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Suzuki SY419, Supplementary Service Manual, Page: 240 / 240

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Suzuki SY419 Supplementary Service Manual Download Page 240

Summary of Contents for SY419

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Page 3: ...F CONTENTS SECTION GENERAL INFORMATION General Information 0A Maintenance and Lubrication 0B HEATING AND AIR CONDITIONING Air Conditioning 1B STEERING SUSPENSION WHEELS AND TIRES Power Steering P S Sy...

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Page 17: ...r the system inoperative Either of these two conditions may result in se vere injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position...

Page 18: ...ch 19 Radiator fan switch 20 Diode 21 Blower fan motor relay 22 To blower fan motor 23 A C compressor relay 24 ECT switch for A C 25 A C evaporator thermistor 26 A C compressor 27 A C controller 1B 2...

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Page 27: ...otrusion on under side of coil ring must match hole in com pressor assembly to prevent movement ant correctly locate lead wire 2 Using special tool C install snap ring as shown Special Tool C 09900 06...

Page 28: ...tic hammer 2 Pipe 6 Adjust clearance between armature plate and magnet clutch by putting shim on compressor shaft Standard clearance c 0 4 0 8 mm 0 016 0 031 in 7 Tighten new armature plate nut as spe...

Page 29: ...rom shaft 1 Key 2 Driver 4 Remove circlip by using special tool F SpecIal Tool F 09900 06108 1 Circlip 5 Remove mechanical seal using special tool G The following explains this removal procedure i Fit...

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Page 42: ...to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the descriptions...

Page 43: ...irm the following Fuel tank is filled with fuel fully Vehicle is equipped with spare tire tools jack and jack handle 1 Place vehicle on level floor and set 200 kg 442 lbs weight slow ly on axle housin...

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Page 52: ...manual Valve clearance specification when cold INTAKE 0 15 0 07 mm EXHAUST 0 30 0 07 mm TURBOCHARGER PRESSURE CHECK WARNING When carrying out road tests select a safe place where no man or no running...

Page 53: ...e and clog replace turbocharger 1 Special tool AIR CLEANER ELEMENT This air cleaner element is of dry type Clean it according to the fol lowing procedure REMOVAL 1 Remove air cleaner upper case from l...

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Page 58: ...specified torque Tightening torque a 25 N m 2 5 kg m b 15 N m 1 5 kg m c 15 N m 1 5 kg m CYLINDER HEAD REMOVAL 1 Remove intake manifold exhaust manifold and EGR valve as sembly 2 Remove cylinder head...

Page 59: ...Valves Valve springs Valve guides Valve seats Swirl chambers Reconditioning the cylinder head INSTALLATION 1 Install cylinder head Refer to the following items in Overhaul checking tuning manual Cylin...

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Page 61: ...pecial tool A B and C 09918 96510 OUT0000136 1 Cylinder head 2 Plug ball SECOND PLUG BALL If oil leaks from plug ball 9 5 mm insert a second plug ball over original ball If oil leaks form plug balls 7...

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Page 64: ...mounting member and suspension frame 10 Remove bolt from engine front torque bush 11 Remove 2 bolts that fix mounting member and front member Then remove mounting member 12 Remove left mounting from b...

Page 65: ...erly and securely Tighten bolts and nuts shown in the figure on the left Tightening torque a 55 N m 5 5 kg m For installing engine hood refer to Hood in Section 9 And per form hood latch operation che...

Page 66: ...upport 1 09916 14510 Valve lifter 2 09916 14910 Valve lifter attachment 09917 66510 OUT0000014 Camshaft oil seal installer 09911 16530 OUT0000013 Front seal installer 09911 16520 OUT0000011 Rear main...

Page 67: ...000062 Tightening angle gauge 09919 46510 OUT0000110 Clamp pliers 09917 96520 OUT0000021 Stem seal remover 09918 96510 OUT0000136 Plug ball installer kit 09915 78220 Pressure gauge attachment ENGINE M...

Page 68: ...rbocharger oil feed pipe flare nut 20 0 2 0 14 7 Turbocharger oil feed pipe union nut 30 0 3 1 22 1 Turbocharger exhaust inlet flange bolt 55 0 5 5 40 6 Turbocharger exhaust outlet flange bolt 22 0 2...

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Page 70: ...ld render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK p...

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Page 80: ...installation check each joint for leakage WATER PUMP Refer to DISMANTLING THE ENGINE and INSTALLING THE TIMING BELT of OVER HAUL CHECKING TUNING MANUAL ENGINE COOLING 6B 11 REQUIRED SERVICE MATERIAL...

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Page 84: ...uel injection pump Tightening torque a 1 6 N m 0 2 kg m b 39 5 N m 4 0 kg m FUEL INJECTION PUMP 1 Load lever 2 Fuel feed line 3 Load lever damper 4 Fast idle control cable 5 Anti stall adjusting bolt...

Page 85: ...ection pump LOAD SWITCH AND COOLANT TEMP SWITCH Refer to the following tables LOAD SWITCH LOW Load Switch CLOSE HIGH OPEN COOLANT TEMP SWITCH Coolant temperature Lower than 60 C 140 F Switch OPEN High...

Page 86: ...tion pump and injectors for leakage clog and bent Are they in good condition Are injectors correct and in good condition Refer to Injector inspection in this section Check fuel injection pump drive sy...

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Page 113: ...ange 09912 56520 OUT0000119 Fuel injection pump wrench 09912 56510 OUT0000077 Vacuum pressure gauge set 09931 76011 Tech 1A kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead pro...

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Page 121: ...20 C Load characteristic 7 7 V 400 A 16 0 N m 1 6 kg m 11 6 Ib ft minimum 740 rpm minimum 68 F Locked characteristic 3 5 V 940 A maximum 28 9 N m 2 9 kg m 20 1 Ib ft minimum Magnetic switch operating...

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Page 130: ...ts terminal as follows Tightening Torque a 50 N m 5 0 kg m 36 2 lb ft b 10 0 N m 1 0 kg m 7 2 lb ft c 4 0 N m 0 4 kg m 2 9 lb ft Adjust accessory drive belt tension referring to AC CESSORY DRIVE BELT...

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Page 141: ...these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnec...

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Page 156: ...ition correctly 1 E ring 2 Select spring guide 3 Reverse select spring 4 Thrust washer 5 E ring 6 Gear shift interlock plate 7 Ball 8 Gear shift interlock spring 9 Gear shift select lever 10 Spring pi...

Page 157: ...ferential gear thrust play 0 05 0 33 mm 0 002 0 013 in Left side Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top surface of gear Using 2 screwdrivers move...

Page 158: ...y with soft jawed vise install final gear with grooved surface directed towards you and tighten bolts with specified torque Grooved surface and the head of bolt should be in the same side as shown in...

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Page 160: ...ng side and tight en them to specification 1 Left case 2 Right case 3 Case bolt 4 Reverse shaft bolt 10 Check locating spring for deterioration and replace with new one as necessary 11 Install steel b...

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Page 163: ...07 Snap ring pliers Opening type 09900 20606 Dial gauge 09900 20701 Magnetic stand 09913 60910 Bearing puller 09913 75810 Bearing installer 09913 75520 Bearing installer 09922 85811 Spring pin remover...

Page 164: ...7A 24 MANUAL TRANSMISSION 09951 76010 Bearing installer 09930 30102 Sliding shaft 09940 53111 Bearing installer 09951 16060 Bush remover 09940 54910 Sensor rotor installer...

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Page 183: ...od Fuel Pump Assembly was necessary during trouble diagnosis be sure to register Fuel Pump Assembly Immobilizer Control Module code in Fuel Pump Assembly and Immobilizer Control Module by per forming...

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Page 195: ...Using SUZUKI scan tool check shut off valve SOV by execut ing F5 SOV TEST command in SELECT MODE menu NOTE For operation procedure of SUZUKI scan tool refer to SU ZUKI scan tool operator s manual 6 Us...

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Page 201: ...placed including when replaced because rechecking by using a known good fuel pump assembly was necessary during trouble diag nosis be sure to register fuel pump immobilizer control module code in immo...

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Page 206: ...is bulletin describes service information on SEIKO SEIKI compressor as shown in the con tents below When servicing the A C system refer to this bulletin first For items not covered by this bulletin re...

Page 207: ...ndicated on the LABEL installed the compressor Also it can be identified by the shape of the service charge valve The manufacturer Seiko Seiki or Sanden can be identified by the label on the compresso...

Page 208: ...nifold gauge set 2 High pressure side Discharge side hose 3 Low pressure side Suction side hose REMOVAL 1 Run engine at idle with air conditioning on for 10 minutes 2 Disconnect negative cable at batt...

Page 209: ...ing point Tightening order Order a b c Tightening Torque a b c 26 N m 2 6 kg m 19 Ib ft Pour new compressor oil with the same amount as that drained from compressor Evacuate and charge system accordin...

Page 210: ...ts and nuts and them remove compressor mounting bracket and its spacer INSTALLATION Reverse removal procedure noting following point Tightening order a b c d When flange bolt e f is attached be carefu...

Page 211: ...for noise wear and grease leak age If there is any defect for clutch plate and clutch pulley replace magnet clutch component Thermal switch 1 Disconnect thermal switch read wire 1 from clutch coil re...

Page 212: ...sec tion 2 Fix clutch plate 1 with special tool A and remove clutch plate bolt 2 Special Tool A 09991 06020 3 Washer 3 Remove clutch plate by using special tool B Special Tool B 09991 06030 4 Disconn...

Page 213: ...prevent movement ant correctly locate lead wire 2 Using special tool C install circlip 2 to compressor assembly 3 as shown Special Tool C 09900 06107 3 Clamp covering portion of read wire 4 Install cl...

Page 214: ...A 09991 06020 1 Clutch plate 3 Washer MECHANICAL SEAL REMOVAL 1 Remove magnet clutch referring to C MAGNET CLUTCH in this section 2 Remove front head mounting screw 8 pcs 1 Case 2 Front head 3 Remove...

Page 215: ...and install it to the shaft Special Tool F 09991 06040 3 Install O ring to case 4 Apply Compressor oil to lip seal and O ring 5 Install front head assembly 1 Front head 2 O ring 6 Tighten front head...

Page 216: ...RS 20 150 cc 99000 99088 00D0 O ring Each component Refrigerant REFRIGERANT DRUM 200 g 95794 50G00 0000 Refrigerant charge SPECIAL TOOLS 09900 06107 Snap ring pliers Opening type 09991 06050 Lip type...

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Page 239: ...Prepared by Overseas Service Department 1st Ed January 1999 2nd Ed Oct 2001 Printed in Japan Printing 252...

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