g...

Page 56: ...f magnet switch coil layer short circuit 3 Failure of returning action in ignition switch Possible cause 1 Loose or broken V belt 2 Battery cables loose corroded or worn 3 Low level of battery electro...

Page 57: ...ing Repair 2 Cover plate incorrectly positioned in plcae Repair 1 Insufficient pressure of wiper arm Replace 2 Deteriorated or hardened blade Replace 3 Blade improperly set Repair or replace 4 Windshi...

Page 58: ...able 2 Not enough oil in transfer Lubricate or replace Replenish 2 15 WATER TEMPERATURE METER Condition Faulty indication No indication Possible cause 1 Incomplete metal to metal contact in terminal c...

Page 59: ...CRIPTION 3 2 ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL 3 5 ENGINE REMOVAL 3 6 ENGINE DISASSEMBLY 3 9 INSPECTION OF ENGINE COMPONENTS 3 17 ENGINE REASSEMBLY 3 35 ENGINE INSTALLATION 3 53 ENGINE MAIN...

Page 60: ...gasoline unit with its S O H C Single overhead camshaft valve mechanism arranged for V type valve configuration This single overhead camshaft is mounted over the cylinder head it is driven from cranks...

Page 61: ...e connecting rod bearings by means of intersect ing passages drilled in the crankshaft and then injected from a small hole provided on the big end of connecting rod to lubricate piston rings and cylin...

Page 62: ...take valve 2 Exhaust valve 3 Rocker arms 4 Camshaft 6 Air induction nozzle 6 Air induction passage 7 Intake manifold a Carburetor _ _ Fig 3 7 3 Cylinder head and valve train 4 Cylinder Block The cylin...

Page 63: ...pection Cooling fan and fan shroud removal required I 13 Cooling fan 14 Camshaft timing belt pulley Replacement Replacement or inspection I 15 Crankshaft timing belt pulley 16 Timing belt Replacement...

Page 64: ...nd air inlet hose 1 Disconnect accelerator cable from carbure tor 10 Disconnect vacuum hoses of TCAC and canister from intake manifold 11 Remove fuel tank filler cap to release fuel vapor pressure in...

Page 65: ...e mount ing bracket and clutch release lever 27 Loosen drain plug to drain transmission oil 28 Remove propeller shaft interconnecting transmission case and transfer case 29 By using a chain block hold...

Page 66: ...echeck to ascertain all hoses electric wires and cables are disconnected from engine and transmission 34 Remove clutch lower plate 35 Separate transmission from engine Throughout this MANUAL 4 cylinde...

Page 67: ...and pans ready for setting aside disassembled parts in an orderly manner Place parts in trays and pans in such a way _ that they can be readily identified Put match Fig 3 4 3 marks or tags on them as...

Page 68: ...th special tool A hitched to belt from crank timing belt pulley and cam flywheel so that crankshaft will not turn shaft pulley after pushing up tensioner The crank timing belt pulley bolt at the plate...

Page 69: ...inside cover Fig 3 4 14 15 Remove water pump 1 Wrench 2 Camshaft timing belt pulley 3 Timing belt inside cover 4 General rod Fig 34 12 12 Using flywheel holder A Special tool remove crankshaft timing...

Page 70: ...r wrench 099 15 473 10 19 Draw water hoses off water pump inlet pipe Fig 3 4 2 1 Fig 3 4 18 20 Disconnect PCV Positive crankcase venti lation valve hose from cylinder head cover 21 Take down intake ma...

Page 71: ...27 Draw camshaft out toward rear end trans mission case side 28 Remove cylinder head ____ Fig 3 4 26 a Use valve lifter D E to compress valve spring in order to free valve cotter pieces for removal I...

Page 72: ...side to valve spring side Figure 3 4 29 NOTE Do not reuse valve guide once disassembled Be sure to use new valve guide Oversize when assembling NOTE Place disassembled parts except valve stem seal an...

Page 73: ...nd connecting rod assembly out through the top of cylinder bore CAUTION l Before pulling piston out scribe cylinder number on its crown l Be sure to identify each bearing cap for its connecting rod by...

Page 74: ...4 36 1 Rotor plate Press a n 1 1 Driver handle 2 Piston 3 Piston pin 4 Piston pin guide 5 Base 6 Support NOTE Itema 1 4 and 5 are in Special tool 1 09810 38210 I 4 b6 7 I Fig 3 4 37 Fig 3 4 39 b Remov...

Page 75: ...g them to determine whether repair is necessary or not Be sure to de scale water jackets Use compressed air to clear internal oil holes and passages Do not disturb set combinations of valves bearings...

Page 76: ...ness gauge readings to within the limit replace cylinder head Leakage of combustion gases from this gasketed joint is often due to a warped gasketed surface such leakage results in reduced power outpu...

Page 77: ...nout of rocker arm shaft Using V blocks and dial gauge check runout If runout exceeds the limit replace rocker arm shaft I Runout limit I 1 0 12 mm 0 004 in 1 I I Fig 3 5 7 0 Wear of rocker arm and ad...

Page 78: ...istor tion at its face and stem and replace as neces sary l Measure thickness of valve head If measured thickness exceeds its limit specified below replace valve Fig 3 5 9 I Valve head thickness I If...

Page 79: ...al runout 0 08 mm 0 003 in I Fig 3 612 Valve Seats CAUTION Valves to be checked and serviced for seat ing width and contact pattern must be those found satisfactory in regard to stem clearan ce in the...

Page 80: ...gles for exhaust valve 2 INLET VALVE SEAT Cutting sequence is the same as for exhaust valve seats but the second angle is 60 Seat width I for 1 3 1 5mm inlet valve seat I 0 0512 0 0590 in Fig 3 5 17 V...

Page 81: ...leakage caused by decreased seating Valve spring for 41 5 mm for 41 5 mm preload 54 7 64 3 lb 50 2 lb 1 63 in 1 63 in Fig 3 5 21 Measuring spring preload l Spring squareness Use a square and surface...

Page 82: ...haft and as necessary cylinder head too I Runout limit 1 0 10 mm 0 0039 in 1 Fig 3 5 23 0 Cam wear Using a micrometer measure height H of cam lobe If measured height is less than respective limits rep...

Page 83: ...e oversize piston 2 Using a cylinder gauge measure cylinder bore in thrust and axial directions at two positions as shown in Fig 3 5 28 If any of the following conditions exists rebore cylinder l Cyli...

Page 84: ...head and ring grooves using a suitable tool Inspect piston for faults cracks or other damage Damaged or faulty piston should be replaced 0 Piston diameter As indicated in Fig 3 5 31 piston diameter sh...

Page 85: ...g 0 2 0 0 3 3 m m 0 7 mm Piston 0 0079 0 0129 in 0 0275 in ring 2nd ring 0 20 0 35 mm 0 7 mm end 0 0079 0 0137 in 0 0275 in QaP Oil riilg 0 20 0 70 mm 1 8 mm 0 0079 0 0275 in 0 0708 in 1 Cylinder bloc...

Page 86: ...nd in defective condition must be replaced Two kinds of rod bearing are available standard size bearing and 0 25 mm under size bearing To distinguish them 0 25 mm undersize bearing has stamped number...

Page 87: ...crankshaft slowly If runout exceeds limit replace crankshaft Limit on runout 0 06mm 0 0023 in l Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner tha...

Page 88: ...determined from micrometer readings If any of journals is badly damaged or if the amount of uneven wear in the sense explained above exceeds its limit regrind or replace the crankshaft I Limit on out...

Page 89: ...es that the cap bore dia of bearing cap is within 49 006 49 012 mm and the fifth rightmost alphabet A indicates that the cap bore dia of cap is within 49 000 49 006 mm r l Fig 3 5 46 Stamped alphabets...

Page 90: ...here are five kinds of standard bearings differing in thickness To distinguish them they are painted in following colors at the position indicated in Fig 3 5 47 Each color indicates the following thic...

Page 91: ...indicates following thickness at center of bearing Color painted Bearing thickness I Green Red 2 121 2 125 mm 0 0835 0 0836 in I I I Black Red 2 124 2 128 mm 0 0836 0 0837 in Red only 2 127 2 131 mm 0...

Page 92: ...mp Flywheel l If ring gear is damaged cracked or worn replace flywheel l If surface contacting clutch disc is damaged or excessibly worn replace flywheel l Check flywheel for face runout with a dial w...

Page 93: ...torque wrenches and constantly refer to the specified values given on p 3 58 l Do not disregard match marks provided on parts Some of them are those given at the time of disassembly l There are many s...

Page 94: ...aring 2 Oi I groove Fig 3 6 3 Ins tatting thrust bearing 4 Install crankshaft to cylinder block 5 Oil crankshaft journals 6 When fitting bearing caps to journals after setting crankshaft in place be s...

Page 95: ...isassem bled a Wash clean and then dry all disassembled parts b Apply thin coat of engine oil to inner and outer rotors oil seal lip portion and inside surfaces of oil pump case and plate c Install ou...

Page 96: ...iston make sure to match piston with cylinder as follows a Each piston has a stamped number 1 or 2 as shown depending on its outer diameter or 2 Piston Fig 3 6 9 b There are also stamped numbers of 1...

Page 97: ...but ordinarily it is not necessary to dis criminate each piston by this number 1 Install connecting rod to piston After applying engine oil to piston pin holes in piston and connecting rod fit connect...

Page 98: ...alling these piston rings to piston with marked side of each ring faced foward top of piston l 1st ring differs from 2nd ring in thickness shape and color of the surface contacting cylinder wall Disti...

Page 99: ...wheel side Fig 3 6 19 Direction of arrow mark on piston head Use piston ring compressor Special tool to compress rings Guide connecting rod into place on the crankshaft Using a hammer handle tap pisto...

Page 100: ...lock After fitting oil pan to block run in secur ing bolts and start tightening at the center move wrench outward tightening one bolt at a time Tighten bolts to specified torque Tightening torque 9 12...

Page 101: ...head Heat cylinder head uniformly at a tempe rature of 80 to 100 C 176 to 212 F using care not to distort head and drive new valve guide into hole with special tools Refer to Fig 3 6 27 Drive in new v...

Page 102: ...ng special tool with hand Tapping or hitting special tool may cause damage on seal 7 i 1 Valve stem seal installer Special tool 09917 98210 2 Valve stem seal Fig 3 6 29 Valve stem seal installation 4...

Page 103: ...n crankshaft pulley side 1 4 4 1 Cylinder head gasket 2 Crankshaft pulley side 3 Flywheel side 4 Locating pin Fig 3 6 33 Cylinder head gasket installation 8 Install cylinder head onto cylinder block T...

Page 104: ...r arm shafts as shown in Fig 3 6 37 tighten rocker arm shaft screws to specified torque Tightening torque 9 12 N m for rocker arm shaft 0 9 1 2 kg m screws 7 0 8 5 lb ft NOTE Valve clearance is adjust...

Page 105: ...and nuts to specified torque Tightening torque N m kg m lb ft for bolts and nuts 18 28 1 8 2 8 13 5 20 0 Water pump 1 Install water pump gasket to cylinder block Use new gasket NOTE Clean cylinder bl...

Page 106: ...pecial tool 1 2 3 Timing belt guide Key Crank timing belt pulley 4 Pulley bolt A Flywheel holder 09924 I 7810 Fig 3 6 42 Installing guide key and pulley 3 Install camshaft timing belt pulley Fit pulle...

Page 107: ...damper Fig 3 646 Tensioner installation 6 Before installing timing belt to camshaft pulley and crankshaft timing belt pulley loosen all valve adjusting screws of intake and exhaust rocker arms fully o...

Page 108: ...o be free of any slack turn crankshaft clockwise fully twice after install ing belt After removing belt slack tighten tensioner stud first and then tensioner bolt to 24 30 N m 2 4 3 0 kg m 17 5 21 5 l...

Page 109: ...o body and then cooling fan and water pump pulley Make sure to refer to p 1 5 of this manual for adjusting procedure Distributor Case 1 Install distributor case O ring to cylinder head 2 Install distr...

Page 110: ...s an j nutS 22 35 2 2 3 5 16 0 25 0 Distributor 1 Install distributor to case For installation besure to refer to SECTION 8 IGNITION SYSTEM in this manual Valve Lash Clearance Adjustment Adjust valve...

Page 111: ...tarted check for oil leak abnormal noise and other malcondition Also check each part for operation 3 8 ENGINE MAINTENANCE SERVICE Fan Belt Adjust belt tension as outlined in SECTION 6 ENGINE COOLING S...

Page 112: ...this state check valve lashes at valves I and 0 Rotate cran kshaft exactly one turn and check the same at valves 8 and I Fig 3 8 3 EX Fig 3 8 4 Fig 3 8 5 Measuring valve lashes 5 Upon completion of ch...

Page 113: ...6 Crank engine with fully charged battery and read the highest pressure on compression gauge Standard Limit Max difference between any two cylinders Compression pressure 14 0 kg cm2 199 0 psi 400 r m...

Page 114: ...8 8 Oil pressure switch 3 Install oil pressure gauge special tool to vacated threaded hole Vacuum Measurement Engine vacuum that develops in intake line is a good indicator of engine condition Vacuum...

Page 115: ...place it is replacea ble a Leaky cylinder head gasket b Leaky inlet manifold gasket c Leaky valves d Weakened valve springs e Maladjusted valve clearance f Valve timing out of adjustment g Ignition mi...

Page 116: ...33 37 3 3 3 7 1 24 0 2 6 5 19 Crankshaft pully bolt I lo 13 I 1 0 1 3 I 7 5 9 0 20 Crankshaft timing belt pulley bolt 21 Timing belt cover bolt and nut I 65 75 I 6 5 7 5 1 47 5 5 4 0 I 9 12 I 0 9 1 2...

Page 117: ...CRIPTION 4 29 MAINTENANCE SERVICES 4 29 4 3 FUEL PUMP FILTER AND LINES 4 31 GENERAL DESCRIPTION 4 31 REMOVAL AND INSTALLATION 4 33 MAINTENANCE SERVICES 4 35 4 4 ACCELERATOR PEDAL 4 36 CAUTION THE ENGI...

Page 118: ...oid valve provided on top of the float chamber is to reduce the evaporative emissions 1 Air horn 2 Float chamber 3 Throttle chamber 4 Pump boot 5 Pump lever 6 Pump rod 7 Bracket 8 screw 9 Therm0 eleme...

Page 119: ...r a l I 29 Fig 4 1 1 Carburetor exploded view 4 3...

Page 120: ...N Fig 4 l 2 Carburetor cross section 4 4...

Page 121: ...maintain a constant level in the chamber As the fuel level in the chamber drops the float and the needle valve drops down allowing the fuel to enter the chamber As the fuel enters the chamber the flo...

Page 122: ...e carburetor bore through the off idle discharge port and the idle discharge hole Mixture control solenoid valve The primary system has the Mixture Control Solenoid MCS Valve In the MCS there is a plu...

Page 123: ...e 6 Idle down channel 7 Off idle discharge port 8 Idle discharge hole 9 Plunger 10 Air jet 11 Mixture adjusting screw 12 Pin 13 Solenoid valve Fuel cut 14 Economizer air bleeder Fuel cut system The pr...

Page 124: ...ctrical signals from the ECM 1 Primary main jet 2 Primary main air bleeder 3 Main discharge nozzle 4 Mixture control solenoid valve 5 Plunger 6 Fuel orifice 7 Fuel passage Fig 4 1 7 Primary main syste...

Page 125: ...bleeder 3 Main discharge hole 4 Primary throttle valve 5 Secondary throttle valve 6 Secondary diaphragm 7 VTV 8 VSV Acceleration Pump System This system operates to supply extra fuel to the primary si...

Page 126: ...re the plunger of the thermo wax is retracted at the up position and the fast idle cam rotates clockwise by the spring force As a result the cam follower pushed down by the cam causes the primary thro...

Page 127: ...gine room is cold below 7 C 44 F and thermal switch is ON 4 When engine speed after engine start is lower than 1 500 r min The ECM sends an electric signal to the Three Way Solenoid Valve TWSV Receivi...

Page 128: ...1 Bracket 3 EGR modulator 2 Twsv Fig 4 1 16 7 Disconnect water inlet and outlet hoses from carburetor 8 Disconnect accelerator cable from carburetor 9 Disconnect vacuum hoses from idle up actuator and...

Page 129: ...ion outlines procedure to be used for overhauling carburetor as removed from engine For removal and installation of carburetor from and to engine refer to the previous page NOTE l Be sure to replace g...

Page 130: ...valve filter 1 Air horn 3 Pump lever 2 Hose 4 Screw Fig 4 l 22 Needle valve seat and filter Fig 4 l 20 Air horn and hoses etc NOTE Never loosen 4 screws fixing element holder at this point 4 Remove mi...

Page 131: ...l Micro switches wide open switch and idle switch l Switch vent solenoid l Fuel cut solenoid valve l Mixture control solenoid valve l Secondary diaphragm choke piston and idle up actuator l Parts made...

Page 132: ...the boss on float chamber as shown in below figure 3 Install spring washer as below figure and torque four screws to specification Tightening torque for screws 4 7 N m 0 4 0 7 kg m 3 5 lb ft 1 Throttl...

Page 133: ...ny service and reinstalled after service work make sure to check switches for operation and adjust if necessary Check and adjustment for micro switches should be carried out with carbure tor removed f...

Page 134: ...air bleeders to air horn 1 Primary slow air No 1 bleeder 2 Secondary slow air bleeder Fig 4 l 36 Installing slow air bleeders 12 Be sure to apply silicone oil to mixture control solenoid valve seal b...

Page 135: ...e emission control system PCV system EG R valve Engine compression Also check the intake manifold carburetor and vacuum hoses for leakage Accelerator Cable Adjustment Check accelerator cable for play...

Page 136: ...on the air horn l Check float height with float weight applied to needle valve l As a gauge for checking float level use something whose thickness measurement is the same as specified level measuremen...

Page 137: ...by blowing air into the hose disconnected from actuator make sure that there is continuity between hoses Fig 4 l 45 1 TWSV Black 2 To intake manifold 3 To actuator Checking TWSV circuit 1 Warm up engi...

Page 138: ...is cold 3 Check to ensure that choke valve to carbure tor bore clearance is within following specifi cations when engine is cool I 6 mm C n NOTE As ambient temperature or engine coolant temperature ri...

Page 139: ...on as follows 1 Disconnect choke piston hose at throttle chamber 2 With choke valve pushed down to its closing side lightly by finger apply vacuum to choke piston hose with vacuum pump gauge and check...

Page 140: ...are in alignment as shown in below figure Fast idle cam Mark on cam Cam follower 3 Disconnect vacuum hose from TWSV and connect special tool vacuum pump gauge to its hose 1 2 3 4 5 6 7 8 T w s v Vacu...

Page 141: ...n above step 4 1 Unloader arm 2 Fast idle cam 3 Accelerator cable Fig 4 7 57 Unloader lever arm Checking Acceleration Pump 1 Remove air intake case 2 Make sure that fuel comes out of pump discharge no...

Page 142: ...ure of the following l Lead wires and hoses of engine emission control systems are connected securely l Accelerator cable has some play that is it is not tight l All vacuum hoses are connected securel...

Page 143: ...specification ac cording to following adjustment procedure Specified Duty I O 5 0 at 750 850 r min After inspection install seal rubber to duty check coupler Idle Mixture Adjustment The carburetor ha...

Page 144: ...l Idle up actuator does not operate 7 Check and adjust idle speed to specification if necessary 8 Remove seal rubber of duty check coupler and connect positive terminal of duty meter t o Blue Red wir...

Page 145: ...output Also the element must be cleaned periodically Dusty and dirty element causes decrease in output and increase in fuel consumption The dusty element even after cleaning should be replaced with a...

Page 146: ...g cap groove to case securely and be sure to clamp cap 4 Install air cleaner outlet hose Fig 4 2 3 Fig 4 2 4 1 1 Clamp 2 Groove 3 Install element and cap by fitting cap groove to case securely and be...

Page 147: ...P FILTER AND LINES GENERAL DESCRIPTION The main components of the fuel system are fuel tank fuel pump and fuel filter and it includes three lines fuel feed line fuel return line and fuel vapor line Fi...

Page 148: ...eturn circuit to the fuel tank In other words the fuel pump is kept in action as long as the engine is running so that the con stant flow of fuel through the pump keeps it cool 2 Fig 4 2 8 Fig 4 2 6 F...

Page 149: ...always observed l Disconnect negative cable at battery l DO NOT smoke and place NO SMOK I NG signs near work area l Be sure to have COZ fire extinguisher handy 0 Wear safety glasses l To release fuel...

Page 150: ...pump from cylinder head 5 Remove fuel pump rod from cylinder head 2 1 Fuel pump rod 2 Cylinder head Installation Reverse removal procedure for installation using care for the following l After oiling...

Page 151: ...r correct hose to pipe connec tion l Clamp hoses securely l Upon completion of installation start engine and check hose joints for leaks MAINTENANCE SERVICES Fuel Lines Visually inspect fuel lines and...

Page 152: ...nstall accelerator pedal return spring securely as shown in figure Fig 4 2 16 Adjustment of full open position 1 Loosen lock nut and tighten bolt slightly 2 Depress Dedal as far as throttle valve open...

Page 153: ...RE CONTROL SYSTEM 5 9 COMPUTER CONTROLLED EMISSION CONTROL SYSTEM 5 10 BOWL VENTILATION SYSTEM 5 12 FUEL CUT SYSTEM 5 13 EXHAUST GAS RECIRCULATION EGR SYSTEM 5 14 5 2 DIAGNOSIS 5 15 5 3 MAINTENANCE SE...

Page 154: ......

Page 155: ...T c c x 5 5 3...

Page 156: ...ocedures as well as a vacuum hose schematic with emission compo nents identified When servicing the engine or emission systems the Vehicle Emission Control Information Label should be checked for up t...

Page 157: ...he intake manifold is low when the opening of the throttle valve is large the PCV valve is wide open due to its spring force Thus a large amount of the blow by gas is drawn into the intake manifold On...

Page 158: ...case 7 Carburetor 8 Intake manifold 9 Check valve 10 Diaphragm 11 Warm air 12 Cold air 13 Orange System Operation When engine is started in cold weather the therm0 valve is closed because the temperat...

Page 159: ...d and liquid vapor separator The fuel vapor from the fuel tank is led into the canister and stored there when the engine is not running The fuel vapor from the carburetor float chamber is also stored...

Page 160: ...nd it reaches to the full open state at about 70 C 158 F While the engine at idle the throttle valve is closed and the vacuum in the intake manifold stays high As the HIC valve opens in this state the...

Page 161: ...old vacuum is constant As manifold vacuum increases according to rapid deceleration manifold vacuum applies to MCV chamber B through jet the MCV opens and introduces fresh air into the intake mani fol...

Page 162: ...the signal of the exhaust gas air fuel ratio sensed by the oxygen sensor is fed back to ECM and the carburetor air fuel ratio is controlled Electronic control module ECM The ECM controls the fuel cut...

Page 163: ...hermal switch 2 Intake manifold Fig 5 I 17 Thermal switch l Throttle position It is sensed by the micro switches wide open switch and idle switch installed on the carburetor 1 Idle micro switch 2 Wide...

Page 164: ...to make the mixture rich When the air temperature in the engine room is high the switch stops operating which means the air fuel ratio of the mixture is not controlled by the switch Refer to Fig 5 1 l...

Page 165: ...d that all below listed three conditions exist the fuel cut solenoid valve operates to cut the fuel feed to the engine temporarily by closing the fuel passage when it received a signal from the ECM Su...

Page 166: ...uch as high speed driving on the other hand the exhaust pressure is high By the high exhaust pressure the diaphragm in the modulator is pushed up and closes its valve As the air does not enter the vac...

Page 167: ...lfunctioning feed back system Carbon monoxide CO Excessive carbon monoxide l Engine not at normal operating temperature emissions are due to a mixture that is rich 0 Maladjusted idle mixture l Imprope...

Page 168: ...Check EGR modulator valve blocked or air flow restricted Check EGR modulator valve operation Engine stalls on decelerations Wrong or no EGR gasket EGR modulator valve blocked of air flow restricted I...

Page 169: ...IAGNOSIS Condition Unstable idle frequent stalling Oil in air cleaner Possible Cause EGR valve hoses misrouted BVSV is out of order Possible Cause PCV valve completely stuck Hose plugged PCV system pl...

Page 170: ...over the end of disconnect ed PCV hose to check for vacuum If there is no vacuum check for clogged hose or valve Replace as necessary 4 After checking vacuum stop engine and check PCV valve for stick...

Page 171: ...tive in above step 2 or 3 inspect following parts according to each procedure Air control actuator 1 Disconnect vacuum hose from therm0 sensor 2 Make sure that damper opens fully when more than 20 cmH...

Page 172: ...s back to zero position as soon as pump operation is stopped Fig 5 3 7 Checking check valve If found defective replace 3 Install check valve with its orange side directed toward therm0 valve EVAPORATI...

Page 173: ...er than 65 C 149 F temperature when HIC bi metal temperature is lower than 45 C 113 F warm it up with hair drier or photo light before checking l Never touch bimetal or valve in HIC 1 Below 45 C 113 F...

Page 174: ...omatical flashing at above mileages proves that system is in good condition Should any of following malcondition occur the system check can be performed according to System check flow chart even when...

Page 175: ...K ENGINE lightflashes Flashing of light proves that system is in good condition If light does not flash it can be caused by one of the following Check them and replace or adjust as necessary l Defecti...

Page 176: ...witch Check for continuity between termi nals When throttle valve is at idle position ohmmeter should indicated zero ohm 4 Open throttle valve by l 4 to l 2 and ohm meter indicator should indicate inf...

Page 177: ...e the clearance between throttle valve and carburetor bore as shown in below figure The clearance should be within 6 0 7 2 mm 0 24 0 28 in If the clearance is out of specified range make adjustment by...

Page 178: ...ap of duty check coupler located on dash panel and connect terminals with a lead wire to short them 6 Turn ignition switch ON and OFF repeatedly without starting engine and check if MCSV operating sou...

Page 179: ...mmeter between terminals on switch side 2 Make sure that switch is ON ohmmeter indicates Zero ohm when atmospheric temperature is below 7 C 44 F and OFF ohmmeter indicates infinity when above 19 5 C 6...

Page 180: ...ygen sensor as it may cause damage to the sensor i 1 Oxygen sertsor side terminal 2 Ground 3 Left side fender 4 While keeping the engine running at 1 500 2 000 rpm turn the wide open micro switch OFF...

Page 181: ...operate Therefore check if the ECM is properly grounded at these two points according to the following procedure 1 Turn OFF the ignition switch 2 Disconnect the coupler from the ECM 3 Connect an ohmm...

Page 182: ...the ground is not securely grounded or disconnected The below figures show the particular points where B and B G wires are grounded Check for their secure grounding by referring to these figures 1 Bod...

Page 183: ...the same with each of the terminals 0 0 0 0 8 and 0 If the measured voltage between each terminal and the body is about 12V each circuit is in good condition 4 If about 12V is not obtained in the abo...

Page 184: ...1 Blue lead wire 11 P B Pink Black lead wire 12 Gr B Gray Black lead wire 13 Lg R Light green Red lead wire 14 B G Black Green lead wire Fig 5 3 43 Checking sensors and their circuits 4 If each ohmmet...

Page 185: ...en the terminals I oxygen sensor signal and ground as shown in below figure 5 If the voltmeter indicator deflects between OV and 0 8V while racing the engine at a speed between idling and 1 500 2 000...

Page 186: ...ECM sends out feed back signal that is feed back system operates properly NOTE If indicator doesn t deflect at all reverse connection positive prod to terminal and negative prod to body and check In...

Page 187: ...ion switch but don t run the engine 3 Connect a voltmeter between the terminal and the body ground as shown in below figure If the voltmeter indicates 11 14V when each equipment is operated individual...

Page 188: ...ON but without starting engine and check to be sure that air passes through solenoid in both cases 1 Carburetor 2 Fuel cut solenoid valve Fig 5 3 48 Fuel cut solenoid valve 2 Warm up engine to normal...

Page 189: ...be sure that diaphragm moves toward in below figure during acceleration and toward during deceleration 1 During acceleration 2 During deceleration 3 Diaphragm Fig 5 3 51 Movement of EGR valve diaphrag...

Page 190: ...SV 2 Cool water 3 Blow air nozzle 4 No air nozzle 5 Thermometer above 65 C 149 F in hot water blow nozzle 3 Air should come out of nozzle 4 6 Fig 5 3 54 Checking B VSV 2 EG R modu latorl 1 Check filte...

Page 191: ...5 Vacuum pump gauge Fig 5 3 57 Checking EG R modulator 2 4 After checking install modulator and connect hoses securely Refer to Fig 5 l l for con necting Three way solenoid valve TWSV 1 Disconnect 2 v...

Page 192: ...THERMOSTAT 6 7 RADIATOR 6 8 WATER PUMP 6 8 6 4 IMPORTANT STEPS FOR REINSTALLATION 6 9 WATER PUMP 6 9 THERMOSTAT 6 9 COOLING FAN AND WATER PUMP BELT 6 9 RADIATOR 6 10 6 5 MAINTENANCE SERVICE 6 10 WATE...

Page 193: ...ad Coolant then returns to the water pump through intake manifold heater inlet hose heater unit heater outlet hose and water intake pipe During normal temperatures thermostat open coolant takes the sa...

Page 194: ...ng the solution to boil Removal of the radiator cap whileengine is hot and pressure is high will cause the solution to boil instantaneously and possibly with explosive force spewing the solution over...

Page 195: ...gh the radiator In the top portion of the thermostat an air bleed valve is provided this valve is for venting out the gas or air if any that is accumulated in the circuit There are two types of thermo...

Page 196: ...hoses loosen screw on each pipe or hose clip and pull hose end off 3 Water Pump Drive Belt 1 Loosen water pump drive belt tension 2 Remove belt 4 Cooling Fan Fan Clutch and Water Pump Pulley 1 Remove...

Page 197: ...ver I Fig 6 11 Fig 6 13 7 Water Pump 1 Drain cooling system Refer to 1 Coolant draining on previous page 2 Remove the radiator shroud and cooling fan clutch at the same time Refer to item 4 on previou...

Page 198: ...alve of thermostat is clear Should this valve be clogged engine would tend to overheat Fig 6 16 1 Air bleed valve 2 Check valve seat for some foreign matters 3 Check thermostatic movement of wax pelle...

Page 199: ...ores removing road grimes and trashes Excessive rust or scale formation on the wet side of the radiator lowers the cooling efficiency Flattened or bent fins obstruct the flow of air through the core t...

Page 200: ...ation 4 Install crankshaft pulley water pump pulley pump drive belt cooling fan clutch and radiator shroud 5 Adjust intake and exhaust valve lashes For adjustment and related data refer to p 3 53 of t...

Page 201: ...wear and cleanliness If it is necessary to replace belt refer to 6 5 for procedure 2 Check belt for tension Belt is in proper tension when it deflects 6 to 9 mm 0 24 0 35 in under thumb pressure about...

Page 202: ...30 50 Ratio of corn Itr 1 4413 36 2 4012 40 pound to us pt 3 04l7 10 5 0715 07 cooling water Imp pt 2 5315 91 4 221422 Reservoir tank 0 6 liters 1 3 1 1 US Imp pt I Total 4 8 liters 10 1 8 4 US Imp p...

Page 203: ...herwise deteriorated 6 Clean frontal area of radiator core NOTE After installing radiator cap 0 to radiator make sure that its ear is aligned with reservoir tank hose I as shown in Figure If not turn...

Page 204: ...ixture coolant refer to page 6 11 of GOLDEN CRUISER 1200 and _ water to radiator and tank Fill radiator to the base of radiator filler neck and reservoir tank to FULL level mark Reinstall reservoir ta...

Page 205: ...7 1 7 2 7 3 7 4 SECTION 7 CAR HEATER CONTENTS DESCRIPTION 7 2 7 ELECTRICAL CIRCUIT HEATER SERVICES 7 4 REMOVAL AND INSTALLATION 7 5 7 3 7 1...

Page 206: ...rates quietly The air is heated by the engine coolant and the warm air is blown into the car interior by the blower motor The blower motor is driven electrically independent of engine speed and operat...

Page 207: ...circuit indicated as blower motor resistance in the diagram Under this condition the blower runs slowly By turning sliding the blower switch lever fully the full battery voltage is applied across the...

Page 208: ...check continuity between Blue White and Blue Black terminals using a circuit tester I Blower resistor specification Several ohms Heater hoses Check heater hoses for the connection con dition breakage...

Page 209: ...and loosen ashtray plate screws 4 Disconnect front food opening cable from lock ass y 5 Loosen panel box stay screw and hood opening cable lock nut on back side of panel box cover 6 Disconnect lead w...

Page 210: ...r installation exercising care to the following 1 Make definitely sure to insert holder plate between holder and body 2 When installing parts be careful to prevent wire harness from being caught betwe...

Page 211: ...hat car heater operates correctly to each control lever position If found faulty adjust by changing control cable clamp position l Check to ensure that each wire harnesses I are securely clamped Ff r...

Page 212: ...ISTRIBUTOR 8 3 IGNITION COIL SPARK PLUG 8 4 8 2 MAINTENANCE SERVICE 8 5 HIGH TENSION CORD 8 5 SPARK PLUG 8 5 IGNITION COIL 8 5 DISTRIBUTOR 8 5 IGNITION TIMING 8 9 DISTRIBUTOR DRIVE GEAR 8 10 8 3 IMPOR...

Page 213: ...d turns on and off the ignitor which switches off the ignition coil primary current Thus the high voltage is induced in the secondary winding of ignition coil and ignition sparks are generated at the...

Page 214: ...ancing action is accomplished by twisting the top shaft piece relative to the bot tom one in the direction of shaft rotation The single rotor is mounted on the top piece The twisting movement is produ...

Page 215: ...motive force voltage in secondary winding in a greater number of coil turns These live parts are housed in a tight insulator case topped by the cap Note that the cap has three terminals one high tensi...

Page 216: ...il Remove ignition coil and check it as follows Measure primary coil resistance Using ohmmeter measure resistance between positive and negative terminals Primary coil resistance 1 35 1 65D Measure sec...

Page 217: ...utor and then ignitor Loosen 2 screws securing generator Using blade screwdriver move generator and adjust air gap to specification 1 lgnitor 2 Generator 3 Generator screw 4 Signal rotor air gap 5 Bla...

Page 218: ...nnect red and white wires from ignitor 4 Connect an ohmmeter a bulb and 12 voltage battery to ignitor as shown in Figure 8 16 Set ohmmeter at 1 ohm to 10 ohm range Then bring ohmmeter negative prod to...

Page 219: ...ect gear teeth for wear and see if the backlash is normal or not Excessive backlash can be told by turning the shaft back and forth with its driven gear in mesh with driving gear Maladjusted ignition...

Page 220: ...er 5 With engine running at specified idle speed direct the timing light to timing check win dow If 10 BTDC timing mark on flywheel appears aligned to timing match mark ignition is properly timed Fig...

Page 221: ...Replacing worn down drive gear is not enough Inspect driven gear a part of the distributor assembly too and replace it if badly worn down Important reminders for removal and installa tion Before remo...

Page 222: ...into gear case in such a way that center of distributor flange will coincide with the distributor mounting screw hole provided in distributor gear case When distributor is inserted properly position o...

Page 223: ...DISASSEMBLY 9 6 STARTING MOTOR INSPECTION 9 7 COMMUTATOR 9 7 FIELD COIL 9 8 9 7 9 8 CONTENTS BRUSH 9 8 BRUSH HOLDER AND SPRING 9 9 DRIVE LEVER 9 9 PINION 9 9 ARMATURE SHAFT BUSH 9 9 MAGNETIC SWITCH 9...

Page 224: ...shown in Fig 9 2 and has field coils mounted in starting motor yoke frame The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected agai...

Page 225: ...using 4 Armature ring 5 Armature stop ring 6 Over running clutch 7 Pinion drive lever 8 Magnetic switch 9 Commutator end cover 10 Brush spring 11 Brush holder 12 Brush 13 Washer 14 Commutator end bush...

Page 226: ...Brush length 17 mm 0 67 in Number of pinion teeth No load characteristic 6 60 A maximum at 11 5 volts 6 600 r min minimum I Load characteristic 150 A maximum at 9 volts and 0 29 kg m torque 1 900 r mi...

Page 227: ...e SUZUKI SUPER GREASE A 99ooo 25010 Use following procedure to remove starter 1 Disconnect negative battery lead at battery 2 Disconnect magnetic switch lead wire BLACK YELLOW and battery cable from s...

Page 228: ...coil lead to terminal on the head of magnetic switch Fig 9 6 2 Take off magnetic switch from starting motor body by removing two mounting screws 3 Loosen 2 bolts and 2 screws to remove commutator end...

Page 229: ...ture is free from bend Bent shaft must be replaced Commutator out of round Standard Limit 0 05 mm 0 0019 in 0 4 mm or less 0 015 in Inspect commutator for wear If below limit replace armature Standard...

Page 230: ...f there is no continuity at any test point there is an open circuit and armature must be replaced Fig 9 16 2 Inspect Field Coil Open circuit test Check for continuity between brush and bare surface If...

Page 231: ...eplaced Fig 9 19 Inspect brush spring for wear damage or other abnormal conditions Replace if necessary Brush spring tension Fig 920 5 Inspect Drive Lever Inspect drive lever for wear Replace if neces...

Page 232: ...hould be replaced Fig 925 Pull in coil open circuit test Check for continuity across magnetic switch s terminal and M terminal If no continuity exists the coil is open and should be replaced Fig 926 F...

Page 233: ...ger does not move replace magnetic switch Fig Before testing disconnect field coil lead from terminal M w 9 28 2 Hold in Test While connected as above with plunger out disconnect negative lead from te...

Page 234: ...een thread end of clutch switch and clutch pedal distance 3 in Fig 9 32 satisfies following specification when clutch pedal is depressed fully Tighten clutch switch lock nut to specified torque Clutch...

Page 235: ...ENERAL DESCRIPTION 10 2 DATA AND SPECIFICATION 10 3 DIAGNOSIS 10 3 REMOVAL 10 6 DISASSEMBLY 10 6 INSPECTION 10 8 ASSEMBLY 10 9 10 2 BATTERY 10 10 GENERAL DESCRIPTION 10 10 CARE OF THE BATTERY 10 10 RE...

Page 236: ...6 Pulley The basic charging system is the IC integral regulator charging system The internal components are connected electrically as shown below Th Th 1 Alternator with regulator ass y 6 Field coil...

Page 237: ...nted in the end frame protects the diodes from high voltages and suppresses radio noise DATA AND SPECIFICATION Nominal operating voltaga Max alternator output 12 volts 45A No load alternator speed I D...

Page 238: ...normally The following procedures also apply to cars with a voltmeter 1 Insure that the undercharged condition has not been caused by accessories left on for extended period 2 Check drive belt for pro...

Page 239: ...TERNATOR SERVICE on p 10 6 and 40 C 0 25Oc 135Oc check field windings for grounds and shorts 4O FI 77 F 275 F If defective replace rotor b Load check Fig 10 4 If voltage is higher than standard value...

Page 240: ...ss y 3 Drive end frame bearing 4 Rotor 5 Rear end frame bearing 6 Rear end frame 7 Regulator aa y 6 Terminal insulation bush 9 Brush 10 Rectifier 11 Rear end cover p i 6 r 10 Fig 706 1 Remove nut and...

Page 241: ...off pulley 10 When removing rear bearing use bearing puller Fig 108 Fig lo 11 8 Remove rotor from drive end frame Fig 109 9 When removing front end bearing remove 4 4 mm bearing retainer screws Fig 10...

Page 242: ...ty between slip ring and rotor If there is continuity replace rotor Fig 10 13 1 Check stator for no open circuits Using an ohmmeter check all leads for con tinuity If there is no continuity replace st...

Page 243: ...ground then swap two leads Of two tester indications one should be about 10 ohms meaning continuity and the other should be infinity non continuity If not replace rectifier assembly Condenser Check c...

Page 244: ...lizer for the electrical system And third it can for a limited time provide energy when the electrical load exceeds the output of the generator Each new car shipped from the factory is fitted with fol...

Page 245: ...rging or reduce charging rate Jump starting in case of emergency with auxiliary booster battery NOTE l Do not push or tow the vehicle to start Damage to the emission system and or to other parts of th...

Page 246: ...the jump start and turn off electrical accessories Then start the engine in the car with the discharged battery 6 Reverse these directions exactly when remov ing the jumper cables The negative cable...

Page 247: ...11 CLUTCH CONTENTS 11 l GENERAL DESCRIPTION 11 2 11 2 REMOVAL 11 3 INSPECTION OF COMPONENTS 11 5 INSTALLATION 11 7 11 5 MAINTENANCk SERVICES 11 8 RECOMMENDED TORQUE SPECIFICATION 11 10 11 2 11 4 11 6...

Page 248: ...diaphragm spring in such a way that the peripheral edge of the spring pushes on the pressure plate against the flywheel with the disc in between when the clutch release bearing is held back Tnis is t...

Page 249: ...isc 7 No 2 bushing 2 Clutch cover 8 Clutch release shaft 3 Lock washer 9 Return spring 4 Cover bolt 10 No 1 bushing 5 Clutch release bearing 11 Shaft seal 8 Clutch release fork pin 12 Shaft cowr Fig 1...

Page 250: ...h cover and disc Fig 1 l 3 Special tool Flywheel holder 09924 17810 Clutch Release Bearing Remove clutch release bearing from transmission input shaft bearing retainer Input Shaft End Bearing Use bear...

Page 251: ...facing by measuring depth of each rivet head depression i e distance between rivet head and facing surface If depressing is found to have reached service limit at any of the holes replace clutch disc...

Page 252: ...abnormal noise when spun anaturned by hand Fig 11 10 Input Shaft Bearing Replace input shaft bearing if it sticks rattles or makes abnormal noise when spun and turned by hand Flywheel Check surface co...

Page 253: ...nput shaft bearing 2 Special tool Input shaft bearing installer 09925 98210 Fig 1 l 13 1 Clutch Disc and Clutch Cover Using special tool clutch center guide install clutch disc and clutch cover Tighte...

Page 254: ...rocedure 11 5 MAINTENANCE SERVICES Clutch Pedal Height Adjust height of clutch pedal with clutch pedal stop bolt so that pedal is level with brake pedal Tighten lock nut after adjusting 4 I I 18 1 Clu...

Page 255: ...nt nut At least 5 mm 0 196 in Fig 1 l 20 Clutch Cable Routing 1 For left hand side steering vehicle Clutch Cable Lubrication Apply grease to hook part of clutch cable Clutch cable 1 Clutch pedal y v F...

Page 256: ...from arrow C 11 6 RECOMMENDED TORQUE SPECIFICATION Be sure to torque each nut or bolt if loosened to specification given below If specified tightening torque for particular bolt or nut is not include...

Page 257: ...GUIDE PINS 12 3 INSPECTION OF COMPONENTS GEAR SHIFT LEVER REVERSE LOW SPEED SELECT GUIDE PINS GEAR SHIFT FORK SHAFT 12 4 INSTALLATION REVERSE LOW SPEED GUIDE PINS GEAR SHIFT LEVER CASE GEAR SHIFT CONT...

Page 258: ...5 16 17 18 19 Gear shift lever knob Gear shift lever Gear shift lever boot No 2 Gear shift lever boot No 1 Gear shift lever case cover Gear shift lever locating bolt Gear shift lever case Reverse sele...

Page 259: ...t lever out of gear shift lever case Fig 12 4 Gear Shift Lever Select Guide Pins 1 After gear shift lever is removed according to foregoing steps 1 through 4 remove gear shift lever case by loosening...

Page 260: ...ct Guide Pins Check both select guide pins where gear shift lever contacts 0 for stepped wear Replace worn select guide pin Move shaft and check low speed select guide pin for smooth movement without...

Page 261: ...re installing them into gear shift lever case Fig 12 11 When fitting low speed select guide pin into gear shift lever case tighten locating bolt while pushing pin so that bolt goes in the groove provi...

Page 262: ...er boot bolt 4 7 0 4 0 7 3 0 5 0 Lever locating bolt 1 4 2 0 1 4 2 0 10 5 14 0 0 Lever case bolt 1 8 2 8 1 8 2 8 13 5 20 0 a Low speed select pin bolt 4 7 0 4 0 7 3 0 5 0 APPLY to Between gear shift l...

Page 263: ...th gear 6 I Circlip 7 Synchronizer reverse hub set 8 Synchronizer key 9 Synchronizer spring 10 Gear bush 11 Needle bearing 12 Reverse gear 13 Main shaft bearing washer 14 Main shaft bearing 15 C ring...

Page 264: ...3rd gear Low soeed qear shift fork High speed gear shift fork Reduction drive gear 2ndqsar Low gear Tar Input shaft ha A Counter shaft Spking Fig 13 2 13 2...

Page 265: ...rReverse idle gear 13 2 TRANSMISSION GEAR RATIO Primary gear ratio 35123 I Primary speed ratio Gear ratio Secondary ratios Speed ratio Overall speed reduction ratio 41 18 2 277 3 466 1 521 Low Second...

Page 266: ...f lever case Fig 13 2 3 Fig 13 2 2 In Engine Room 3 Disconnect negative and positive cords from battery terminals 4 Disconnect back light and fifth switch lead wires at coupler respectively 5 Disconne...

Page 267: ...Remove clutch release shaft spring from shaft With special tool A applied in such a position as shown in Fig 13 3 2 tap the end of special tool to take out bush and cap Clutch release bush remover A...

Page 268: ...ut main shaft assembly A steel bar similar in shape to screwdriver may have to be used to pry two cases apart as shown In such a case do not stick bar too far into between two mating faces or faces ma...

Page 269: ...ft with gear Fig 13 8 Fig 13 6 2 Remove countershaft rear bearing Bearing puller B 09913 65135 Fig 13 7 4 Remove circlip from countershaft Push out countershaft to extension case side by using hydraul...

Page 270: ...10 2 Remove circlip retaining hub of high speed synchronizer sleeve and slide off sleeve hub third driven gear and needle bearing from main shaft Fig 13 13 Fig 13 l 1 3 Remove circlip retaining rear b...

Page 271: ...ow there is a ball in washer which is located under bearing Be sure to prevent it from falling off and getting lost Hydraulic press Fig 13 16 Fig 13 18 7 Remove bearing washer and reverse gear bush on...

Page 272: ...hift yoke pin High speed gear shift fork 5th select return spring Reverse gear shift rim spring E ring 14 Fig 13 21 Gear shift yokel For shift yoke removal drive out yoke pin with spring pin remover s...

Page 273: ...be careful not to let locating ball interlock ball and spring fly away 1 CAUTION 3 Drive yoke pin out of low speed gear shift fork as in above step 2 and pull out fork shaft and fork When removing yo...

Page 274: ...Sleeves Check contact surfaces for wear or damage Measure clearance between fork and sleeve I Maximum clearance j 1 0 mm 0 039 in 1 Main Shaft Check each part of shaft for wear discoloration or damag...

Page 275: ...two at peripheral teeth as shown in Fig 13 35 If clearance exceeds service limit replacement is necessary I Clearance between gear and ring I I I Standard S e r v i c e l i m i t 1 fJ l O 1 4mm 1 iI n...

Page 276: ...hs of key and slot or in other words the key clearance in the slot and is prescribed to extend at least a third l 3 of the chamfer With the synchronizer properly assembled on the shaft push in and twi...

Page 277: ...TALLATION NOTE l Before installation wash each part and apply specified gear oil to sliding faces of bearing and gear l Use new circlips on shaft for reinstallation Don t reuse used circlips l Tighten...

Page 278: ...r needle bearing spring synchronizer ring low gear ball and washer onto main shaft Fit ball into hole in shaft and install washer so that its slot comes over ball 0 To direct washer correctly bring it...

Page 279: ...d to main shaft rear bearing and sleeve so that the side whose inside is stepped is also directed to main shaft rear bearing Sleeve Main shaft rear bearing side H b Fig 13 48 7 Fit reverse hub circlip...

Page 280: ...all synchronizer ring needle bearing and input shaft Fig 13 56 Counter Shaft and Reverse Idle Gear 1 Drive counter shaft front bearing into lower case Then using plastic hammer drive counter shaft int...

Page 281: ...r shaft rear bearing onto it Fig 13 61 Fig 13 59 4 Install idle gear and washer onto reverse gear shaft and pin into it Install above as assembled into lower case with pin ij and washer tongue aligned...

Page 282: ...t order 1 Install 3 locating springs into 3 holes in upper case Fit locating ball in Fig 13 64 on top of locating spring in hole 1 Locating spring 2 Locating ball 3 Upper case 2 Insert low speed gear...

Page 283: ...rse gear shift shaft into upper case as described in 2 and 3 Yokes 1 Install low speed gear shift yoke as shown below using care for its direction Low speed ear shift yoke Yoke pin 3 JJ Yoke pit Yoke...

Page 284: ...and reverse gear shaft installed in lower case check to ensure that bearing stopper rings are fitted in both sides of lower case as shown below Also check for 2 knock pins 0 Fig 13 75 Fig 13 73 2 Make...

Page 285: ...ER GREASE A 99000 25010 to oil seal lip 3 Clean surface of extension case to mate with transmission case and uniformly apply sealant SUZUKI BOND No 1215 99000 31110 Fig 13 80 6 Tighten case bolts to s...

Page 286: ...r bolts 18 28 1 8 2 8 13 5 20 0 4 Check transmission input shaft for easy rotation by hand 5 Check each select and shift shaft for opera tion Clutch Release Bearing Before installing bearing apply gre...

Page 287: ...I 20 Fig 13 85 Oil filler plug Oil drain plup Oil level plug After filling transmission with oil torque oil filler and drain plugs to specification Tightening torque N m for oil drain and kg m lb ft f...

Page 288: ...each bolt and nut according to specification given below whenever loosened If specified torque for particular bolt or nut is not included in the list refer to page O 13 System Gear shifting control Tr...

Page 289: ...FLOWS OF TRANSFER DRIVE 14 3 14 3 GEAR RATIO DATA 14 4 14 4 TRANSFER SERVICES NOT REQUIRING TRANSFER REMOVAL 14 5 14 5 REMOVAL 14 6 14 6 DISASSEMBLY 14 8 14 7 INSPECTION OF COMPONENTS 14 12 14 8 REAS...

Page 290: ...hree axis configuration and two sliding clutches The selection is effected by actuating these clutches from a single control lever located beside the driver s seat The gear box is mounted on a chassis...

Page 291: ...ar clutch Gear shift control lever position a wheel drive Rear wheel drive Fig 14 2 4 Wheel Drive HIGH All Wheel Drive on HIGH Under the conditions of rear wheel drive described above front shifter fo...

Page 292: ...to couple rear shaft to front shaft and rear shifter fork actuates rear clutch to couple low gear to rear shaft Front shaft and rear shaft run together on From LOW To front whe Fig 14 4 14 3 GEAR RATI...

Page 293: ...t front shaft bearing 5 Transfer output front shaft Replacement or inspection Replacement Replacement 6 Transfer front case Replacement 7 Front drive clutch hub Replacement or inspection 8 Front drive...

Page 294: ...5 2 Remove clamp and boot from transfer gear box Fig 14 7 4 Drain out oil from gear box by loosening its drain plug Fig 14 8 5 Disconnect speedometer drive cable from transfer gear box Transfer gear...

Page 295: ...6 Disconnect 4WD switch lead wire at coupler 7 Remove 3 mounting nuts securing gear box to chassis and take down gear box 14 7 Fig 14 11...

Page 296: ...31 Speedometer Driven Gear Loosen speedometer driven gear case bolt and remove speedometer driven gear case with gear Transfer Front Case Remove the indicator light switch from front case NOTE Use car...

Page 297: ...ening center case and rear case together Do not loosen bolt at this point By tapping rear case and output rear shaft with a plastic hammer separate center and rear case Fig 14 22 Given below are proce...

Page 298: ...and spring will jump out of hole use care not to lose them Fig 14 25 4 Hammer output rear shaft with a plastic hammer to drive it out of center case 5 Pull out counter gear Remove counter shaft loosen...

Page 299: ...e to prevent damage to needle roller bearing in output rear shaft when removing clutch hub A 0 9 9 2 6 3 8 0 1 0 Fig 14 30 9 Remove front bearing by using bearing puller and puller attachment special...

Page 300: ...s case remove input shaft from rear case by hammering thick part of case with a plastic hammer Fig 14 34 14 7 INSPECTION OF COMPONENTS Gear Teeth Inspect gear teeth 0 internal teeth of rear clutch sle...

Page 301: ...ith gear bearing and thrust washer installed on shaft check for side clearances of gears If clearance exceeds service limit replace thrust washer I Side clearance of gear Standard Service limit I outp...

Page 302: ...ng them in reassembly with gear oil and SUZUKI SUPER GREASE A 99000 25010 l Oil seals 0 rings gaskets and similar sealing members must be in perfect condition For these members use replacement parts i...

Page 303: ...14 44 1 After installing bearing long high gear and thrust washer press fit bearing 1 and then hub by using bearing installer special tool Bearing installer A 0991384510 Fig 14 45 2 Fit circlip secur...

Page 304: ...nce may cause oil leakage broken bearing and abnormal noise l Take the same measurement at 3 to 4 diffe rent positions and use their mean 6 1 1 Center case Center case 5 5 Bearing circlip Bearing circ...

Page 305: ...case Available shim 0 1 0 3 0 5 mm size thickness 0 004 0 012 0 020 in I Output shaft Just as with input shaft take measurements of A B and C as indicated in Fig 14 48 1 calculate shim thickness and i...

Page 306: ...ts face without depressions against case and fit its bent portion securely into groove in case NOTE Apply ample amount of grease to both surfaces of washer so as to lubricate sliding surfaces and prev...

Page 307: ...l needle roller bearings spacer and counter gear on counter shaft Fig 14 55 6 Install output shaft assembly to center case Fig 14 56 7 When installing front drive shift shaft and reduction shift shaft...

Page 308: ...hammer Tighten center case securing bolts to specified torque NOTE l Matching must be made carefully so as not to move countershaft thrust washers out of place l Be sure to install shims determined i...

Page 309: ...nter case 3 Check front case to ensure that it is provided with 2 dowel pins Fig 14 65 4 Install front case to center case Fig 14 66 5 When installing speedometer driven gear and its gear case in rear...

Page 310: ...tal position in both front to rear and side to side directions Oil level plug and oil filler plug are one and the same as shown in figure If oil flows out of filler plug hole or if oil level is found...

Page 311: ...ock Universal joint flange Oil filler and drain plug Cross joint bolt nut Transfer mounting nut Transfer mounting bracket bolt Universal joint flange nut Counter shaft lock plate bolt Center case bolt...

Page 312: ...15 PROPELLER SHAFTS CONTENTS 15 1 GENERAL DESCRIPTION 15 2 15 2 REMOVAL 15 3 15 3 INSTALLATION 15 3 15 4 MAINTENANCE SERVICES 15 4 15 5 TIGHTENING TORQUE 15 5 15 6 DISASSEMBLY 15 6 15 7 REASSEMBLY 15...

Page 313: ...e from the transmission to the transfer gear box No 2 shaft and No 3 shaft extend from the transfer gear box the former driving the front axle and the latter the rear axle The cross spider in each uni...

Page 314: ...tally in its front and rear direc tion However if only car front is hoisted be sure to drain transmission oil before with drawing propeller shaft No 1 Fig 15 2 The installing procedure is reverse of t...

Page 315: ...ks 15 4 MAINTENANCE SERVICES Lubrication Inside yoke of each universal joint has a grease nipple At regular intervals stated in the recom mended servicing schedule pump in grease to relubricate joint...

Page 316: ...GHTENING TORQUE Check following bolts and nuts for tightness and retighten them as necessary Fastening parts I N m I kg m lb ft I Propeller shaft bolt 23 30 2 3 3 0 84 nut 17 0 21 5 15 5 Bolts Nuts Fi...

Page 317: ...0 16 in Fig 15 14 3 Tapping yoke with a hammer completely remove bearing race 4 Take out bearing race on the other side in the same way as in 2 and 3 l Disassembling on flange yoke side Push out beari...

Page 318: ...to bearing race to prevent rollers in bearing race from coming out Fig 15 17 1 Copper hammer 2 Bearing race 3 Yoke 4 Spider 2 Insert the other bearing race on the opposite side into yoke tapping with...

Page 319: ...6 inspect propeller shaft and flange yoke for damage and propeller shaft for runout If damage is found or shaft runout exceeds specifications replace I I 1 Runout limit 0 8 mm 0 031 in Fig 15 19 15 8...

Page 320: ...NERAL DESCRIPTION 16 2 16 2 REMOVAL 16 3 16 3 DISASSEMBLY 16 6 16 4 INSPECTION AND ADJUSTMENT OF COMPONENTS 16 7 16 5 REASSEMBLY 16 13 16 6 INSTALLATION 16 15 16 7 MAINTENANCE SERVICES 16 16 16 8 RECO...

Page 321: ...iding action occurs in tooth meshing between pinion and gear Here lies the reason why use of hypoid gear oil is specified for the differential Four differential pinions are used in the differential ca...

Page 322: ...e so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pedal with caliper removed Fig 16 2 Fig 16 3 At each tie rod end remove nut and disconnect the e...

Page 323: ...down carrier assembly For Rear Differential After taking down rear wheels remove brake drums by using special tools NOTE Before removing brake drum check to ensure that parking brake lever is not pull...

Page 324: ...ll plug ready for use when disconnect ing pipe As pipe comes off the wheel cylinder plug the pipe to prevent brake fluid from leaking out And remove 4 brake backing plate securing bolts Fig 16 9 2 Plu...

Page 325: ...andled at the time of reas sembly Fig 16 13 Scribed match marks At each side loosen bolts on bearing adjuster stopper remove bearing cap securing bolts and take off cap Lift differential case assembly...

Page 326: ...To check thrust play assemble differential gearing and case as shown in Fig 16 19 fasten ing together two case halves by tightening securing bolts to prescribed torque By compar ing thrust play readin...

Page 327: ...l indicator on dummy letting the indicator spindle protrude 5 to 6 mm from the bottom of dummy as shown in Fig 16 21 1 5 6 mm 0 197 0 236 in 16 8 2 Feed dummy pinion with bearings into the carrier pos...

Page 328: ...ily by tightening torque of bevel pinion nut Adjust preload of bevel pinion bearings as follows 1 Install pinion bearings spacer bevel pinion oil seal and universal joint flange to diffe rential carri...

Page 329: ...from pinion by running in one adjuster and running out the other adjuster by equal amount Turning the adjuster one notch changes backlash by about 0 05 mm 0 002 in CAUTION l Adjust preload on side bea...

Page 330: ...while holding the pinion in a braking manner and examine the contact patterns in reference to the following chart c Contact is roughly centered and somewhat more displaced toward toe than toward heel...

Page 331: ...eplace the defective member Irregular patterns If the pattern is not oval it means that bevel gear is defective High or low spots on tooth surfaces or on the seat of bevel gear are the cause of irregu...

Page 332: ...Drive Bevel Gear Bolts Bolts securing bevel gear to differential case are subject to shear stress since drive is transmitted by these bolts from gear to case For this reason they are special bolts mad...

Page 333: ...nstaller 09913 75510 2 For outer race of gear side bearing use special tools 3 After installing proper bevel pinion shim s press fit inner race to bevel pinion using special tools Special tool Bearing...

Page 334: ...Fig 16 31 0 Scribed match marks Fig 16 32 Sealant SUZUKI BOND NO 1215 99000 31110 Front Axle Shaft and Steering Knuckle For installation them refer to Front Suspen sion Installation in SECTION 17 of t...

Page 335: ...ntial oil Hypoid gear oil specification SAE 8OW 90 75W 80 or 75W 90 Oil Front 2 0 litres 4 2 3 5 US Imp pt capacity Rear 1 5 litres 3 2 2 6 US Imp pt It is highly recommended to use SAE 75W 90 gear oi...

Page 336: ...ajor repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute des...

Page 337: ...ingpins for steering action The Barfield joint transmits drive without varying the angular velocity of drive The Barfield joint is enclosed by the knuckle which is shaped integral with the knuckle arm...

Page 338: ...haft drive flange 4 Wheel hub 5 Dust cover 6 Oil seal 7 King pin 8 King pin bearing 9 Oil seal 10 Steering knuckle 11 Disc brake holder 12 Disc brake caliper 13 Shock absorber 14 Spring bumper 15 Axle...

Page 339: ...itted in two groups of raceways one group is on the outer race and the other group on the inner race Each ball is in its own raceways as if it were locked between the two races in the direction of rot...

Page 340: ...bush bracket bolts remove stabilizer Fig 17 1 5 Leaf Spring 1 Raise car In this operation garage jack or hoist must not be positioned against front suspension related parts When garage jack is used p...

Page 341: ...per with a wire hook or the like so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pedal with caliper removed Fig 17 1 9 4 Remove brake disc NOTE If...

Page 342: ...rive flange and take off drive flange Fig 17 1 13 8 Straighten bent part of lock washer and remove wheel bearing lock nut with special tool I Fig 17 1 15 Special tool Front Wheel Bearing Nut Socket Wr...

Page 343: ...lts securing kingpins upper lower At this point king pins mustn t be removed Fig 17 1 19 3 Remove disc dust cover caliper holder and wheel spindle Fig 17 1 20 4 Remove tie rod end castle nut and disco...

Page 344: ...eering knuckle removal p 17 8 and 17 9 and then follow steps 2 and 3 given below 2 Drain oil from differential housing by loosen ing drain plug Fig 17 1 23 7 Pull off steering knuckle NOTE When steeri...

Page 345: ...nd pull motion is given to live axle shaft and wheel spindle held in both hands as shown in figure There should be no play at all but a play of up to 1 5 mm 0 06 in is permissible If play exceeds serv...

Page 346: ...earing with new one Fig 17 1 32 Steering Knuckle Oil Seal The oil seal used at the spherical sliding joint between the knuckle and the inner case accom plishes the additional purposes of keeping out r...

Page 347: ...Fig 17 1 34 17 12...

Page 348: ...17 13...

Page 349: ...l 7 0 9 0 kg m 51 O 65 0 lb ft Install lock washer in body outer side 1 Stabilizer nut q Paint Tighten to the following specified torque in unloaded condition 22 35 N m 2 2 3 5 kg m 16 0 25 0 lb ft St...

Page 350: ...and left leaf springs by means of spring seats and U bolts The two shock absorbers right left are installed with their lower ends attached to the spring seats and the upper ends to the chassis frame a...

Page 351: ...chassis to support raised body NOTE Don t let rear axle housing hang on brake hose or pipe If it occurs hose or pipe may be d amag ed To prevent it always hold rear axle housing of raised car with sa...

Page 352: ...he shaft grind with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin Rear wheel bearing retainer ring Rear axle shaft Break with a chisel the thin ring and it can b...

Page 353: ...Fig 17 2 12 17 18...

Page 354: ...17 19...

Page 355: ...in diameter cut off Cover with a vinyl envelope as shown so that drill dust will not scatter around Leaf Spring and Bumper 1 Inspect leaf spring for crack wear and damage NOTE Special attention must b...

Page 356: ...ad 2 2 6 6 lb If preload is not within the above specifica tion adjust bearing preload according to following adjustment Adjustment 1 After removing wheel bearing lock nut and lock washer tighten bear...

Page 357: ...loaded tightened condition there will be no appreciable rattle of wheel To check king pins and their tapered roller bearings jack up the front end and shake wheel to feel any rattle as shown in figure...

Page 358: ...tighten king pin bolts to specified torque Knuckle arm starting 1 O 1 8 kg 2 20 3 96 lb torque force without oil seal Available sizes of 0 1 0 5 mm shim for kingpins 0 004 0 02 in r QzL King pin shim...

Page 359: ...ply grease Apply sealer n Rear Wheel Bearing 1 Check wheel bearings for wear When measur ing thrust play apply a dial gauge to drum center Thrust play Limit Rear 0 8 mm 0 03 in 1 When measurement exce...

Page 360: ...Fig 17 3 19 Fig 17 3 20 Fig 17 3 21 5 Fig 17 3 23 Ci Fig 17 3 24 Fig 17 3 22 17 25...

Page 361: ...UE SPECIFICATIONS Fastening parts Front wheel bearing lock nut Differential oil drain plug 1 8 2 5 1 8 2 5 13 5 18 0 Differential oil filler level plug 35 50 3 5 5 0 25 5 36 0 Rear hub nut 5 0 8 0 5 0...

Page 362: ...and LOCK When the knob is set to the FREE position the axle shaft and wheel are disconnected and the revolution of the front wheels becomes free When it is set to the LOCK position the axle shaft and...

Page 363: ...ll gasket A and free wheeling hub body ass y on front wheel hub I N m kg m lb ft Tightening torque 20 30 2 0 3 0 14 5 21 5 Fig 17 5 5 4 Put bolt into front axle shaft and pull out the shaft and fit sn...

Page 364: ...To check free wheeling hubs operation jack up the front end move the knob of free wheeling hub between FREE and LOCK positions and check for smoothness Also check if wheel operates correctly with the...

Page 365: ...RECOMMENDED TORQUE SPECIFICATIONS NOTE All steering system fasteners are important parts in that they could affect the performance of vital parts and systems and or could result in major repair expen...

Page 366: ...l with the dead axle sleeve Another damping action is available which will be mentioned below The steering system formed by the components named above is designed for easy steering high durability and...

Page 367: ...Left hand steering vehicle Drag I Steering wheel Steering lower shaft od Steering damper Steering gaar box upper shaft 18 3 Fig 18 1 1...

Page 368: ...18 1 Steering angle inside 29 3 Steering angle outside 26 3 Steering wheel diameter 400 mm 15 74 in Minimum turning radius 5 1 m 16 73 ft 5 Toe in 2 6 mm 0 079 0 236 in ig Camber 1 degree 1 45 Kingpi...

Page 369: ...the plastic shear pins which maintain column length especially Steering Hand Wheel 1 Disconnect negative battery cable 2 Pull horn button to remove Fig 18 3 3 After loosening steering shaft nut remov...

Page 370: ...witch 3 Remove the bolt joining steering shafts in engine room Fig 18 9 4 Remove steering column ass y NOTE l Don t separate steering column assembly into steering column and shaft If column or shaft...

Page 371: ...witch 3 Remove the bolt joining steering shafts in engine room Fig 18 9 4 Remove steering column ass y NOTE l Don t separate steering column assembly into steering column and shaft If column or shaft...

Page 372: ...er from pitman arm CA2 Special tool Tie rod end remover 09913 65210 18 8 3 Steering gear box is secured in place by mounting bolts Remove these bolts and take down gear box Fig 18 14 Tie Rod and Tie R...

Page 373: ...justment of worm shaft starting torque The steering gear box is provided with adjust ing bolt which gives preload to sector shaft Fig 18 19 1 Adjusting bolt Make an adjustment according to the followi...

Page 374: ...orm shaft starting torque is checked all right another check should be carried out on worm shaft operating torque in its entire operating range turning the worm shaft all the way to the right and left...

Page 375: ...0 mm 0 0 039 in from the bottom of slot If not replace column assembly 2 Within 0 1 0 mm 0 0 039 in 3 Thickness gauge Fig 18 23 1 A j 635 5 mm 25 02 in Fig 18 24 3 Take measurement B of steering lowe...

Page 376: ...aft 2 Align hub on steering lock with groove of steering shaft and rotate shaft to assure that steering shaft is locked Fig 18 28 1 Hub 2 Groove Fig 18 29 4 Turn ignition key to ACC or ON position and...

Page 377: ...ll steering damper stay directing its circular boss side upward l Mount steering damper and steering damper stay bolts from the top l Torque steering damper pin nut and damper nut to specification whi...

Page 378: ...II before fining it 1 Steering column seal I Steering column bolt tightening torque I When installing the steering column 1 make sure to fit seal rubber in the rubber 1J Steering column nut tightening...

Page 379: ...Steering Lower Shaft and Joint Universal joint rubber joint bolt Steering rubber ir Fig 18 31 11 0 18 0lb ft 18 15...

Page 380: ...tighten tie rod end lock nuts to specified torque 18 8 WHEEL ALIGNMENT Front alignment refers to the angular relation ship between the front wheels the front suspension attaching parts and the ground...

Page 381: ...ed to check alignment and follow manufac ture s instructions 6 Regardless of equipment used to check alignment the car must be on a level surface both fore and aft and transversely 7 Check to be sure...

Page 382: ...for rattle and damage If rattle and damage is found replace defective part with a new one 0 Steering Rubber joint Inspect rubber joint for evidence of crack or breakage and make sure that its bolts a...

Page 383: ...tire or snow chain clearance to body and chassis NOTE NOTE Do not mix different types of tires on the same car such as radial bias and bias belted tires except in emergencies because car handling may...

Page 384: ...ce by scraping and wire brushing Installing wheels without good metal to metal contact at the mounting surfaces can cause wheel nuts to loosen which can later allow a wheel to come off while the car i...

Page 385: ...ting a tire the bead area should be well lubricated with an approved tire lubricant After mounting inflate to 220kPa 32 psi so that beads are completely seated WARNING Do not stand over tire when infl...

Page 386: ...flange bolt 20 30 2 0 3 0 14 5 21 5 Steering gear box nut 7 0 9 0 7 0 9 0 51 O 65 0 Drag rod castle nut 30 70 3 0 7 0 22 0 50 5 I I I Tie rod end castle nut 30 55 3 0 5 5 22 0 39 5 Tie rod end lock nu...

Page 387: ...uality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and weakeni...

Page 388: ...included within the brake circuit which connects the master cylinder and the rear wheel brake In this brake system the disc brake type is used for the front wheel brake and a drum brake type leading...

Page 389: ...condary piston stopper bolt 5 Seal ring 6 Piston stopper seal ring 7 Cylinder cup 8 Master cylinder seal ring 9 Connector screw 10 Reservoir connector grommet 11 Master cylinder reservoir 12 Cylinder...

Page 390: ...aulic component is removed or brake line disconnected bleed the brake system The torque values specified are for dry unlubricated fasteners 1 Piston stopper circllp 2 Piston stopper 3 Piston stopper s...

Page 391: ...he pressure acts on rear wheel brakes right left One circuit operation Secondary chamber b circuit failure In this case the leftward movement of the piston A has but little effect in causing the fluid...

Page 392: ...he disc creating friction to stop the car For details refer to OPERATION in the next page NOTE Lubricate parts as specified Do not use lubricated shop air on brake parts as damage to rubber compo nent...

Page 393: ...seal Piston seal Winder Rubber seal I I I Piston Hydraulic pressure OFF Fig 19 7 Clearance correction Piston Hydraulic pressure ON When oil pressure is applied to the piston the piston moves forward...

Page 394: ...or by clean ing wheel brake parts with a dry brush or with compressed air A water dampened cloth should be used Many wheel brake parts contain asbestos fibers which can become airborne if dust is crea...

Page 395: ...mber on the piston 2 3 Being actuated by this pressure the piston 2 moves to the left piston 3 moves to the right in the following figure and presses the brake shoe against the brake drum thus produci...

Page 396: ...e amount of clearance B by means of the return spring In this way the brake shoe to drum clearance is automatically adjusted constant every time the brake pedal is depressed The brake shoe to drum cle...

Page 397: ...parts where indicat ed with silicone grease provided in kits The torque values specified are for dry unlubricated fasteners If any hydraulic component is removed or brake line disconnected bleed the b...

Page 398: ...lve has a double function of a vacuum valve and air valve That is as shown in the figure the booster control valve closes between the A and B chambers as its outer end C contacts the booster piston se...

Page 399: ...it is In this way a small brake pedal depressing force is made into a strong push to the master cylinder push rod to produce high hydraulic pressure Vacuum valve C I Control valve 1 Booster control v...

Page 400: ...ad After taking down the wheel remove brake pads according to the following procedure 1 Remove caliper antirattle clip Fig 19 17 2 Remove caliper guide pin caps 2 pcs 3 Remove caliper guide pins 2 pcs...

Page 401: ...an be pushed out of cylinder WARNING Do not apply too highly compressed air which will cause piston to jump out of cylinder It should be taken out gradually with moderately compressed air Do not place...

Page 402: ...NTS Brake Pad Check pad lining for wear When wear exceeds its limit replace with a new one Fig 19 27 CAUTION Never polish pad lining with sandpaper If lining is polished with sandpaper hard particles...

Page 403: ...atches on disc surface noticed at the time of specified inspection or replacement are normal and the disc is not defective if these are not serious But when there are deep scratches or scratches all o...

Page 404: ...linder taking care not to twist it Piston and Boot 1 Before inserting piston into cylinder install boot onto piston as shown below 1 Boot 2 Piston 2 Fit boot as it is in the above figure into boot gro...

Page 405: ...ct flexible hose to caliper as shown below and tighten hose bolt to specified torque Connect the other end of hose to chassis body bracket being careful not to kink it with front wheels directed strai...

Page 406: ...djustment Disc for flatness Improper flatness brings disc into contact with lining during rotation and makes rotation heavy To check this measure disc deflection Spring measure 19 3 REAR DRUM BRAKE RE...

Page 407: ...drums are removed they should be thoroughly cleaned and inspected for cracks scores deep grooves Cracked Scored or Grooved Drum A cracked drum is unsafe for further service and must be replaced Do no...

Page 408: ...disassembled parts for wear cracks corrosion or damage NOTE Clean wheel cylinder components with brake fluid Fig 19 46 Fig 19 45 If one of brake linings is worn to or beyond service limit all linings...

Page 409: ...d and ratchet and push down ratchet as shown in figure 2 Ratchet 3 Driver Above figure shows ratchet position where brake shoe todrum clearance 3 Install parking brake shoe lever stopper plate NOTE Ma...

Page 410: ...o specified torque 3 Install breather plug cap 8 12N m 14 18 N m 0 8 1 2 kg m I 4 1 8 kg m 4 6 0 8 5 lb ft 10 5 13 0 lb ft 1 Brake back plate 3 Brake pipe 2 Brake pipe flare nut 4 Wheel cylinder bolts...

Page 411: ...Parking brake shoe lever 3 Brake back plate Fig 19 52 1 Parking brake shoe lever stopper Plate 2 Connect brake cable joint to parking brake shoe lever by using joint pin Insert joint pin down from the...

Page 412: ...oil 6 Torque wheel nuts and brake drum nuts to specification NOTE If brake backing plate was removed from wheel cylinder or brake pipe was disconnected from wheel cylinder Bleed air from brake system...

Page 413: ...allow brake fluid to get on painted surfaces 6 Remove 2 attaching nuts and washers 7 Remove master cylinder DISASSEMBLY 1 Remove circlip 2 Remove primary piston by using compressed air as shown Be ca...

Page 414: ...ng the fluid boiling point Keep all fluid containers capped to prevent contamination Fluid to fill reservoir with is indicated on reservoir cap of the car with embossed letters or in owner s manual su...

Page 415: ...Depress and install circlip nuts to specification 3 When using new grommets lubricate them with the same fluid as the one to fill reser voir with Then press fit grommets to master cylinder Grommets mu...

Page 416: ...anel 5 Attaching nuts 6 Master cylinder 7 Gasket 8 Split pin 9 Master cylinder pin 10 Gasket 11 Attaching nuts Fig 19 65 49 P I ii 1 Vacuum check valve 2 Grommet 3 Booster No 1 body 4 Piston rod 5 Rea...

Page 417: ...No 1 and No 2 bodies to facilitate their installation No 1 body projecting part No 1 body projecting part No 2 body depressed part Make match marking I Fig 19 70 5 Remove booster from special tool an...

Page 418: ...ecial tools as shown NOTE Removed oil seal must not be reused 1 Special tool 09951 082101 Special tool k 109951 W lO 0 9 Remove diaphragm from pressure plate NOTE Don t use screwdriver or any other to...

Page 419: ...ter piston rod is adjusted to provide specified clearance between piston rod end and master cylinder piston Master Fig 19 76 Clearance D Booster piston rod mwe 09950 98210 3 1 Gasket 2 Master cylinder...

Page 420: ...amage Replace Damaged or worn seal surfaces Replace Damage or wear Replace Damage Replace Damage or bend Replace 1 Scratches scores pits dents or Replace unless easily other damage affecting rolling o...

Page 421: ...allation apply grease as shown Sliding surface against piston sealed surface Fig 19 81 3 Compress air valve assembly and insert valve stopper key NOTE Be sure that valve assembly is in piston A as ind...

Page 422: ...pring Then check to be sure that spring is in piston spring guide Fig 19 88 1 No 2 body 2 Return spring 3 Piston Put spring into piston spring guide 11 Put No 1 and No 2 bodies together by aligning ma...

Page 423: ...ee page 19 33 Check length of push rod clevis Refer to Fig 19 91 1 Install booster to dash panel as shown Then connect booster push rod clevis to pedal arm with pin and split pin 2 Torque booster atta...

Page 424: ...Fig 19 6 1 19 38 19 6 PARKING BRAKE...

Page 425: ...k in extreme right and extreme left turn conditions If hose makes any contact remove and correct Fill and maintain brake fluid level in reser voir Bleed brake system NOTE Be sure to install brake flex...

Page 426: ...refer top 19 19 Install the flexible hose so that it won t be kinked when the steering wheel is straightened After installing the flexible hose turn the steering wheel to the right fully and check tha...

Page 427: ...talling backing plate onto axle housing apply SEALING COMPOUND 366E 99000 31090 to mating sur faces of both parts Brake backing plate compound hose groove securely and clamp hose Air bleeder To flexib...

Page 428: ...EL INSPECTION Be sure to use particular brake fluid either as marked on reservoir cap of that car or recom mended in owner s manual which comes along with that car Use of any other fluid is strictly p...

Page 429: ...hown as A in figure is within 0 5 1 O mm 0 02 0 04 in Then tighten lock nut to specified torque 1 Brake pedal 2 Contact plate 3 Stop light switch 4 Lock nut EXCESSIVE PEDAL TRAVEL CHECK 1 Start the en...

Page 430: ...ically according to maintenance schedule and whenever wheels are removed for tire rotation or other reason For wear check of pad linings refer to p 19 16 REAR BRAKE DRUM INSPECTION Inspect brake drum...

Page 431: ...ble adjusting nut Pi St per n u t cab e Fig 19 8 8 No 1 BRAKE PEDAL PLAY INSPECTION Pedal play should be within below specification If out of specification check stop light switch for proper installat...

Page 432: ...specified torque and check entire brake circuit to make sure that no fluid leakage exists Right brake caliper I r ____ I I A n i Left brake caliper 1 Left wheel cylinder Fig 19 8 10 1 Fill master cyl...

Page 433: ...ith and without a tester Ordinarily it is possi ble to roughly determine its condition without using a tester NOTE For this check make sure that no air is in hydraulic line INSPECTION WITHOUT TESTER C...

Page 434: ...and make sure that pedal travel doesn t change Fig 19 8 19 Check Air Tightness Under Load 1 With engine running depress brake pedal Then stop engine while holding brake pedal depressed Hold Fig 19 8...

Page 435: ...ooster nut lo 16 1 O 1 6 7 5 11 5 7 Brake pipe 6 way joint bolt 6 1 0 0 6 1 O 4 5 7 0 8 Brake flare nut 1 4 1 8 1 4 1 8 10 5 13 0 9 Brake pedal shaft nut 1 8 2 8 1 8 2 8 13 5 20 0 10 Universal joint f...

Page 436: ...20 2 DESCRIPTION 20 2 REMOVAL 2 3 INSTALLATION 20 5 WINDSHIELD 20 8 CLEANlNG 20 8 INSTALLATION 20 9 20 3 BACK DOOR APPLICABLE TO HARD TOP VEHICLE 20 11 CHASSIS DIMENSIONS 20 13 20 2 WINDSHIELD 20 4 20...

Page 437: ...inge 7 Door upper hinge 8 Door weatherstrip 9 Door trim board 10 Door glass 11 Glass bottom channel 12 Regulator 13 Regulator roller holder 14 Inside handle 15 Door key cylinder 16 Outside handle 17 D...

Page 438: ...e inside handle case Fig 20 1 3 3 Remove inside pull handle 4 Loosen two screws securing the stopper band and take off the band 5 Remove door trim board Fig 20 1 5 6 Remove the door water proof film F...

Page 439: ...carrying out door glass removal steps 1 through 6 and 8 move on to the following steps to take off the door window regulator 1 Remove 2 screws securing the door window regulator roller holder upper si...

Page 440: ...STALLATION Door Window Glass or Regulator Reverse the removal sequence to install the door window glass or regulator However be careful of the following points Door window regulator When installing do...

Page 441: ...dle Install the handle at the angle as specified in below figure with the door window glass closed raised all the way up Fig 20 1 19 Front Door Lock Reverse the removal sequence to install the door lo...

Page 442: ...decrease striker spacers fitted in A position behind the striker to adjust dimensions to below values as shown in below figure After adjustment check the difference in level between the door and ther...

Page 443: ...glass and window panel body Fig 20 2 2 NOTE When removing the urethane gum from the window panel body apply a masking tape along the edge of the gummed surface to protect the painted surface from dama...

Page 444: ...5 Glass installation When assembling the glass into the weather strip s glass channel and when assembling the glass and weatherstrip assembly to the window panel body soapy water must not be used as l...

Page 445: ...agent should be of the type which conforms to the material of the weatherstrip having the above mentioned strength Also it must not affect the painted surface weatherstrip or glass l Until when the bo...

Page 446: ...Door weatherstrip 16 Door stop male DOOR LOCK AND STRICKER ADJUSTMENT Door Outside Open Rod When installing open rod onto outside open handle 0 adjust clearances A to 0 2 mm 0 0 079 in and B to 2 mm...

Page 447: ...er to right or left CAUTION Do not adjust the door lock t l 31 0 320mm Door inner panel 1 22 1 26 in Striker fitting surface Spacer fitting position E Handling of Back Door Balancer WARNING l Handle t...

Page 448: ...20 13...

Page 449: ...NING LAMP 21 8 OIL PRESSURE LAMP 4 WHEEL DRIVE LAMP 21 10 SEAT BELT WARNING LAMP BUZZER I I 21 14 21 15 WIRING HARNESS ROUTING 21 16 WIRING DIAGRAM SECTION 21 BODY ELECTRICAL EQUIPMENT CONTENTS 21 9 2...

Page 450: ...21 2...

Page 451: ...ight 16 Temp meter and parking brake light 17 Illumination light Charge light 18 Tachometer Engine oil pressure light 19 Seat belt warning buzzer CHECK ENGINE light 20 Combination meter Diode 21 Check...

Page 452: ...t illumination light meter illumination light Wire color B Black Br Y Brown Yellow R Red R w Red White RIBI Red Blue B Y Black Yellow WIBI White Blue W R WhitelRed W Y White Yellow To right side posit...

Page 453: ...ing a focusing tester etc How ever the method described here does not use such tester Beam alignment Unless otherwise obligated by the local regulations align the headlight beams according to the foll...

Page 454: ...tch kept in LOW BEAM position tester should indicate continuity between terminals 0 and Similarly there should be continuity between terminals and when in HIGH BEAM position Fig 21 6 Switch connector...

Page 455: ...lue 14 Green Red 15 Meter pilot light Right 16 Meter pilot light Left 17 White Green When hazard warning switch is OFF Yellow lead is connected to Yellow Blue lead 0 When the hazard warning switch is...

Page 456: ...erminals 1 and 3 with lever in left turn position Possible cause Fusible link is blown off Open circuit due to poor point contact in turn signal dimmer switch Defective relay unit Open circuit in haza...

Page 457: ...rrent flows through the motor and shunt circuit and the motor stops and the wiper blade stays in the specified position INTERVAL WIPER RELAY CIRCUIT OPTIONAL When the wiper switch is set to the interv...

Page 458: ...lue white white Blue lr d rzay Black 1 Battery 2 Main switch 3 Fuse box 4 Wiper motor 5 Wiper washer switch 6 Washer motor Wire color B Black B B1 Black Blue BI Blue BIIR Blue Red BI W Blue White Y B1...

Page 459: ...Yellow White 15 Blue 16 Blue Red 17 Blue Black 18 Black 19 Blue White 21 5 WATER TEMPERATURE METER AND GAUGE The water temperature meter is located in the combination meter and its gauge unit on the...

Page 460: ...rrent flowing through the meter coil is changed to control the meter pointer That is when fuel is full the fuel level gauge unit resistance is decreased with more current flowing into the meter coil c...

Page 461: ...cylinder reservoir brake fluid level warning lamp in gage cluster and check relay Also this circuit is additionally provided with parking brake switch which warns that parking brake is applied when e...

Page 462: ...h so operates that it is switched OFF when oil pressure is produced by the started engine and then fed to switch Fig 21 23 W R White Red 6 Black RI0 RedlBlack 1 Battery 2 Main switch 3 Fuse 4 Oil pres...

Page 463: ...nd the buzzer stops sounding whether the seat belt is worn or not 1 Battery B B1 Black Blue 2 Main switch B W Black White 3 Fuse BI B Blue Black 4 4WD lamp W Y White Yellow 5 4WD switch Fig 21 26 INSP...

Page 464: ...test lamp to wire as illustrated below Make sure that the illumination controller knob is turned rightwise to brighten the test lamp leftwise to darken it 1 Battery Fig 21 30 2 Illumination controlle...

Page 465: ...place a Set the voltmeter positive lead to the heat wire positive terminal end b Set the voltmeter negative lead with a foil strip to the heat wire positive terminal end to then move it along the wir...

Page 466: ...B B7 Ignition coil Fuel cut solenoid TWSV MCSV vent solenoid B W 15A 3 BIBI ECM Heater blower motor L9 Rear defogger optional Y G 15A Wiper motor washer motor Y El 15A BIBI Turn signal light Back up...

Page 467: ...le Use special care not to let it contact sharp edges of body or other parts 0 Connect connectors securely Engine Room Wiring 1 Wire harness No 2 2 Battery 3 To starter alternator head light small lig...

Page 468: ...mp 7 ToVSV 6 Thermal switch 9 Mount this terminal horizontal ly as shown 10 Thermostat cap 1 Wire harness No 2 2 To distributor 3 To fifth switch 4 To back up light switch 5 To ignition coil 6 Condens...

Page 469: ...2 To wire harness No 2 3 To wire harness No 2 4 To fuse box 5 Horn relay 6 To combination switch 7 To clutch switch 8 To stop lamp switch 15 Door warning buzzer 9 To heater blower motor 16 Check relay...

Page 470: ...ition switch 7 To clutch switch 8 Defroster hose 9 Brake pedal 10 Clutch pedal 11 Clamp lead wires of ignition switch and combination switch using care not to allow lead wires to contact the edge of s...

Page 471: ...SECTION 22 SERVICE DATA CONTENTS 22 1 SPECIFICATIONS 22 2 SERVICE DATA 22 1 SPECIFICATIONS Convertible Hardtop For Canadian specification vehicle 22 1 22 4 22 1...

Page 472: ...ction ratio 0 5 mm2 fusible link 1 O l Of 1 O l 0 10 15 15 l 5 15 l 5 l 0 5 5 5A Dry single disc 5 forward all synchromesh 1 reverse 3 727 Gear ratios Transfer gear ratios Overall reduction ratios low...

Page 473: ...angle Caster angle King pin angle BRAKE SYSTEM Type Wheel brake Parking brake CAPACITIES Cooling solution Fuel tank 2 6 mm 0 08 0 24 in lo 00 3 30 I front rear 9 00 4 wheel hydraulic Disc brake floati...

Page 474: ...0059 in 0 75 mm 0 0295 in Camshaft thrust clearance 1 Inlet 37 500 mm 1 4763 in 37 400 mm 1 4724 in Cam height I Base circle lift E x h a u s t 37 500 mm 1 4763 in Fuel pump cam 40 000 mm 1 5748 in 37...

Page 475: ...22 5...

Page 476: ...22 6...

Page 477: ...22 7...

Page 478: ...22 8...

Page 479: ...22 9...

Page 480: ......

Page 481: ......

Page 482: ...Prepared by SUZUKI MOTOR CO LTD Technical Department Automobile Service Division 1st Ed November 1987 Printed in Japan...

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